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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 08/368,838, filed Jan. 5, 1995, now abandoned.
BACKGROUND OF THE INVENTION
Operating room personnel have been aware for years that the repeated touching of the operating room or surgical lamp handle to redirect the illumination pattern or to bring the lamp closer to the area of concern, or to move the lamp farther away, can bring about the spread of contagious diseases through contact with the handle. Such contagious or communicable diseases are borne in or on the human body fluids and tissues which become attached to the exterior surfaces of the gloved (or ungloved) hands of operating personnel, doctors, nurses and other technicians, and are transmitted to the lamp handle or adjusting means through direct contact.
In the environment in which operating room personnel work, i.e. inside the human body, body fluids such as blood and the tissues comprising the organs, muscles and skin of the human body may potentially transmit a number of diseases and viral infections through contact. The process of surgery requires the incision or cutting into the body resulting in the outflow of blood and other body fluids as well as the scattering of various body tissues outside of the point of incision or cut. Some of such fluids and particles of tissues may become attached to the gloved hands of the operating room personnel. Cleaning and sterilization of the lamp handles or adjusting means has remained a serious problem for operating room and other hospital personnel because of their construction and the materials utilized to formulate the handle.
During operating procedures the lamp is almost continually repositioned for better lighting into the point of incision, the interior of the patient's body. The lamp handle is touched by a variety of operating room personnel in attempts to refocus the light onto the desired point of illumination on or in the body of the patient. Refocusing the light emitted by the lamp is accomplished with possibly contaminated exterior surfaces of the gloves worn by the operating room personnel who are still performing the surgical procedure. Anything such personnel may have come into contact with (known or unknown) while their gloved hands were in contact with the human patient will necessarily be transmitted to the surface of the lamp handle or other adjusting means upon touching the surface of such handle or adjusting means.
There have been some attempts to provide covers for surgical lamps for use in a surgical operatory. U.S. Pat. No. 4,777,574 Eisner! discloses a thin, tear-resistant, semi-rigid but elastic material for covering the entirety of a variety of different types of dental surgical lamp adjusting means. The lamp handle shield of the Eisner patent is sufficiently flexible so as to stretch over a variety of different shaped handles. Another flexible surgical lamp handle cover is taught by U.S. Pat. Nos. 5,036,466 and 5,188,454 Quintanilla, et al.!. These patents teach a semi-permanent, non-disposal surgical lamp handle cover which provides an asceptic medium for manual adjustment of the operating room lamp during surgical procedures. While the lamp cover of Eisner is disposable after each surgical procedure, the lamp handle cover of Quintanilla, et al. is described as semi-permanent in nature, although such cover can be disengaged and removed after each surgical procedure.
Semi-rigid surgical light handle covers are described in U.S. Pat. No. 4,559,671 Andrews, et al.! and U.S. Pat. No. 4,605,124 Sandel, et al.!. These patents disclose semi-rigid covers for principally protecting the grip portion of the handle of the surgical lamp, as well as an upward and radially outward extending projection which serves to prevent contact with the handle support elements of the surgical lamp.
Another semi-rigid surgical lamp handle cover is disclosed in U.S. Pat. No. 4,844,252 and Des. U.S. Pat. No. 313,670 Barron, et al.!. The disclosure of the Barron, et al. patents teaches a multi-part disposable lamp handle for use on a surgical or operating room light. A similarly constructed device is disclosed in U.S. Pat. No. Des. 298,864 Jefferson! which describes a disposable handle for operating room lights.
With the exception of the Eisner patent, all of the rest of the patents describe teachings of a variety of flexible or semi-rigid surgical lamp handle covers which may either be exchanged for the existing handle, cover the existing handle for one or more procedures, or cover the existing handle and be disposable after each procedure. The flexible or semi-rigid surgical lamp handle covers are flexible only to the extent that they are collapsible so as to be folded into a small container, bag or envelope, but in no way approach the flexibility of the material utilized in the Eisner teaching.
With reference to the lamp handle cover in the Eisner patent, the specific structure described and taught is for T-type and C-type shaped lamp handles. There is no enabling disclosure or teaching of a cover for an I-type or straight handle cover which has a radially outwardly extending upper portion to cover the handle support and lamp connection means for the handle for that type adjusting means for surgical or clinical lamps. Neither does the Eisner patent, or any of the other patents, suggest the substitution of the material used in the Eisner patent for the semi-rigid materials described as being used in the other cited patents.
Surgical or clinical lamps are not usually thought of as disease transmission devices. The lamps are usually cleaned, but not sterilized, after conclusion of a surgical procedure and before the next surgical procedure. Sterilization of the surgical (or clinical) lamp (and its handle or adjusting means), which is large and cumbersome to manipulate and usually mounted to the ceiling or wall of an operating or treatment room, is not easily accomplished as the sterilization which can be done with small surgical instruments. Although the lamp and its handle or adjusting means may be sprayed with a disinfecting agent, such practice does not entirely eliminate bacterial or viral forms on the lamp. Thus, attempted disinfection of the lamp between patients does not entirely create a sterile field and the surgical or clinical lamp (and its handle or adjusting means) may continue to be a disease transmission device.
It is, therefore, an object of the present invention to provide a clean or sterile field around an operating room (surgical) or treatment (clinical) lamp handle or adjusting means in order to alleviate, or entirely eliminate, the task of removal and sterilization of the handles or adjusting means.
It is a further object of the present invention to alleviate or entirely eliminate, significantly increased inventory costs by providing a single barrier which will fit over a broad spectrum of differently shaped handle or adjusting means and accommodate both the shape and size of the handle or adjusting means for both operating room and other healthcare settings where surgical or clinical lamps are operated and clean or sterile fields are required.
It is another object of the present invention to provide a barrier or shield which is highly elastic and stretchable, yet tear-resistant, and which is capable of covering the handle or adjusting means of the surgical or clinical lamps regardless of different shapes and sizes of those handles or adjusting means.
It is still a further object of the present invention to provide a barrier or shield which is disposable after a single use and which is easily applied and removed so that the barrier or shield will have greater acceptance among users in the healthcare field.
Other objects will appear hereinafter.
SUMMARY OF THE INVENTION
The surgical or clinical lamp handle or adjusting means covering, barrier, shield or prophylactic of the present invention is comprised of a thin, tear-resistant elastic material which is disposable after a single use for covering the exposed surfaces of each of several different shaped and sized surgical or clinical lamp handles or adjusting means, as well as the handle or adjusting means supports which support and connect the handle or adjusting means to the surgical or clinical lamp.
The present invention may be described as a disposable sterile surgical or clinical lamp shield or prophylactic for placement over and in proximate contact with the means for adjusting the illuminated focal point of said lamp for significantly reducing the spread of communicable and infectious diseases which may be transmitted by or through contact with human body fluids and tissues during a first and subsequent use of said lamp and its adjusting means in conjunction with the treatment of two or more patients. The use of such barrier will eliminate the need for repeated sterilization of the lamp and its adjusting means between such uses for the two or more patients.
The invention may be particularly described as comprising an elongated substantially cylindrical lower gripping portion conjoined to an inverted conically shaped upper flange portion terminating in a substantially circular aperture surrounded by a stiffening radial rib means for fitting over the lamp adjusting means and clinical lamp adjusting means supports to provide a gripping portion of the clinical lamp adjusting means without contamination of other surfaces of said lamp. The shield or prophylactic to fully accomplish its intended purpose has sufficient elastic material memory to maintain itself in position covering said adjusting means without slippage until manual removal. The shield or prophylactic has a preferred thickness in the range between 0.5 and 10 mils with the outer surface of the shield or prophylactic having a medium to high degree of frictional contact. The shield or prophylactic may be made from an elastomeric or elastic material, natural or man-made, or any combination thereof, with the material exhibiting sufficient deformability to stretch over the clinical lamp adjusting means, toughness and/or tear-resistance to withstand pulling and stretching during application and/or removal and material memory to return to and/or retain its original size and shape after application and/or removal.
The invention also contemplates a method for applying and removing a disposable sterile surgical or clinical lamp shield or prophylactic for providing a barrier to infectious disease contamination by the means for adjusting the illuminated focal point of said lamp which may be transmitted by or through contact with human body fluids and tissues during a first and subsequent use of said lamp and its adjusting means in conjunction with the treatment of two or more patients. This, again, eliminates the need for repeated sterilization of the lamp and its adjusting means between such uses for the two or more patients. The method includes the steps of providing a shield or prophylactic having an elongated substantially cylindrical lower gripping portion conjoined to an inverted conically shaped upper flange portion terminating in a substantially circular aperture surrounded by a stiffening radial rib means for fitting over the lamp adjusting means and lamp adjusting means supports to permit gripping of the lamp adjusting means without contamination of other surfaces of the lamp; mounting the shield or prophylactic over a hollow cylindrically shaped applicator means by stretching the lower gripping portion over a first end and the outside of the applicator means so a substantial portion of the lower gripping portion overlies the exterior of the applicator means with the interior surface of the lower gripping portion of the shield or prophylactic facing outward and the remaining portion of the lower gripping portion folded over the inside out portion of the lower gripping portion such that the upper flange portion is positioned proximally to the first end of the applicator means; applying the shield or prophylactic to the lamp adjusting means by unrolling the stretched and mounted shield or prophylactic by centering the applicator means adjacent the distal end of the lamp adjusting means and passing the applicator means upward over the lamp adjusting means of the lamp so as to stretch the shield or prophylactic completely over the lamp adjusting means; and maintaining the shield or prophylactic in position covering the lamp adjusting means without slippage until manual removal.
The protection may be enhanced by stretching the radial rib of the upper flange portion of the shield or prophylactic over surfaces adjacent to the lamp adjusting means which connect the lamp adjusting means to the lamp to cover the surfaces and to further secure the shield or prophylactic in position.
BRIEF DESCRIPTION OF THE DRAWINGS
For the purpose of illustrating the invention, there is shown in the drawings forms which are presently preferred; it being understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown.
FIG. 1 is a side elevational view of the prophylactic cover of the present invention showing the cover fully extended.
FIG. 2 is a side elevational view of the prophylactic cover of the present invention showing the cover mounted over an applicator means for placement of the cover over the surgical or clinical lamp handle or adjusting means.
FIG. 3 is a side elevational view of the prophylactic cover of the present invention showing the cover mounted over the applicator means of FIG. 2 in position for application over one type of surgical or clinical lamp handle or adjusting means.
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description is of the best presently contemplated mode of carrying out the invention. The description is not intended in a limiting sense, and is made solely for the purpose of illustrating the general principles of the invention. The various features and advantages of the present invention may be more readily understood with reference to the following detailed description taken in conjunction with the accompanying drawings.
Referring now to the drawings in detail, where like numerals refer to like parts or elements, there is shown in FIG. 1, a surgical or clinical lamp handle or adjusting means cover 10. The cover 10 may be referred to hereinafter as a shield, a barrier, or a prophylactic cover, all of which are to be understood as having the identical meaning.
The prophylactic cover 10 is shown in FIG. 1 in a fully extended position, although there is no radially outward flexion or extension, as the material from which the barrier 10 is made is in a relaxed state. The barrier or shield 10 may be formed from any elastomeric or elastic material, natural or man-made, or any combination thereof. The elastomeric or elastic material should exhibit sufficient deformability to stretch over a variety of differently shaped and sized surgical or clinical lamp handle or adjusting means and exhibit sufficient toughness and/or tear-resistance to withstand pulling and stretching during application and/or removal. The barrier or shield 10 should also exhibit sufficient material memory to return to and/or retain its original size and shape after application and/or removal. The outer surface of the barrier or shield 10 is preferred to have a medium to high degree of frictional contact to provide sufficient firmness of grasp during surgical or clinical procedures where hands, gloved or ungloved, may be slippery from contacting body fluids or otherwise.
The barrier, shield or prophylactic cover 10 of the present invention is generally comprised of a lower portion 12 and an upper portion 14. The lower portion 12 of the cover 10 preferably has a shape corresponding to an elongated cylinder having a closed first or bottom end 16 with the opposite end of the elongated cylindrical segment of the lower portion 12 conjoined to an equal sized substantially circular opening of the upper portion 14. The upper portion 14 is shaped substantially in the form of an inverted cone having a truncated vertex which meets and is joined to the substantially circular opposite end of the elongated cylindrical shaped segment of the lower portion 12. The inverted conically shaped upper portion 14 terminates in a radial rib or rim 18 which surrounds the upper open end 20 of the cover 10. The radial rib 18 completely circumscribes the opening or aperture 20 of the cover 10 and is generally formed from material which is permitted to overroll itself to form the stiffening rib (rim) 18 surrounding the upper opening 20.
With reference to FIG. 2, the apparatus of the present invention, the barrier, shield or prophylactic cover 10, is shown mounted over an applicator means 22 for use in more easily placing the cover 10 over a variety of differently shaped and sized handles or adjusting means of surgical or clinical lamps. The applicator means 22 is shaped in the form of a hollow cylinder, having interior and exterior surfaces, and may take the form of a plastic or paper expansion ring or tube. The applicator means 22 has equally sized open ends for ease of application of the cover 10 to the lamp handle or adjustment means 24 for lamp handles having a diameter smaller than the diameter of the applicator means 22.
The cover 10 placed over a first end of the applicator means 22 and partially stretched inside out over the exterior of the applicator means 22 so that substantially all of the lower (or grip) portion 12 overlies the exterior of the cylindrically shaped applicator means 22 with its interior surface facing outward. The remainder of the lower (or grip) portion 12 of the cover 10 is folded back over itself so that the upper portion 14 of the cover 10 is positioned just below the first end of the applicator means 22 over which the lower portion 12 has been stretched. The stretching of the lower (or grip) portion 12 of the cover 10 over the first end of the applicator means 22 does not deform (by stretching) the bottom end 16 of the barrier 10, as such bottom end 16 is useful as a centering point when applying the barrier 10 over one of a variety of differently shaped and sized lamp handle or adjusting means 24. The upper opening 20 of the barrier 10 is positioned closely proximate to the first end of the applicator means 22 as shown in FIG. 2.
The placement or application of the barrier or shield 10 of the present invention can be best described with reference to FIG. 3. A lamp handle or adjustment means 24 is shown having an elongated cylindrical lower segment 26 and an outwardly flared upper segment 28 to provide a gripping surface for manual manipulation and aiming of the surgical or clinical lamp to which the lamp handle or adjustment means 24 is attached by the connection or support means represented as 30 in FIG. 3.
The applicator means 22 is positioned below the lamp handle or adjustment means 24 centering the bottom end 16 of the cover 10 under the elongated cylindrically shaped lower segment 26 of the lamp handle or adjustment means 24. Once the bottom end 16 of the barrier or shield 10 is positioned in contact with the distal end 32 of the lower segment 26 of the lamp handle or adjusting means 24, the applicator means 22 can be moved upward along the exterior of the lower segment 26 which causes the barrier or shield 10 to be pulled away from the applicator means 22 so as to roll and stretch over so as to overlie the lower segment 26 of the lamp handle or adjustment means 24 with the lower (or grip) portion 12 of the barrier or shield 10.
As the applicator means 22 approaches the upper or flared segment 28 of the lamp handle or adjustment means 24, the lower portion 12 of the barrier or shield 10 has been transferred from its folded overlying position over the exterior of the applicator means 22 and been rolled out and stretched over the lower segment 26 of the lamp handle or adjustment means 24 such that the upper portion 14 of the barrier or shield 10 is now positioned to contact and overlie the upper or flared segment 28 of the lamp handle or adjustment means 24. The upper (or flange) portion 14 of the barrier 10 provides protection against the gloved hand of any operating room personnel contaminating surfaces adjacent to the gripping portion of the lamp handle and adjusting means 24. The flange portion 14 is supported by the radial rib 18 and can be stretched radially outward so that the rib 18 can be positioned over a handle flange to provide a secure fit and complete barrier coverage of all elements of any lamp handle or adjusting means 24.
When the barrier or shield 10 is fully in position contacting and being stretched over the lower segment 26 and the upper or flared segment 28 of the lamp handle or adjustment means 24, the barrier or shield 10 is no longer in contact with the applicator means 22 and said applicator means 22 can be withdrawn by sliding downward and off of the now covered lamp handle or adjustment means 24. For proper placement and stretching of the cover 10 over the lamp handle or adjustment means 24, the diameter of the applicator means 22 is preferably in the range of 1/8" to 3/8" larger than the largest diameter measurement of any of the differently shaped and sized lamp handle or adjustment means 24. Thus, once the prophylactic cover 10 is positioned over the lamp handle or adjustment means 24 of a surgical or clinical lamp, the applicator means can be slid downward and off of the now covered lamp handle or adjustment means 24 and discarded.
Once positioned, the barrier, shield or prophylactic cover 10 protects against contamination and cross-contamination by the lamp handle or adjusting means 24 without such cover. Therefore, the application, by stretching the barrier, shield or prophylactic cover 10 over the lamp handle or adjustment means 24 of a surgical or clinical lamp, provides a barrier or shield to gross or microcontamination, or bacterial or viral contamination, of the lamp handle and proximal surgical or clinical lamp surfaces. Any contamination which occurs during a surgical procedure will remain on the exterior surface of the barrier, shield or prophylactic cover 10 and can be disposed of in the appropriate manner for suspected infectious waste and contaminated items by removing the cover 10 at the end of such treatment or procedure. Removal of the barrier or shield 10 is accomplished by rolling the barrier or shield 10 downward over itself and off of the lamp handle or adjustment means 24, and then discarding the cover 10 in an appropriate manner.
The shield, barrier or prophylactic cover 10 of the present invention is preferably manufactured from latex having a thickness in the range of 0.5 to 10 mils as this thickness is desired for the shield to exhibit the identified properties set forth above. Further, the barrier or shield 10 can be provided in either sterile or asceptic packaging depending upon its use in either a sterile field or in only a substantially clean and infection free environment.
The barrier, shield or prophylactic cover 10 of the present invention can be used with all presently manufactured shapes and sizes of surgical and clinical lamp handles or adjustment means due to its ability to adapt and/or conform to the variety of exterior shapes of these lamp handles or adjusting means. The present invention provides a significant step forward in the application and removal of such barriers, shields or prophylactic covers to reduce the spread of infectious or contagious and communicable diseases of either the bacteriological or viral type which are borne on the body fluids and tissues of humans. Without a barrier, shield or prophylactic cover of the present invention, the surgical or clinical lamp handle or adjusting means would be a likely place for the harboring and transmittances of infection and disease.
The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, the described embodiments are to be considered in all respects as being illustrative and not restrictive, with the scope of the invention being indicated by the appended claims, rather than the foregoing detailed description, as indicating the scope of the invention as well as all modifications which may fall within a range of equivalency which are also intended to be embraced therein. | A surgical or clinical lamp handle or adjusting means covering, barrier, shield or prophylactic comprised of a thin, tear-resistant elastic material which is disposable after a single use for covering the exposed surfaces of each of several different shaped and sized surgical or clinical lamp handles or adjusting means, as well as the handle or adjusting means elements which support and connect the handle or adjusting means to the surgical or clinical lamp for preventing the spread of infectious disease. | 5 |
.Iadd.This application is a continuation of application Ser. No. 07/635,362, filed on Feb. 6, 1991, now abandoned, which is a reissue of Moyer 6-4, Ser. No. 06/934,062, filed on Nov. 24, 1986, U.S. Pat. No. 4,803,540. .Iaddend.
TECHNICAL FIELD
This invention relates generally to packages for semiconductor integrated circuits.
BACKGROUND OF THE INVENTION
An essential part of semiconductor integrated circuit manufacture resides in the placing of the integrated circuit chip into a package so that the chip can be conveniently contacted electrically as well as mounted in a physically secure manner. The chip itself is mounted on a lead frame which has a plurality of fingers for electrical connections and a paddle for physical support. The paddle is connected physically to an external mounting frame by paddle support arms. Electrical contacts are made through wires bonded to the fingers and to the paddle.
Although the package could be assembled using a lead frame in which the paddle remains in the same plane as do the fingers, it has often been found desirable to assemble a package using a lead frame in which the paddle has been depressed, i.e., made lower, with respect to the external mounting frame and fingers. It has been found that this configuration reduces the number of edge shorts between the electrical contact wires and the chip. It also allows a balanced flow condition during molding. As will be readily appreciated by those skilled in the art, the depressed positioning will necessarily lead to a physical deformation of the paddle support arms during the forming process because the lead frame is initially a flat metal piece. The deformation will generally be in the form of a necking down, i.e., a constriction of paddle support arms in the transverse axial direction.
As feature sizes in integrated circuits continue to decrease and the scale of integration continues to increase, package designers must make more interconnects in an amount of space that is, at best, equal to that previously available. The only expedient way this may be accomplished is to decrease the width of the fingers and paddle support arms to permit placement of more fingers in either the same or a smaller area. Consequently, the combined effect of the constriction and decreased feature size may lead to problems such as loss of physical integrity and distortion of the paddle support arms. If these arms are also used for electrical connections, there may be undesirable changes in the electrical characteristics as well.
SUMMARY OF THE INVENTION
A semiconductor integrated circuit package is described which as a semiconductor integrated circuit chip and a lead frame, on which said chip is mounted, having a plurality of fingers, a paddle and a plurality of paddle support arms with the paddle support arms having a deformation absorbing member. The lead frame is formed so that the paddle is in a depressed position with respect to the external mounting frame .Iadd.and to at least a portion of the fingers. .Iaddend.The deformation absorbing member is designed to maintain the desired mechanical characteristics after forming. It may also retain the desired electrical characteristics if the arms are used for electrical connections. In one embodiment, the deformation absorbing member is an annular member which contracts in a direction transverse to the load direction. In another embodiment, the deformation absorbing member is a T bar. The paddle is supported by the paddle support arms which terminate in a T before contacting the external mounting frame. The legs of the T. perpendicular to the paddle support arm axis, are designed to deflect and absorb the deformation that results from the metal forming process of depressing the paddle. In all embodiments, the deformation absorbing member localizes the deformation which occurs during the mounting step producing the deformation.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side view of a package according to the invention;
FIG. 2 is a top view of an embodiment of this invention; and
FIG. 3 is a top view of another embodiment of this invention;
FIGS. 4 and 5 illustrate still other embodiments of this invention; and
FIG. 6 illustrates the embodiment shown in FIG. 5 along line A-A'.
For reasons of clarity, the elements of the devices depicted are not drawn to scale.
DETAILED DESCRIPTION
A side view of an exemplary integrated circuit package is depicted in FIG. 1. Depicted are semiconductor chip 1 which is mounted on paddle 3 by means of epoxy material 5. Paddle 3 is part of the lead frame which also has a plurality of fingers 7 and paddle support arms 9 for physical support. The fingers 7 are connected to the external mounting frame 13. There are electrical connections 15 between the chip and the fingers 7. As can be seen, the paddle 3 is positioned lower than the external mounting frame 13 because the paddle support arms have been deformed. .Iadd.It can also be seen that the paddle is positioned lower than the lead frame fingers; i.e., it is depressed with respect to at least a portion of the lead frame fingers. .Iaddend.This arrangement is desirable because it facilitates making, e.g., the electrical connections as previously discussed. The paddle support arms are bent to accommodate the vertical mismatch and each has a deformation absorbing member which localizes the deformation to the vicinity of that member.
FIG. 2 is a top view of the single site depicted in FIG. 1 of a typical lead frame. Depicted are a lead frame site comprising an external mounting frame 13, a paddle 3, a plurality of fingers 7, and a plurality of paddle support arms 9 extending from the paddle. Each paddle support arm has a deformation absorbing member 11. For reasons of clarity, not all fingers are depicted. In the embodiment depicted in FIG. 2, the deformation absorbing member 11 comprises an annular member, i.e., a member with expanded dimensions in the direction perpendicular to the major axis of the paddle support arm. The annular member is depicted as being circular although other shapes, e.g., oval, can be used.
During the forming operation, i.e., as the paddle is depressed with respect to the external mounting frame, .Iadd.and to at least a portion of the lead frame fingers, .Iaddend.the deformation absorbing member constricts in the direction perpendicular to the axis of motion. However, due to the size and shape of the deformation absorbing member, the desired electrical and physical characteristics are maintained after the forming operation as the paddle support arm does not form a necked down region. Thus, it is essential that the deformation absorbing member compensate for the axial motion along the paddle support arm. Further steps required for packaging need not be desired in detail as they are well known to those skilled in the art.
FIG. 3 illustrates another embodiment of a paddle support arm 11 having a deformation absorbing member which comprises a T bar with the two ends of the T mounted to the external mounting frame .Iadd.and to at least a portion of the fingers.Iaddend.. During the forming operation, the paddle support arms move radially inward causing the ends of the T to deflect about the mounting axis in the direction shown by the arrows.
Other embodiments are contemplated, and two embodiments are depicted in FIGS. 4 and 5. In FIG. 4 the deformation absorbing member comprises an S bend while in FIG. 5 it comprises a wrinkle. FIG. 6 shows the wrinkle along line A-A' in FIG. 5. | A lead frame for mounting a semiconductor chip in an integrated circuit package incorporates a deformation absorbing member as an integral part of the paddle support arm so that the initial, desired physical and electrical characteristics are unaltered after a forming operation such as paddle downsetting. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation in part of and claims priority of International patent application Serial No. PCT/IB2012/050679, filed Feb. 15, 2012, and published in English as WO2012/110960, which claims priority of Indian patent application 0389/DEL/2011, filed Feb. 15, 2011. The contents of these applications are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a novel isolated bacterial strain of Gluconacetobacter oboediens and an optimized economic process for microbial cellulose production therefrom. In particular, the present invention relates to a low cost optimized process for microbial cellulose production under static culture conditions by a new bacterial species Gluconacetobacter oboediens MTCC 5610 isolated from fruit residues. More particularly, the present invention relates to the isolation of a novel, potent cellulose producing bacterial species from fruit residues and the development of an economic process for the production of microbial cellulose in any amount, size, shape and dimension and further provides the drying methods therefor.
[0003] The main exploitation of microbial cellulose is in the medical field where it can be used as wound dressings or bandages, artificial skin, for making artificial vessels and other biomedical devices. Besides this, microbial cellulose can also be used in many other industrial sectors like cosmetics, paper, textile, food, environmental remediation and also in manufacturing of many products like audio diaphragms, baby care products, sports goods etc.
BACKGROUND OF THE INVENTION AND DESCRIPTION OF PRIOR ART
Cellulose in General (Plant)
[0004] Cellulose is the most abundant biological macromolecule on the planet earth. It forms the basic structural matrix of the cell walls of nearly all plants, many fungi and some algae. It is a major biopolymer of tremendous economic importance as it find multifarious uses in industries such as textiles, pulp and paper, cosmetics, healthcare, food, audio products, sport goods, etc, as well as in the preparation of cellulose derivatives such as cellophane, rayon, cellulose acetate and few others. Apart from this, cellulose is also used for environmental remediation especially in treating oil spills and removing toxic materials. The demand for cellulose has traditionally been met by wood and cotton, which contain over 50% and over 94% cellulose, respectively. However, plant resources cannot sustain an increasing demand for cellulose requirements due to fast diminishing forest resources, decreased land holdings for agriculture and other environmental concerns. This along with the difficulty in removal of hemicellulose or lignin inherently associated with cellulose limits its applications. It, therefore, necessitates a search for a commercially viable alternative to plant cellulose.
Microbial Cellulose as an Alternative to Plant Cellulose and its Importance
[0005] Microbial cellulose has emerged as an important and viable alternative to plant cellulose. Since ages, cellulose is recognized as the major component of plant biomass. However, it also represents a major chunk of microbial extracellular polymers. The cellulose produced by microbes is called microbial cellulose (MC). It is an exopolysaccharide. Some bacteria are in condition to produce cellulose, as reported from the strains of the genera Gluconacetobacter (formerly Acetobacter ), Agrobacterium, Pseudomonas, Rhizobium and Sarcina.
[0006] The production of cellulose by Acetobacter xylinum was reported for the first time in 1886 by A. J. Brown. He observed that the resting cells of Acetobacter produced cellulose in the presence of oxygen and glucose. This non-photosynthetic organism can procure glucose, glycerol, or other organic substrates and can convert them into pure cellulose. A. xylinum was reported as the most efficient producer of MC. The production of cellulose can be carried out in either solid-phase cultivation or submerged culture. Investigations have been focused on the mechanism of biopolymer synthesis, as well as on its structure and properties, which determine practical use thereof (Legge, 1990; Ross et al., 1991). Acetobacter xylinum produces two forms of cellulose: Cellulose I, the ribbon like polymer, and Cellulose II, the thermodynamically more stable amorphous polymer. Plant and bacterial cellulose are chemically the same, β 1,4 glucans, having same molecular formula (C 6 H 10 O 6 ) n but their physical features are different (Yoshinaga et al., 1997). As compared to plant cellulose, bacterial cellulose is chemically purer, has a high degree of crystallinity, polymerization, tensile strength, shear resistance and high water holding capacity. Fibrils of bacterial cellulose are about 100 times thinner than that of plant cellulose, making it more porous material.
[0007] Research on microbial cellulose production has been sporadically attempted with an increased impetus after 1990s. Production of microbial cellulose was carried out either in static or shaking culture. Glucose is supposed to be the most common carbon source for microbial cellulose production. However, there are many reports of microbial cellulose production using other carbon sources. In a study by Oikawa et al (1995) microbial cellulose production is carried out using D-Arabitol by Acetobacter xylinum . Similarly, Yang et al (1998) carried out the production of microbial cellulose by Acetobacter xylinum under shaking conditions using glucose, fructose, and sucrose individually and in combination. Microbial cellulose production by Acetobacter xylinum has been also attempted using D-xylose as a carbon source by Ishihara et al (2002). Keshk and Sameshima (2005) evaluated the effect of different carbon sources on the production of bacterial cellulose by Acetobacter xylinum and found that glycerol gave the highest yield of bacterial cellulose. In 2008, Hong and Qiu, developed a new carbon source from konjac powder that enhanced production of bacterial cellulose by A. aceti subsp. xylinus in static cultures.
[0008] Optimization studies on the production of microbial cellulose can enhance the yield both in static and shaking condition. Many scientists have attempted to optimize the culture conditions in order to enhance microbial cellulose production. In 2002, Heo and Son developed an optimized, simple and chemically defined medium for bacterial cellulose production by Acetobacter sp. V9 in shaking culture. In 2005, Bae and Shoda, statistically optimized the culture conditions for the bacterial cellulose production in shaking condition by Acetobacter xylinum using response surface methodology. Kim et al (2006) developed an optimized medium for the production of microbial cellulose in static condition by Glucanocetobacter sp. isolated from persimmon vinegar. An optimized medium for microbial cellulose production in static condition by Acetobacter sp. 4 B-2 was developed by Pourramezan et al., (2009), who studied the bacterial cellulose production using two categories of carbon sources (monosaccharides and disaccharides) and found sucrose to be the best carbon source for cellulose production. Jung et al., (2010) used a cost effective molasses-corn steep liquor medium for microbial cellulose production under shaking culture conditions by Acetobacter sp. V6.
[0009] Microbial cellulose yield in static cultures is mostly dependent on the surface/volume ratio. Microbial cellulose synthesis in static conditions can be achieved either in a one step [as attempted by most of the workers] or a two-step procedure using agitated fermentation followed by the static culture (Okiyama et al., 1992). They also scaled up the production upto 800 ml.
[0010] Attempts to produce microbial cellulose using conventional fermentors in order to scale up production in agitated condition have yielded few significant results. Bungay and Serafica (U.S. Pat. No. 6,071,727, 2000) worked on the production of microbial cellulose using a rotating disc or linear conveyer bioreactor. Chao et al (2000) used an airlift reactor for the production of microbial cellulose by Acetobacter xylinum . Tung et al (1997) modified the airlift reactor to improve the performance of fermentation processes. The production of microbial cellulose by Acetobacter xylinum was carried out in a jar fermentor and the effect of the pH and dissolved oxygen on production was observed (Hwang et al., 1999). In 2005, Bae and Shoda produced bacterial cellulose by Acetobacter xylinum subsp. sucrofermentans using molasses medium in a jar fermentor.
[0011] Microbial cellulose can be dried either by freeze drying, air drying, vacuum oven drying or drying in a simple oven. Most of the workers have dried microbial cellulose in a vacuum oven (Chao et al., 2000, Bae and Shoda, 2005, Kim et al., 2006 and Pourramezan et al., 2009). The purified bacterial cellulose pellets were dried to a constant weight at 80 to 105 degree C. in a conventional oven (Hwang et al., 1999 and Son et al., 2001). Harris et al., 2010 (U.S. Pat. No. 7,709,631 B2), have air dried the microbial cellulose mats at 37° C. using polypropylene mesh as base for drying.
[0012] Reference may be made to the study of Kim et al (2006) which utilizes a bacterial strain Gluconacetobacter sp. RKY5 for cellulose production. The strain was isolated from persimmon vinegar as opposed to the strain of Gluconacetobacter oboediens isolated in the present invention from fruits residue. Also, the bacterial strain Gluconacetobacter oboediens is novel cellulose producing bacterial strain and has not been yet reported to produce cellulose. This is the first report of cellulose production by Gluconacetobacter oboediens and that too with much higher yield. The higher microbial cellulose yield by the bacterium of the present invention can be explained on the fact that Gluconacetobacter oboediens MTCC 5610 is more potent than the strain of Kim et al (2006). Also, the difference in the final yields of microbial cellulose in the present study and the study of Kim et al lies in the method of process optimization. After process optimization w.r.t. different parameters by “one variable at time approach” and then, “Response Surface Methodology”, (statistical optimization), the inventors of the present invention achieved a maximum microbial cellulose production of 11.8 g/L, which can be further increased by auxiliary optimization experiments. However, it may be noted that Kim et al (2006), have optimized the process parameters by only “one variable at a time approach” and no statistical optimization was carried out in their study. Further, the process of the present invention is more economic and simple for microbial cellulose production as compared to their process.
[0013] Consequently, by all the facts reported above it can be concluded that the bacterial strain Gluconacetobacter oboediens MTCC 5610 is different from the strains reported in the prior art for microbial cellulose production. Further, the process optimization for achieving higher yields was more efficient and economic than that carried out by the earlier studies.
[0014] In summary, the drawbacks of the hitherto reported literature can be summarized as follows:
There are only few reports on the microbial cellulose production by newer species of Acetobacter ( Gluconacetobacter ) and other bacterial strains. Most of the work on microbial cellulose has been carried out using Acetobacter xylinum , which is the most common and well known cellulose producer. Most of the researches have been conducted only upto flask level, (i.e 30 or 50 ml production medium in a 250 ml Erlenmeyer flask) and a calculated yield per litre is presented. These results do not clearly explain the scalability of the production. There are few reports of microbial cellulose production in static culture condition providing significant titers. There is no report directly related to the scale up of microbial cellulose production in static culture. Most of the workers have scaled up the production in agitated culture either in a jar fermentor or airlift fermentor. Static culture is important as it produces microbial cellulose in a sheet or mat form which is essential for some important applications of microbial cellulose especially in the medical field as wound dressings, artificial skin substitute, material for arterial implants and others. Detailed description on the drying method and recovery of the microbial cellulose therefrom has not been presented by any of the workers. Drying step is very important as it gives the final dry weight i.e final yield of the microbial cellulose produced. There is only one patent by Harris et al., 2010 (U.S. Pat. No. 7,709,631 B2) which has explained the air drying process of microbial cellulose, wherein they have kept the microbial cellulose mats between two pieces of polypropylene mesh and further, kept them in an incubator at 37° C. for 18-36 h. However, the use of polypropylene mesh and incubator thereby for drying is less economical as compared to the process used in the present invention i.e. drying on a wooden plank and a porous fabric which is quite economical.
OBJECTS OF THE INVENTION
[0019] The main object of the present invention is therefore to provide a novel isolated bacterial strain of Gluconacetobacter oboediens MTCC 5610 isolated from fruit residues, which is capable of producing appreciable amounts of microbial cellulose.
[0020] Another object of the present invention is to provide an optimized process for large scale production of microbial cellulose in static culture which is economically viable and cost effective.
[0021] Still another object of the present invention is to obtain high microbial cellulose yield using cheap agro wastes.
[0022] Yet another object of the present invention is to provide a novel method for the efficient drying of the microbial cellulose.
[0023] Still another object of the present invention is to scale up the production of microbial cellulose upto any amount and size under static culture conditions.
SUMMARY OF THE INVENTION
[0024] The present invention provides a novel and potent cellulose producing bacterial species, Gluconacetobacter oboediens isolated from fruit residue (this bacterial culture has been deposited at MTCC, IMTECH, Chandigarh under the deposition number MTCC 5610). The production of microbial cellulose by this bacterium was process optimized and thus, an efficient and economic process for producing high tires of microbial cellulose was developed. Further, a novel and improved method for drying of microbial cellulose was developed wherein the microbial cellulose mats were dried using a wooden plank and porous fabric as a base at temperature of 30 to 40 degree C. The microbial cellulose production was successfully scaled upto 5 liters volume of production medium in trays. The present invention also involves the production and optimization of microbial cellulose in different shapes and sizes (gloves and vessels) which will be of great help for curing burn and injured persons/patients.
[0025] Thus, the present invention provides an optimized economic process for the production of microbial cellulose in static conditions from a new bacterial species, Gluconacetobacter oboediens . The microbial cellulose producing bacterial species was isolated from mixed fruit residues obtained from local market of Satya Niketan, New Delhi—110021, India. The fruit residue was mixed with sugar and water in the ratio of 1 to 3:0.1 to 0.5:2 to 4 respectively followed by incubating for 10 to 15 days at 25 to 35 degree C. in a wide mouthed plastic container so as to isolate the microbial cellulose producers.
[0026] Accordingly, the present invention provides a novel isolated bacterial strain of Gluconacetobacter oboediens having accession number MTCC 5610, wherein the said strain being deposited at the Microbial Type Culture Collection, MTCC, Chandigarh, India a depository recognized under the Budapest Treaty.
[0027] The invention further provides an optimized economic process for the production of microbial cellulose using the isolated bacterial strain MTCC 5610, wherein the said process comprising the following steps:
a) growing the bacterial isolate of Gluconacetobacter oboediens MTCC 5610 under aerobic and static culture conditions in the production medium having 0.1 to 20.0% of a carbon source; 0.5 to 8.0% of a nitrogen source; 0.1 to 0.5% of salts for 4 to 15 days; wherein the pH during cultivation is in the range of 3.0 to 12.0 and the temperature ranges from 10 to 45 degree C.; b) recovering the microbial cellulose mat from the medium of step [a], followed by drying at a temperature of 10 to 45 degree C. for 40 to 45 hours.
[0030] In an embodiment of the invention, the microbial cellulose was produced by growing Gluconacetobacter oboediens under aerobic conditions in the production medium with pH value ranging from 3.0 to 12.0 containing carbon and nitrogen sources in the range from 0.1 to 20.0% and 0.5 to 8.0% respectively, wherein the temperature during cultivation was maintained in the range of 10 to 45 degree C.
[0031] In another embodiment of the invention, the carbon source used is very economic; preferably commercially available table sugar.
[0032] In yet another embodiment, the nitrogen source used for the production of microbial cellulose may be a a cheap agro waste.
[0033] The present invention further relates to a process for drying of the microbial cellulose, scale up of the production in trays and production of microbial cellulose in different shapes.
[0034] In an embodiment, the present invention provides a novel process for the drying of microbial cellulose at 30 to 40 degree C.
[0035] In another embodiment of the invention, the scale up of the microbial cellulose production was carried out in different tray sizes upto 5 liters.
[0036] In yet another embodiment of the invention, a wooden plank and a porous fabric was used for drying of the microbial cellulose.
[0037] In still another embodiment, the microbial cellulose was produced in the shape of gloves and vessels.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0038] In the drawings accompanying the specification, FIG. 1 reveals the formation of a mat like structure (microbial cellulose) on the surface of the fruits residue.
[0039] In the drawings accompanying the specification, FIG. 2 shows the mechanism of cellulose biosynthesis.
[0040] In the drawings accompanying the specification, FIG. 3 shows the picture of microbial cellulose observed under epifluorescent microscope after staining with calcofluor white stain.
[0041] In the drawings accompanying the specification, FIG. 4 shows the scanning electron micrograph of the microbial cellulose.
[0042] In the drawings accompanying the specification, FIG. 5 illustrates the drying process of microbial cellulose at temperature of 30 to 40 degree C. on a wooden plank.
[0043] In the drawings accompanying the specification, FIG. 6 reveals the scale up process of microbial cellulose production in trays.
[0044] In the drawings accompanying the specification, FIG. 7 shows the production of microbial cellulose in different shapes (eg. gloves and vessels).
DETAILED DESCRIPTION OF THE INVENTION
[0045] The present invention provides a process for the isolation of microbial cellulose producing novel bacterial strains isolated from mixed fruit residues. The mixed fruit residue used in the present invention for the isolation of cellulose producing bacteria was collected from a local market of Satya Niketan, New Delhi—110021, India. Of the several isolated strains the novel bacterial strain of Gluconacetobacter oboediens was selected for further studies as it was found to be the most potent microbial cellulose producer. This strain was deposited at the Microbial Type Culture Collection, MTCC, Chandigarh, India a depository recognized under the Budapest Treaty and has been accorded the deposit number MTCC 5610.
[0046] The detailed morphological, cultural and biochemical characteristics of the isolated strain of Gluconacetobacter oboediens MTCC 5610 are as follows:
[0000] Tests Characteristics Growth on agar medium Small, circular and rough colonies; Pellicle-forming colonies in presence of glucose Growth in liquid medium Not uniform Colour Off-white to cream Pigment production No Gram reaction Negative Morphology Rod shaped Arrangement Singly, in pairs or in short chain Sporulation No Motility Motile Growth on 3% ethanol in the + presence of 5-8% acetic acid Growth at a glucose + concentration of 30% (w/v) Requirement of acetic acid for − growth Growth on methanol − Acid formation from D-Glucose + Acetic acid production from + ethanol Cellulose formation +
Complete Process of Isolation of the Bacterial Strains from Fruit Residue is Described Herein Below:
[0047] For isolation of cellulose producing bacterial strains, each of the collected fruit residue was mixed with sugar and water in the ratio of 1 to 3:0.1 to 0.5:2 to 4, respectively. The mixture was then kept in a wide mouthed plastic container and covered with a piece of cloth. The container was kept at temperature of 25 to 35 degree C. for 10 days undisturbed and observed for the formation of a pellicle (mat like structure) on the top of the fruit residue mixture. The mat like structure obtained was analyzed for the presence of cellulose fibrils by calcofluor staining and electron microscopy. The cellulose producing bacteria from the pellicle was isolated after treatment of pellicle with cellulase enzyme (1 mg/ml) at 50 degree C. for 48 h. Further, the bacterial strain obtained was identified on the basis of its physico-chemical properties.
[0048] The present invention further describes an optimized economic process for the production of microbial cellulose by the said bacterial strains.
[0049] The process of the invention involves the following steps:
Isolation of microbial cellulose producer/s was carried using different fruit residues viz. pineapple, apple, orange, pomegranate, sweet lime and mixed fruit. A newer and potent MC producing bacterial species, identified as Gluconacetobacter oboediens was obtained from mixed fruit residue. Process optimization for maximum microbial cellulose production by the said bacterium was carried out by two approaches: 1) One variable at a time approach, 2) Response surface methodology.
[0053] Different physiological and nutritional factors were optimized in order to maximize microbial cellulose production viz. agitation, production medium, pH, temperature, inoculum age, inoculum size, incubation period, carbon and nitrogen sources, metal ions, vitamins etc.
[0054] Production of microbial cellulose was carried out under shaking and static culture conditions in Hestrin-Schramm medium (containing (%): glucose, 2.0%, peptone, 0.5%, yeast extract, 0.5%, citric acid, 0.115% and disodium hydrogen phosphate, 0.27%). Static culture was found to be more suitable for production of MC giving higher yield (0.45 to 0.75 g/l) as compared to shaking culture (0.08-0.18 g/l).
[0055] Microbial cellulose production was carried out using eight different production media. Results showed that CSL-Fructose medium (containing per litre: Corn Steep Liquor 40 ml, Fructose, 70 g, K 2 HPO 4 , 1 g MgSO 4 .7H 2 O, 0.25 g, (NH 4 ) 2 SO 4 , 5.0 g, FeSO4.7H 2 O, 3.6 mg, CaCl 2 .2H 2 O, 14.7 mg, NaMoO 4 .2H 2 O, 2.42 mg; ZnSO 4 .7H 2 O, 1.73 mg, MnSO 4 .5H 2 O, 1.39 mg; CuSO 4 5H 2 O, 0.05 mg Vitamin solution, 10 ml. Vitamin solution consisted of (per 1 L): Inositol, 200 mg; Nicotinic acid, 40 mg: Pyridoxine hydrochloride, 40 mg; Thiamine hydrochloride, 40 mg; Calcium pantothenate, 20 mg, Riboflavin, 20 mg, Folic acid, 0.2 mg; D-biotin, 0.2 mg), supported maximum microbial cellulose production, yielding 1.43 to 2.1 g/l microbial cellulose. Thus, this medium was selected for further optimization studies. Hereinafter, CSL-Fructose medium is also referred to as the production medium.
[0000]
Table depicting the yield of Microbial
cellulose in different production media
Production medium
MC (g/l)
Hestrin-Schramm medium
0.87
CSL-Fructose medium
1.43-2.1
Y3-3 medium
0.9
Generic medium
0.45
Defined medium
0.41
Coconut water medium
1.1
Pineapple juice medium
1.3
Improved medium
0.56
[0056] Production of microbial cellulose by MTCC 5610 was carried out at different pH ranging from 2 to 12 adjusted with different buffers. pH in the range from 3 to 8 was found to be optimum for maximum production yielding 1.9 to 2.5 g/l microbial cellulose.
[0000]
Table depicting the Effect of pH on microbial cellulose production
pH
MC (g/l)
2
nil
3
1.90
4
2.51
5
2.32
6
2.10
7
2.03
8
1.97
9
1.25
10
0.94
11
0.23
12
nil
[0057] The bacterium MTCC 5610 was grown at temperature ranging from 10 to 45 degree C. Maximum microbial cellulose production [2.1 to 2.52 g/l] was obtained at temperature ranging from 25 to 35 degree C.
[0000]
Table depicting the Effect of temperature
on microbial cellulose production
Temperature
MC (g/l)
10
0.08
15
0.31
20
1.1
25
2.44
30
2.52
35
2.14
40
0.94
45
nil
[0058] The microbial cellulose production by MTCC 5610 was carried out for different time periods under the conditions optimized so far. It was observed that the maximum microbial cellulose production (2.3 to 4.1 μl was obtained after 4 to 10 days of incubation period.
[0059] In the present invention, pieces of microbial cellulose mat containing Gluconacetobacter oboediens MTCC 5610 were used as inoculum. Inoculum age and size were optimized for microbial cellulose production. Inoculum of 1 to 5 days with a size of 5 to 12 mat pieces of 10×12 mm per litre was found to be optimum for maximum cellulose production (3.2 to 6.7 g/l).
[0060] Further, different nutritional factors viz., carbon and nitrogen sources, metal ions, vitamins etc. were optimized for maximizing microbial cellulose yield. Different carbon sources (monosaccharides and disaccharides) were used for microbial cellulose production and sucrose was found to be best and cheapest carbon source as compared to fructose (control) producing maximum microbial cellulose (6.5 to 7.2 g/l).
[0061] In order to make the production medium more cost effective, three different low cost carbon sources were evaluated for microbial cellulose production, viz. jaggery, cane molasses and table sugar. Among these, table sugar was found to a promising carbon source giving yield equivalent to sucrose. Table sugar is 15-20 times cheaper as compared to sucrose. Thus, the selection of table sugar as the carbon source resulted in an economic medium for microbial cellulose production. The production of microbial cellulose was carried out at different concentrations of table sugar ranging from 0.1 to 20%. Maximum production was obtained at 1.0 to 10.0% concentration of table sugar.
[0062] Microbial cellulose production was carried out in the presence of different organic and inorganic nitrogen sources. Corn steep liquor, an agro waste, was found to the best nitrogen source supporting maximum microbial cellulose production. Ammonium sulphate supported microbial cellulose production as an additive. Different concentrations of corn steep liquor ranging from 0.5 to 8.0% were used for producing microbial cellulose. Corn steep liquor at a concentration of 1.0 to 5.0% was found to be optimum for microbial cellulose production yielding 7.1 to 8.7 g/l microbial cellulose.
[0063] The basal production medium optimized so far contains a number of metal ions (metal salts) in traces. The effect of these metal ions was evaluated by carrying out microbial cellulose production in the absence and presence of these salts. It was observed that the microbial cellulose production was equal both in the absence and presence of these metal ions. Thus, all these metal salts were omitted from the production medium. This made the production medium more simple and economic. However, it was observed that the other two metal salts i.e. magnesium sulphate and dipotassium hydrogen phosphate significantly affected microbial cellulose production. The production of microbial cellulose decreased in the absence of these two salts.
[0064] The basal production medium optimized so far also contained different vitamins. The effect of these vitamins was evaluated on the production medium in the similar manner as for metal ions. The microbial cellulose production was found to be equivalent in the absence and presence of these vitamins. Thus, the vitamins were also omitted from the production medium. This made the cellulose production medium much more simple and economic.
[0065] The microbial cellulose production was further optimized by a statistical approach, Response Surface Methodology to enhance the productivity. Results show that the interaction of the most influential parameters (CSL, sugar and inoculum size) obtained after one variable at a time approach resulted in a maximum yield of 12.0 to 16.0 g/l of microbial cellulose after a period of 4 to 10 days of incubation at sugar: 1.0-8.0 (% w/v); CSL: 1.0-5.0 (% v/v) and inoculum size, 1 to 8 (mat pieces/L), whereas the maximum yield by response surface methodology was 18.0 to 20.0 g/l.
[0066] The microbial cellulose mats produced were processed and purified by alkali and acid treatment. The mats were further bleached to remove the remaining colour of the medium. The mats were finally washed with water and dried. The microbial cellulose mats were dried by freeze drying and air drying. Freeze dying provides a white paper like sheet of microbial cellulose. This method of drying is quite costly as it consumes a lot of electricity. Thus, in order to make the drying process cost effective the microbial cellulose mats were air dried using a novel, simple and economic method. The mats were dried on a wooden plank and a porous fabric at a temperature of 30 to 40 degree C. It was observed that air dying of microbial cellulose provides a transparent sheet of microbial cellulose.
[0067] Scale up of microbial cellulose production was carried out upto 5 litres in trays. It was observed that the production of microbial cellulose was successfully scaled upto 5 litres yielding 60-80 g of microbial cellulose. This proves that microbial cellulose can be successfully produced to any amount and size.
[0068] Further, the microbial cellulose was produced in different shapes, viz. gloves and vessels. This explains one of the most important properties of microbial cellulose that it can be molded in any shape, which makes microbial cellulose an important and versatile material for different medical applications.
[0069] Thus, it can be inferred that the microbial cellulose produced by the novel isolated strain of Gluconacetobacter oboediens MTCC 5610 has immense importance in different sectors, especially in the medical field. The important applications of microbial cellulose are presented in the following table:
[0000]
INDUSTRIAL SECTORS
APPLICATIONS
Health care
1. Wound care dressings
2. Drug delivery agent, either oral or dermal
3. Artificial skin substrate
4. Component of dental and arterial implants
Cosmetics and Beauty
1. Skin creams
2. Astringents
3. Base for artificial nails
4. Thickener and strengthener for fingernail
polish
5. Tonics
6. Nail conditioners
Food
1. Desserts (Nata de Coco, low calorie ice
creams chips, snacks, candies)
2. Thickners (ice cream and salad dressing)
3. Base for weight reduction
4. Sausage and meat casings
5. Serum cholesterol reduction
6. Kombucha elixir or Manchurian tea
Cellulose derived
Production of cellophane, carboxymethyl
products
cellulose and cellulose acetate
Clothing and shoe
1. Artificial leather products
2. One piece textiles
3. Highly adsorptive materials
Petroleum and mining
1. Mineral and oil recovery
2. Recycling of minerals and oils
Papers
1. Archival document repair
2. Paper base for long lived currency
3. Specialty papers
4. Napkins
Forest products
1. Artificial wood strengthener (plywood
laminates)
2. Filler for paper
3. High strength containers
4. Multilayer plywood
5. Heavy duty containers
Audio products
Superior audio speaker diaphragms
Outdoor sports
1. Disposable tents and camping gear
2. Sport clothes
Public utilities
1. Water purification via ultra filters
and reverse osmosis membranes
Babycare products
1. Disposable recyclable diapers
Automotive and aircraft
1. Car bodies
2. Airplane structural elements
3. Sealing of cracks in rocket casings
EXAMPLES
[0070] The following examples are given by way of illustration and therefore should not be construed to limit the scope of the present invention.
Example 1
Isolation of Cellulose Producer/s from Fruit Residues
[0071] The isolation of cellulose producer/s was carried out using six different fruit residues (apple, pineapple, orange, sweet lime, pomegranate and mixed). Here, each fruit residue was mixed with sugar and water in the ratio of 1:0.2:3, respectively. The mixture was kept in a wide mouthed plastic container and covered with a piece of cloth. The container was kept at temperature of 30 degree C. for 10 days undisturbed and observed for MC production. After 10 days, it was observed that at the top of the pineapple, orange, sweetlime and mixed fruit residue mixtures, a mat like structure was deposited. This mat like structure was analyzed for the presence of cellulose fibrils by calcofluor staining and electron microscopy. The results showed that the mat like structure was composed of a network of ultrafine cellulose fibrils and it also contained rod shaped bacterial cells producing cellulose [ FIGS. 1 , 3 & 4 ].
Example 2
Screening of the Bacterial Isolates Obtained from Fruit Residues for Microbial Cellulose Production
[0072] All the isolates obtained from different fruit residues were evaluated for their potential to produce microbial cellulose. These isolates were inoculated individually in 250 ml Erlenmeyer flasks containing 50 ml cellulose production medium (Hestrin-Schramm medium) containing (g/l) glucose, 20; peptone, 5; yeast extract, 5; disodium hydrogen phosphate, 2.7 and citric acid, 1.15; and incubated for 15 days at 30 degree C. under static conditions for cellulose production. A compact mat was formed on the air-liquid interface of the medium by all the isolates. The mat was removed from the medium and examined for the presence of cellulose fibrils by calcoflour staining and SEM observation [ FIGS. 3 & 4 ]. The mat was found to be composed of cellulose fibrils. The isolate obtained from the mixed fruit residue was found to be the most potent cellulose producer producing maximum microbial cellulose (0.45 to 0.75 g/l). Further, it was identified as Gluconacetobacter oboediens by 16S rRNA (875 base pair) analysis. Sequence of 16S rRNA has been provided herein.
[0000]
SEQ ID No. 1: 16S rRNA sequence of
Gluconacetobacter oboediens
TTTTTTTCCCCCCCGGAACGTCACGCGGCATCCTGATCCGCGATTACTAG
CGATTCCACCTTCATGCACTCGAGTTGCAGAGTGCAATCCGAACTGAGAC
GGCTTTTTGAGATCGGCTCGGTGTCACCACCTGGCTTCCCACTGTCACCG
CCATTGTAGCACGTGTGTAGCCCAGGACATAAGGGCCATGAGGACTTGAC
GTCATCCCCACCTTCCTCCGGCTTGTCACCGGCAGTTCCTTTAGAGTGCC
CACCCAGACGTGATGGCAACTAAAGGCGAGGGTTGCGCTCGTTGCGGGAC
TTAACCCAACATCTCACGACACGAGCTGACGACAGCCATGCAGCACCTGT
GCTGGAGGTCTCTTGCGAGAAATGCCCATCTCTGGACACGGCCTCCGCAT
GTCAAGCCCTGGTAAGGTTCTGCGCGTTGCTTCGAATTAAACCACATGCT
CCACCGCTTGTGCGGGCCCCCGTCAATTCCTTTGAGTTTCAACCTTGCGG
CCGTACTCCCCAGGCGGTGTGCTTATCGCGTTAACTACGACACTGAATGA
CAAAGTCACCCAACATCCAGCACACATCGTTTACAGCGTGGACTACCAGG
GTATCTAATCCTGTTTGCTCCCCACGCTTTCGCGCCTCAGCGTCAGTCAT
GAGCCAGGTTGCCGCCTTCGCCACCGGTGTTCTTCCCAATATCTACGAAT
TTCACCTCTACACTGGGAATTCCACAACCCTCTCTCACACTCTAGTCGCC
ACGTATCAAATGCAGCCCCCAGGTTAAGCCCGGGAATTTCACATCTGACT
GTGTCAACCGCCTACGCGCCCTTTACGCCCAGTCATTCCGAGCAACGCTT
GCCCCCTTCGTACTACAGCGCTGCGCGCGCGCACACAAAG
Example 3
Air Drying (Drying at Room Temperature) of Microbial Cellulose
[0073] The air drying method of microbial cellulose has one drawback i.e it sticks to the base on which it is kept for drying and it becomes difficult to recover it. For solving this problem, two bases were discovered and used for the air drying of the microbial cellulose mats. These were: a wooden plank and a porous fabric. The wet mats of purified microbial cellulose were placed on these two bases and left for 45 hours at a temperature of 35 degree C. After this time period, the mats were fully dried. It was observed that the mats did not sticked on the bases used and were easily recovered [ FIG. 5 ].
[0074] The reason behind the success of these two bases is that both the materials are porous and the air passes through them, while in all the other cases where the mat sticks on the base, a vacuum is created because the bases used were not porous but rigid and do not allow any air to pass through them. Therefore, the microbial cellulose sticks on these bases and cannot be removed.
Example 4
Scale Up of Microbial Cellulose Production Upto 5 L in Static Culture in Different Tray Sizes
[0075] Trays of four different sizes viz. 18×14×5 cm 3 , 28×23×5 cm 3 , 33.5×28×4.5 cm 3 and 42×34×7 cm 3 were used for scale up of production of microbial cellulose upto 5 L in static culture. The trays were sterilized and the sterilized production medium was poured aseptically in trays with different volumes i.e. 200, 500, 1000, 2000, 3000, 4000 and 5000 ml. These trays were inoculated with mat pieces (2 to 8 mat pieces of 10×12 mm per litre) and incubated at a temperature of 30 degree C. for 10 days under static conditions [ FIG. 6 ].
[0076] After incubation it was observed that a compact and rigid microbial cellulose mat having considerable strength and dimension as the respective tray size and depth of the medium was produced successfully upto 5 L. The dimension of the 5 L microbial cellulose mat was 42×34×2.7 cm 3 with a cellulose yield of 60 to 80 g.
Example 5
Production of Microbial Cellulose in the Shape of Gloves and Vessels
[0077] In this experiment, latex gloves and silicon tubes (30 cm long) of different diameters viz. 3 and 6 mm (inner diameter) were used for producing microbial cellulose in their respective shapes. These materials were sterilized at 15 psi for 15 min. Before sterilization, both mouth ends of the silicon tubes were closed with a piece of klin wrap.
[0078] Cellulose production medium was prepared and sterilized. Now, the sterilized medium was poured aseptically in the gloves (200 ml) and tubes (10-40 ml capacity). The gloves were hanged with the help of a support in a big glass container. They were incubated at a temperature of 35 degree C. for 5 days under static conditions. It was observed that the microbial cellulose was successfully produced in the shape of gloves and tubes/vessels [ FIG. 7 ].
Advantages
[0079] The main advantages of the present invention are:
The bacterial species used in the present invention, Gluconacetobacter oboediens , is a new microbial cellulose producer. The production of microbial cellulose by this species of Gluconacetobacter is not reported earlier. This is the first report of microbial cellulose production by this bacterial culture. Thus, the present invention relates to the production of microbial cellulose by a novel microorganism. The optimized production medium i.e. CSL-Fructose medium used for microbial cellulose production is simple and economic containing low cost carbon and nitrogen sources, viz. table sugar & corn steep liquor (agro waste), respectively and only few salts in traces. It provides an optimized, efficient and cost effective process for the production of high titers of microbial cellulose and further, its successful scale up in static culture in trays. All the optimization experiments of microbial cellulose production conducted in 1 litre volume have the potential to be scaled up in all sets of experiments. The present invention also provides a novel and economic method for air drying of microbial cellulose mats using a wooden plank and porous fabric as a base. This step is very important as after drying only, the final dry weight of the microbial cellulose can be taken. | The present invention provides a novel and potent cellulose producing bacterial species, Gluconacetobacter oboediens which was isolated from mixed fruit residue deposited at MTCC, IMTECH, Chandigarh under the deposition number MTCC 5610. The process for the production of microbial cellulose by this bacterium was optimized and thus, an efficient and economic process for producing high titres of microbial cellulose was developed. Further, a novel and improved method for drying of microbial cellulose has been developed wherein the microbial cellulose mats were dried using a wooden plank and porous fabric as a base at room temperature. The microbial cellulose production was successfully scaled up to 5 liters volume of production medium in trays. The present invention also recites the production and optimization of microbial cellulose in different shapes and sizes (gloves and vessels) which will be of great help for burn and injured persons/patients. | 2 |
This is a division, of application Ser. No. 595,652, filed July 14, 1975 now U.S. Pat. No. 4,048,078 issued Sept. 13, 1977.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to an oil recovery method, and more specifically to a method for recovering oil or petroleum from a subterranean viscous petroleum containing formation such as a tar sand deposit in which a fluid comprising superheated steam and air is introduced into the formation to displace the oil.
2. Description of the Prior Art
There are known to exist throughout the world many subterranean petroleum containing formations from which the petroleum cannot be recovered by conventional means because of the relatively high viscosity thereof. The best known of such viscous petroleum containing formations are the so-called tar sands or bituminous sand deposits. The largest and most famous such deposit is in the Athabasca area in the northeastern part of the Province of Alberta, Canada which is known to contain over 700 billion barrels of petroleum. Other extensive deposits are known to exist in western part of the United States, and Venezuela, and lesser deposits in Europe and Asia.
Tar sands are frequently defined as sand saturated with a highly viscous crude petroleum material not recoverable in its natural state through a well by ordinary production methods. The hydrocarbon contained in tar sand deposits are generally highly bituminous in character. The tar sand deposits are generally arranged as follows. Fine quartz sand is coated with a layer of water and the bituminous material occupies most of the void space around the wetted sand grains. The balance of the void volume may filled with connate water, and occasionally a small volume of gas which is usually air or methane. The sand grains are packed to a void volume of about 35%, which corresponds to about 83% by weight sand. The balance of the material is bitumen and water. The sum of bitumen and water will almost always equal about 17% by weight, with the bitumen portion varying from about 2% to around 16%.
It is an unusual characteristic of tar sand deposits that the sand grains are not in any sense consolidated, that is to say the sand is essentially suspended in the solid or nearly solid hydrocarbon material. The API gravity of the bitumen usually ranges from about 6 to about 8, and the specific gravity at 60° F. is from about 1.006 to about 1.027. Approximately 50% of the bitumen is distillable without cracking, and the sulfur content averages between 4 and 5% by weight. The bitumen is also very viscous, and so even if it is recoverable by an in situ separation technique, some on-site refining of the produced petroleum must be undertaken in order to convert it to a pumpable fluid.
Bitumen may be recovered from tar sand deposits by mining or by in situ processes. Most of the recovery to date has been by means of mining, although this is limited to instances where the ratio of the overburden thickness to tar sand deposit thickness is economically suitable, generally defined as one or less. In situ processes have been proposed which may be categorized as thermal, such as fire flooding or steam injection, and steam plus emulsification drive processes. Generation of thermal heat necessary to mobolize the bitumen by means of a subterranean atomic explosion has been seriously considered, although has not yet been attempted.
Despite the many proposed methods for recovering bitumen from tar sand deposits, there has still been no successful exploitation of such deposits by in situ processing on a commercial scale up to the present time. Accordingly, there is a definite need in the art for a satisfactory in situ combustion process, and especially in view of the enormous reserves present in this form which are needed to help satisfy present energy needs, there is a substantial need for a workable method for recovery of bitumen from tar sand deposits.
SUMMARY OF THE INVENTION
In its broadest aspect this invention relates to a method for recovering petroleum from subterranean, viscous petroleum containing formations including tar sand deposits, said formations being penetrated by at least one injection well and by at least one production well, comprising:
(a) establishing a fluid communication path in the formation between the injection well and the production well;
(b) injecting via an injection well a fluid comprising superheated steam and air under pressure into the formation whereby in situ combustion is initiated in the formation providing heat and pressure for driving the petroleum in the formation toward the production well, and
(c) recovering petroleum from the formation via the production well.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE depicts an injection well through which the superheated steam-air mixture is injected into the formation which is equipped to serve as a superheater.
DETAILED DESCRIPTION OF THE INVENTION
In the first step of this process a communication path is established in the formation. The ideal communication path is an essentially horizontal, pancake shaped zone of high permeability preferably at or near the bottom of the tar sand or petroleum reservoir.
It is sometimes discovered that there is a water saturated zone in the very bottom of the petroleum reservoir, and this may be utilized successfully to establish the fluid communication path in accordance with our process. The water-saturated zone may be opened up by injecting into the zone a heated fluid such as steam, which will channel preferentially through this water saturated zone to the production well. Asphaltic or other solid or semi-solid hydrocarbon materials present in the water saturated zone will be melted and rendered mobile, and the permeability will be opened up considerably thereby.
Generally, it will be necessary to open up the communication path through the formation by some other means such as hydraulic fracturing. Hydraulic fracturing is a well known technique for establishing a communication path between an injection well and a production well. Fracturing is usually accomplished by forcing a liquid such as water, oil or any other suitable hydrocarbon fraction into the formation at pressures of from about 300 to about 1,500 psig which are sufficient to rupture the formation and to open up channels therein. By use of this method it is possible to position the fracture at any desired vertical location with respect to the bottom of the oil filled zone. It is not essential that the fracture planes be horizontally oriented, although it is of course preferable that they be.
In any event, a communication path of some sort is created, generally confined to the lower portion of the petroleum reservoir. After the fracture has been established, and without diminishing the fracture pressure, a propping agent may be injected into the fracture in order to prevent healing of the fracture which would destroy its usefulness for fluid flow communication purposes. Gravel and sand or mixtures thereof are employed as propping agents, and it is desirable in the instance of tar sand deposits that a wide variation of particle sizes be employed to avoid flowing of the tar sand materials back into the propped fracture zone.
In the next step of the process of this invention a fluid comprising about 20 to about 80 percent by weight of superheated steam and from about 80 to about 20 percent by weight of air at temperatures ranging from about 200° to about 1800° F and pressures ranging from 50 to about 2000 psig is injected into the communication path previously formed in the formation.
In preparing the superheated steam and air mixtures generally steam at a pressure of about 300 to about 1000 psig. is generated in conventional boilers at temperatures preferably above 800° F.
An alternate procedure for injecting the superheated steam-air mixture is to equip the well to serve as a superheater.
By this method air and superheated steam are injected via an injection well into a subterranean hydrocarbon-bearing formation with a minimum of heat loss to extraneous earth formations by a method which comprises:
(a) placing three tubular means inside the well casing so as to provide an annular space between each tubular means and the casing, wherein the said three tubular means comprise an open-end innermost tubular means in communication with a closed end intermediate tubular means and an outer tubular means extending into the formation and being perforated so that there is communication with the hydrocarbon reservoir and wherein said casing extends into the hydrocarbon reservoir,
(b) injecting steam into the annular space between the open end innermost tubular means and the closed end intermediate tubular means and withdrawing condensate via the open-end innermost tubular means whereby the intermediate tubular means is heated,
(c) injecting steam having a temperature below that of the steam injected in step (b) into the annular space between the outer tubular means and the intermediate tubular means whereby the steam injected in (c) is superheated and forcing the superheated steam into the hydrocarbon-bearing formation via the perforations in the outer tubular means, and
(d) injecting air into the annular space between the casing and the outer tubular means and forcing the said air into the hydrocarbon formation.
Such an injection well is shown in the Figure. In this arrangement three strings of concentrically located tubing, that is 10, 11, and 12, are employed inside of casing 9. Closed-end tubing string 10 penetrates the well to a depth above perforations 13. A smaller open-ended tubing string 12 penetrates the closed end tubing 10 to a depth just above that of the closure in tubing string 10. Tubing string 11 which as a larger diameter than string 10 penetrates the oil-bearing formation and is equipped with perforations 13 which are positioned so that they open into the oil-bearing zone. Well casing 9 is seated at a point just below the top of the oil-bearing formation and is open at the lower end.
Steam of about 80 percent quality is formed in generator 20 and passed via line 22 into the annular space 21 between tubing strings 10 and 12. As the steam passes down this annular space the walls are heated and the steam which condenses collects at the bottom of closed-end tubing 10 after which the condensate is returned to steam generator 20 via tubing 12 and line 24. Steam from steam boiler 26 having a temperature below that of the steam-flowing in line 22 is injected via line 28 into annular space 30 where it is superheated as it passes downwardly through annular space 30. This superheated steam is then forced into the oil-bearing formation via perforations 30 of tubing strings. Air is injected into annular space between casing 9 and tubing 11 and enters the oil-bearing formation at 34. Thus, in the above-described well arrangement the injection well serves as a superheater.
If described, the fluid, that is the oil-displacing fluid, injected into the formation may comprise an alkaline fluid or an alkaline fluid containing a minor amount of a useful group of the water-soluble, oxyalkylated, nitrogen-containing aromatic compounds are those having the formula:
R(OR').sub.n OH,
wherein R is selected from the group consisting of: ##STR1## wherein R' is alkylene of from 2 to 4 inclusive carbon atoms and n is an integer of from about 5 to about 50 and preferably from about 5 to about 20. These novel water-soluble oxyalkylated products can be conveniently prepared by a number of processes well known in the art and their preparation is more completely described in U.S. Pat. No. 3,731,741 which is incorporated herein by reference in its entirety.
Another group of solubilizing agents which are highly useful in the process of this invention include compounds of the formula: ##STR2## wherein r is an integer of from about 3 to about 10, s is an integer of from about 5 to about 50 and wherein the sum of 5 plus s is not more than 55.
Solubilizing agents of this type can be formed in the same manner as described in U.S. Pat. No. 3,731,741 employing as starting aromatic compounds 8-quinolinesulfonic chloride, 6-quinolinesulfonyl bromide, etc., as initiators and reacting the initiator first with the necessary amount of propylene glycol of the required molecular weight followed by the necessary amount of ethylene glycol of the required molecular weight. The quinoline starting, material may also be substituted by other innocous groups such as alkoxy of from 1 to 4 carbon atoms, alkyl, etc.
EXAMPLE I
This invention is best understood by a reference to the following examples which are offered only as illustrative embodiments of this invention, and are not intended to be limitative or restricted thereof.
A tar sand deposit is located at a depth of 875 feet and it is determined that the thickness of the formation is 120 feet. It is also determined that the petroleum is in the form of a highly bituminous hydrocarbon, and its viscosity at the formation temperature is much too high to permit recovery thereof by conventional means. An injection well is drilled to the bottom of the formation, and perforations are formed between the interval of 850-875 feet, i.e., the bottom of the petroleum saturated zone. A production well is drilled approximately 600 feet distance from the injection well, and perforations are similarly made slightly above the bottom of the petroleum saturated zone. The production well is also equipped with a steam trap so that only liquids can be produced from the formation, and vapors are excluded therefrom.
A fluid communication path low in the formation is formulated by fracturing the formation using conventional hydraulic fracturing techniques, and injecting a gravel-sand mixture into the fracture to hold it open and prevent healing of the fracture.
In the next step a fluid comprising a mixture of about 50 weight percent steam and about 50 weight percent air at a temperature of about 1000° F and at a pressure of about 300 psig. is introduced into the formation at the rate of 5000 lbs/hour. via the previously prepared fluid communication path. Injection of the steam-air mixture is continued and the production of viscous oil via the production well commences after about 30 days and gradually increases an injection of the oil-displacing fluid is continued. At the end of 60 days produciton of the viscous hydrocarbons is significantly increased over production of similar wells in the same formation utilizing only steam injection.
EXAMPLE II
In this example viscous oil is recovered from a tar sand at a depth of 700 feet and having a thickness of about 28 feet. An injection well is drilled to the bottom of the hydrocarbon bearing structure and the casing perforated in the interval 705 to 715 feet. In a like manner a production well drilled at a distance of about 465 feet from the injection well is perforated at a depth of 700-710 feet, i.e., near the center of the tar sand formation at that location.
In the next step a fluid communication path is formed by fracturing the formation in both wells using conventional hydraulic fracturing technique. A gravel-sand mixture is injected into the formation to hold it open and to prevent healing of the fracture. A mixture fluid comprising a mixture of about 40 percent by weight of steam and about 60 percent by weight of air at a temperature of about 1200° F and at a pressure of about 1000 psig together with 0.001 weight percent of sodium hydroxide and 0.002 weight percent of a solubilizing agent of the formula: ##STR3## is injected into the fluid communication path via the injection well at a rate of 600 lbs/hour. Injection of this fluid is continued and after about 20 days production of viscous oil is commenced via the production well. Production increases gradually as injection of the fluid is continued. At the end of 60 days the level of production reaches is substantially in excess of that obtained with similar wells in the same formation utilizing only steam injection. | Petroleum may be recovered from viscous petroleum containing formations including tar sand deposits by first creating a fluid communication path in the formation, followed by injecting via an injection well a fluid comprising superheated steam and air into the formation via the fluid communication path whereby in situ combustion occurs providing heat and pressure for driving the petroleum in the formation toward the production well. Recovery of the displaced petroleum is accomplished via the production well. | 4 |
FIELD OF THE INVENTION
This invention relates to powder insufflating devices and/or the coating of teeth; and more particularly it relates to a dental powder insufflator for blowing metered amounts of powdered material, e.g. therapeutic material, into a patient's mouth and/or onto the patient's teeth.
BACKGROUND OF THE INVENTION
In the treatment of dental or mouth problems there is a need for a convenient and accurate means for delivering selected amounts of powdered chemotherapeutic material, such as adhesive and microcapsules, or a fluoride salt containing powder, or other desired treatment materials, in predetermined repeated dosages to a patient's teeth, or in the form of a metered single dosage, with the ability to select the specific teeth to be treated.
Although insufflation devices for introducing medicinal powder into various body cavities are known, none of the previosly known devices provides the ability to repeatedly furnish a desired number of accurately known dosages and to direct the dosages to a patient's teeth. Furthermore, the previously known insufflation devices are relatively cumbersome, are difficult to refill, are subject to frequent clogging, and cause excessive loss and wastage of the powdered medicinal material.
A preliminary search reveals the following prior U.S. Pat. Nos. which appear to illustrate the present state of the art:
Harris,--3,998,226
Lazisky,--2,800,673
Crain et al.,--1,934,793
Kark,--2,501,279
Davis,--2,570,774
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to overcome the deficiencies in the prior art, such as mentioned above.
Another object is to provide for the improved blowing of powder onto teeth.
A further object of the invention is to provide a novel and improved apparatus for delivering a predetermined dosage of powdered material to a patient's teeth.
A still further object of the invention is to provide an improved insufflation device for blowing powder onto teeth, or for delivering medicinal powder to the mouth or other parts of the body, the device being simple in construction and compact in size, and providing accurate metering of the powder.
A still further object of the invention is to provide an improved device for blowing chemotherapeutic material onto a patient's teeth in accurately measured dosages, and for repeating such dosages as required, with the ability to direct the dosages of powdered material to specific teeth, the device being substantially self-clearing so as to minimize clogging, being easy to refill, and providing economical utilization of the powdered therapeutic material.
A still further object of the invention is to provide an improved insufflation device for blowing doses of chemotherapeutic powdered material onto a patient's teeth, or for delivering doses of other medicinal powdered material to other parts of the body, the device being inexpensive to manufacture, being easy to manipulate, and having a minimum number of moving parts.
A still further object of the invention is to provide an improved device for blowing predetermined dosages of medicinal powder or other powdered chemotherapeutic material onto a patient's teeth, the device providing accurately metered doses of the material by the use of an apertured slidable dosing bar reciprocably disposed between the bottom dispensing duct of a powder reservoir and an offset delivery conduit leading to a discharge nozzle, the conduit carrying a stream of pressurized air, the bar having a metering aperture registrable with the dispensing duct and being movable longitudinally to bring the powder-filled metering aperture into registry with the delivery conduit, thereby allowing repeated measured doses of powder material to be delivered to the air stream of the device, and preventing loss of the powdered material when the dosing bar is not reciprocated.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and advantages of the invention will become apparent from the following description of possible specific embodiments, and from the accompanying drawings thereof, wherein:
FIG. 1 is a longitudinal vertical cross-sectional view taken through one form of powder blower device constructed in accordance with the present invention.
FIG. 2 is a horizontal cross-sectional view taken substantially on the line 2--2 of FIG. 1.
FIG. 3 is a fragmentary horizontal cross-sectional view of a portion of the structure of FIG. 2, but showing the dosage metering bar in a dosage-delivering position.
FIG. 4 is a longitudinal vertical cross-sectional view of a modified, semi-automatic form of powder blower device constructed according to the present invention.
It is to be understood that such embodiments are intended to be merely exemplary and in no way limitative.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the drawings, and more particularly to FIGS. 1 to 3, 11 generally designates a powder blower device according to the present invention. The device 11 comprises a handpiece consisting of an elongated housing 12 on which is mounted a powder storage hopper 13 having a downwardly tapering bottom portion 14 terminating in a discharge duct or orifice 15.
Designated at 16 is a shuttle bar which is slidably mounted in a longitudinal recesss 17 formed in housing 12 and extending subjacent duct 15. Housing 12 is formed at its forward portion with a bore 18 aligned with recess 17 and containing a coiled spring 19 which bears between housing end plate 20 and the left hand edge of bar 16, as viewed in FIG. 1, biasing bar 16 rightwardly toward the position shown in FIG. 1, namely, toward a rightward limiting position in recess 17.
Rigidly secured to the right end of bar 16, as viewed in FIG. 1, is a longitudinal rod element 21 extending slidably through a guide bore 22 in the right end portion of housing 12 and provided at its outer end with a push button or head 23 for exerting manual operating pressure on the dosage bar 16.
Bar 16 is formed with a dosage aperture 24 which registers with duct 15 in the normal position of bar 16, as shown in FIG. 1.
Secured in housing 12 is a longitudinally extending rigid discharge conduit 25 provided at its outer end with a powder blower nozzle element 26. Conduit 25 has an inner end portion 27 which extends perpendicular to and communicates with recess 17. Said conduit end portion 27 is aligned with the inner end 28 of an inclined air conduit 29 which is secured in housing 12 and which is connected to a compressed air source 30, which may comprise a compressor, blower, air bottle, or any other suitable regulated air pressure source.
Dosage bar 16 is formed with a longitudinal slot 31 which is located so that its left end portion, as viewed in FIG. 1, registers with and communicatively connects conduit portions 27 and 28 in the normal position of bar 16 shown in FIG. 1.
When button 23 is pushed leftwardly, as viewed in FIG. 1, the powder-filled dosage aperture 24 is moved leftwardly and can be brought into registry with the aligned conduit portions 27,28, whereby the dosage of powder is caught by the air stream through the conduit 25 and is discharged from the nozzle 26 toward its intended dental area, for example, a tooth 32 to be treated with the powder.
The rod 21 may be of suitable length to cause registry of aperture 24 with the aligned conduit portions 27,28 when button 23 engages the right end wall surface of housing 12, as shown in FIG. 3.
The elongated slot 31 allows the passage of air for nozzle cleaning purposes during inactive periods of use.
It will thus be seen that the powder blower device 11 can be employed to repeatedy deliver on demand consistent doses of a dry powder, dental therapeutic agent, or the like, shown at 33, to the teeth. For example, the therapeutic agent may comprise a microencapsulated cariostatic agent in an adhesive powder dispersion. The manually triggered device 11 transfers a predetermined dose volume of dental therapeutic agent 33 from the storage hopper 13 into the air stream conduit 25, which conveys the powder to the desired dental area via the aimed delivery nozzle 26, as above described. The transfer is accomplished by the reciprocating shuttle bar 16 containing the dosage metering cavity 24. In the inactivated mode the cavity 24 is aligned with the hopper orifice 15. When activated, the receiving cavity 24 is aligned with the delivering air stream conduit portions 27,28.
The hopper 13 retains the powder 33 in a dry form without spillage or compaction and is easily refilled. For example, the hopper 13 may have a screw cover cap 34 which can be removed for refilling the hopper; any other suitable refilling means may be employed, such as an attachable vial.
The powder storage hopper orifice delivers the stored powder 33 to the receiving cavity 15 of the shuttle bar 16, said cavity 15 performing two functions: (1) it determines the single dose volume of the powder agent to be delivered, and (2) it defines the receptacle wherein the powder is conveyed from the hopper orifice 15 to the air stream conduit elements 27,28.
The shuttle bar return spring 19 reciprocates the shuttle bar 16 when inactivated in order to realign the shuttle bar receiving cavity 24 with the hopper orifice 15 so that the next powder charge may enter the cavity 24.
The recess 17 maintains the shuttle bar 16 in proper position in the housing 12 and restrains the shuttle bar from undesired movement relative to the hopper 13 and the air stream conduit elements 27,28. Also, the recess 17 has a sufficiently close fit with the shuttle bar 16 to prevent the powder from spilling during the transport from the hopper to the air stream. As seen in FIGS. 1 and 2, the housing 12 can be the support member for the delivery nozzle 26 and accessory components.
As above mentioned, when the device 11 is actuated the powder is introduced into the air stream and is conveyed to the delivery nozzle 26. Said nozzle 26 performs the following functions:
a. It is the instrument for aiming the powder at a specific dental area in need of therapy.
b. It restricts the size of the spray area.
c. It determines the position of the powder blower relative to the mouth and teeth.
d. It determines the ejection velocity of the air/powder suspension.
In operation, the air source 30 is activated, the powder blower hopper 13 is filled with the appropriate powder, and the nozzle 26 is held adjacent to the dental area to be treated. The shuttle bar control button 23 is actuated as above described to transfer the dose of powder from the hopper to the air stream, by which it is conveyed automatically via nozzle 26 to the selected dental area.
The air source 30 provides the compressed air conveyance for the powder, and the cleansing air for the shuttle bar 16 to prevent powder from jamming between the shuttle bar and the surfaces of recess 17.
FIG. 4 illustrates a semi-automatic form of powder blower according to the present invention wherein the compressed air source 30 is used to activate the shuttle bar via an integral piston. Thus, the shuttle bar, designated at 40, is integrally connected to the stem 41 of a piston 42 contained in a cylindrical bore 43 in the blower housing 44, and is biased leftward, as viewed in FIG. 4, by a coiled spring 45 surrounding the stem 41. The shuttle bar 40 has an end abutment head 46, movable in a recess 47 in housing 44, which limits the leftward travel of bar 40 to a blocking position relative to the hopper orifice 15. The shuttle bar 40 has a metering aperture 48 which is normally located in the air stream path defined between the aligned air conduit portions 49,50 leading to the powder delivery nozzle 51. The compressed air source 30 is connected to a main conduit 52 via a control valve 54, and the conduit portion 49 is connected to said main conduit 52 via an adjustable restriction 53. Main conduit 52 is normally connected to the bore 43 through the diametral passage 55 of the piston 56 of a control valve assembly 57 mounted in housing 44. The valve assembly 57 has an operating lever 58 engaging a piston pin 59 on valve piston 56, which is biased upwardly, as viewed in FIG. 4, by a coiled spring 60. Valve piston 56 has a vent passage 61 which is communicatively connected to bore 43 in place of passage 55 when lever 58 is rotated downwardly to a limiting position against the top flange 62 of valve assembly 57.
When control valve 54 is opened, compressed air through passage 55 acts on piston 42 and moves shuttle bar 40 rightwardly a distance D to bring metering cavity 48 beneath hopper orifice 15, causing cavity 48 to receive a charge of powder 33. The operator then suitably positions the nozzle 51 adjacent to the dental area to be treated and exerts squeezing force on the handpiece, thereby rotating lever 58 to its limiting inward position. This moves valve piston 56 to a position which vents bore 43 and allows spring 45 to return piston 42 to normal position thereof shown in FIG. 4, wherein the powder-filled cavity 48 is returned to alignment position between conduit portions 49,50. The air stream from conduit portion 49 then carries the powder dose to the nozzle 51 for application to the dental area being treated. Release of the valve control lever 58 allows the piston 42 to return the shuttle bar 40 to charging position, for repeating the dosage if required.
Refilling of the hopper may be accomplished by replacing the powder vial 63, when the hopper is empty, with a new full vial. This is done with the handpiece in an inverted position as compared with the operating position thereof shown in FIG. 4.
While certain specific embodiments of improved powder blowing devices have been disclosed in the foregoing description, it will be understood that various modifications within the spirit of the invention may occur to those skilled in the art. Therefore it is intended that adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. | A device for blowing powder onto teeth, the device consisting of a handpiece in the form of a housing connected to a compressed air source and having a discharge nozzle member which can be inserted in a patient's mouth and can be directed towards the patient's teeth. The housing has a powder reservoir with a bottom supply duct. An apertured shuttle bar is reciprocably slidably mounted beneath said duct and has a metering hole registrable with said supply duct and then, by longitudinally moving the bar, with a discharge conduit arranged to receive compressed air from the source so as to discharge a metered amount of powder in said hole into the nozzle member for delivery to the patient's teeth. | 0 |
RELATED APPLICATIONS
This application is a division of U.S. patent application Ser. No. 11/953,927 filed on Dec. 11, 2007 which is a division of U.S. Pat. No. 7,361,993 Ser. No. 10/908,346 filed on May 9, 2005 and issued Apr. 22, 2008.
FIELD OF THE INVENTION
The present invention relates to the field of integrated circuits; more specifically, it relates to terminal pads for an integrated circuit and methods for fabricating the terminal pads.
BACKGROUND OF THE INVENTION
Integrated circuits include devices such as metal-oxide-silicon field effect transistors (MOSFETs) formed in a semiconductor substrate, interconnected into circuits by wires in interconnect layers formed on top of the substrate. At the highest or uppermost level of an integrated circuit chips, these wires must be connected to terminal pads which allow wirebond or solder bump connections to a next level of packaging, such as to a module or circuit board. Conventional terminal pads are complex structures because of the structural strength and contamination seal the terminal pad must provide. For integrated circuit chips for low cost or commodity products and such as used in wireless technology, conventional terminal pad structures and fabrication processes add significant costs to the fabrication process. Therefore, there is a need for cost performance terminal pad structures and fabrication processes having structural strength and contamination seal abilities.
SUMMARY OF THE INVENTION
A first aspect of the present invention is a method of forming a terminal pad, comprising: providing an electrically conductive wire formed in a dielectric layer on a substrate, a top surface of the wire coplanar with a top surface of the dielectric layer; forming a passivation layer on the top surface of the dielectric layer and the top surface of the wire, the passivation layer comprising a lower dielectric layer on the top surfaces of the dielectric layer and the wire, an intermediate dielectric layer on a top surface of the lower dielectric layer and an upper dielectric layer on a top surface of the intermediate dielectric layer; forming a trench in the passivation layer, the trench extending from a top surface of the passivation layer to a bottom surface of the passivation layer, the top surface of the wire exposed in the bottom of the trench; forming a conformal and electrically conductive liner directly on sidewalls of the trench and in direct physical and electrical contact with the top surface of the wire exposed in the bottom of the trench; and filling the trench with an electrical core conductor, a top surface of the core conductor, a top surface of the liner and a top surface of the passivation layer coplanar, the core conductor and the liner comprising the terminal pad.
A second aspect of the present invention is a structure, comprising: an electrically conductive wire formed in a dielectric layer on a substrate, a top surface of the wire coplanar with a top surface of the dielectric layer; a passivation layer on the top surface of the dielectric layer and the top surface of the wire, the passivation layer comprising a lower dielectric layer on the top surfaces of the dielectric layer and the wire, an intermediate dielectric layer on a top surface of the lower dielectric layer and an upper dielectric layer on a top surface of the intermediate dielectric layer; a conformal and electrically conductive liner on sidewalls of the trench and in direct physical and electrical contact with the top surface of the wire contained within the trench; and an electrical core conductor, a top surface of the core conductor, a top surface of the liner and a top surface of the passivation layer coplanar, the core conductor and the liner comprising a terminal pad.
A third aspect of the present invention is a method of forming a terminal pad, comprising: providing an electrically conductive wire formed in a dielectric layer on a substrate, a top surface of the wire coplanar with a top surface of the dielectric layer; forming an electrically conductive barrier layer on the top surface of the dielectric layer and the top surface of the wire; forming an electrically conductive layer on a top surface of the conductive barrier layer; subtractively removing regions of the conductive barrier layer and regions of the conductive layer to form the terminal pad; forming an electrically non-conductive passivation layer on the top surface of the dielectric layer and all exposed surfaces of the terminal pad, the passivation layer comprising a lower dielectric layer on the top surface of the dielectric layer and on the all exposed surfaces of the terminal pad and an intermediate dielectric layer on a top surface of the lower dielectric layer; and forming a via in the passivation layer, the via extending from a top surface of the passivation layer to a top surface of the terminal pad.
A fourth aspect of the present invention is a structure, comprising: an electrically conductive wire formed in a dielectric layer on a substrate, a top surface of the wire coplanar with a top surface of the dielectric layer; an electrically conductive barrier layer on the top surface of the dielectric layer and the top surface of the wire; a terminal pad comprising an electrically conductive layer on a top surface of an electrically conductive barrier layer, the terminal pad in physical and electrical contact with the wire; an electrically non-conductive passivation layer on the top surface of the dielectric layer and all exposed surfaces of the terminal pad, the passivation layer comprising a lower dielectric layer on the top surface of the dielectric layer and the all exposed surfaces of the terminal pad and an intermediate dielectric layer on a top surface of the lower dielectric layer; and a via in the passivation layer, the via extending from a top surface of the passivation layer to a top surface of the terminal pad.
BRIEF DESCRIPTION OF DRAWINGS
The features of the invention are set forth in the appended claims. The invention itself, however, will be best understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIGS. 1A through 1F are cross-sectional views illustrating fabrication of a terminal pad structure according to a first embodiment of the present invention;
FIGS. 2A and 2B are top views of terminal pads according the first embodiment of the present invention;
FIGS. 3A through 3F are cross-sectional views illustrating fabrication of a terminal pad structure according to a second embodiment of the present invention; and
FIGS. 4A through 4B are top views of terminal pads according to the second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1A through 1F are cross-sectional views illustrating fabrication of a terminal pad structure according to a first embodiment of the present invention. FIG. 1A illustrates an exemplary integrated circuit chip prior to formation of a terminal pad according to the first embodiment of the present invention. In FIG. 1A formed on a substrate 100 , are wiring levels 105 and 110 . Wiring level 105 includes a dielectric layer 115 . Wiring level 110 includes a dielectric layer 120 and a dielectric layer 125 . Formed in dielectric layer 105 is a damascene wire 130 comprising an electrically conductive liner 135 and an electrically conductive core conductor 140 . Formed in interlevel dielectric layer 110 is a damascene wire 145 and integral via 150 comprising an electrically conductive liner 155 and an electrically conductive core conductor 160 . Top surface 165 of dielectric layer 125 , top surface 170 of conductive liner 155 and top surface 175 of core conductor 160 are coplanar.
In one example dielectric layers 115 and 125 independently comprise silicon dioxide (SiO 2 ), or a low K (dielectric constant) material, examples of which include but are not limited to hydrogen silsesquioxane polymer (HSQ), methyl silsesquioxane polymer (MSQ), polyphenylene oligomer, and SiO x (CH3) y . A low K dielectric material has a relative permittivity of 4 or less.
In one example, conductive liners 135 and 155 independently comprise Ti, TiN, Ta, TaN, W or combinations thereof. In one example, core conductors 140 and 160 comprise copper or copper alloys. Dielectric layer 120 may act as a diffusion barrier for materials of core conductors 140 and 160 . In the example of core conductor 160 being copper, dielectric layer 120 may be a diffusion barrier for copper and may comprise, for example, silicon nitride. Conductive liners 135 and 155 may act as a diffusion barriers for materials of core conductors 140 and 160 respectively. In the example of core conductor 160 being copper, conductive liners 135 and 155 may be diffusion barriers for copper.
While two levels of wiring are illustrated in FIG. 1A , any number of wiring levels similar to wiring levels 105 and 100 may be employed. Wiring level 110 , should be considered the last wiring level before terminal pads are formed. The distinction between a wiring level and the terminal pad level of an integrated circuit is a wiring level interconnects an upper wiring level to a lower wiring level or to contacts to devices such as metal-oxide-silicon field effect transistors (MOSFETs) while terminal pads are connected to a lower wiring level only (there may be terminal pad to terminal pad connections) and there are no wiring levels above the terminal pad level.
In FIG. 1B , a dielectric passivation layer 180 is formed in direct contact with top surface 165 of dielectric layer 125 , top surface 170 of conductive liner 155 and top surface 175 of core conductor 160 . Passivation layer 180 includes a lower dielectric layer 185 formed on top surface 165 of dielectric layer 125 , top surface 170 of conductive liner 155 and top surface 175 of core conductor 160 , an intermediate dielectric layer 190 formed on lower dielectric layer 185 and an upper dielectric layer 195 formed on intermediate dielectric layer 190 . In one example, lower dielectric layer 185 comprises silicon nitride (SiN) or silicon carbide nitride (SiCN) and is between about 0.05 micron to about 0.1 micron thick. In one example, intermediate dielectric layer 190 comprises silicon dioxide and is between about 0.5 micron to about 2 microns thick. In one example, upper dielectric layer 195 comprises silicon nitride and is between about 0.5 micron to about 2.0 microns thick. Passivation layer prevents contamination such as ionic contamination (e.g. chlorine, water vapor) from reaching core conductor 160 , which is particularly important when core conductor 160 comprises copper or aluminum. Formed on top of upper dielectric layer 195 is an optional chemical-mechanical-polish (CMP) polish stop layer 197 .
In FIG. 1C , a trench 200 is etched through optional polish stop layer 197 (if present), upper dielectric layer 195 , intermediate dielectric layer 190 and lower dielectric lower dielectric layer 185 to expose top surface 175 of core conductor 160 but not expose any portion of liner 155 or any portion of dielectric layer 125 . Trench 200 is thus “fully landed” (see FIGS. 2A and 2B ) on wire 145 . Trench 200 may be formed by any number of well-known photolithographic processes followed by any number of well-known directional etch processes such as reactive ion etch (RIE).
In FIG. 1D , a conformal conductive liner 205 is formed on all exposed surfaces of core conductor 160 , lower dielectric layer 185 , intermediate dielectric layer 190 , upper dielectric layer 195 and optional polish stop layer 197 (if present). An electrically conductive fill 210 is formed on conductive liner completely filling trench 200 .
In FIG. 1E , a CMP process is performed, to create a terminal pad 215 comprising an electrically conductive liner 220 and an electrically conductive core conductor 225 , a top surface 230 of upper dielectric layer 195 , a top surface 235 of conductive liner 220 and a top surface 240 of core conductor 225 being coplanar. In one example, conductive liner 220 comprises comprise Ti, TiN, Ta, TaN, W or combinations thereof. In one example, conductive core 225 comprises Al or AlCu (not more than about 1% Cu). The fact that terminal pad 215 is a damascene structure (recessed or inlayed into a supporting layer) adds strength to the overall terminal pad structure. The fact that pad 215 is “fully landed” on wire 145 and damascened into passivation layer 180 seals wiring level 110 and all lower wiring levels from contamination.
If optional polish stop layer 197 (see FIG. 1B ) was formed in FIG. 1A , it may be thinned by the CMP process as illustrated in FIG. 1E . Alternatively, optional polish stop layer 197 may not be present in FIG. 1E (and subsequently in FIG. 1F ) because of the possibility of the polish stop layer being entirely consumed by the CMP process.
At this point wirebond connections may be made to terminal pad 215 . Wirebonding is a process whereby, thin gold or aluminum wires are attached to the pads using pressure and heat energy or ultrasonic energy. Generally, an interfacial alloy is formed between the wirebond wire and terminal pad.
In FIG. 1F , further processing is performed in order to make a solder bump connection to terminal pad 215 . Solder bump connections are also known controlled collapse chip connections (C 4 ). In FIG. 1F a ball limiting metal (BLM) pad 245 is formed on terminal pad 215 . BLM pad 245 completely overlaps terminal pad 215 (See FIGS. 2A and 2B ). A solder bump 250 is then formed on BLM pad 245 . Solder bump 250 is illustrated after a thermal reflow process has been performed. In one example, BLM pad 245 and solder bump 250 are formed by evaporation through a metal mask. In a second example, BLM pad 245 is formed by evaporation through a metal mask and solder bump 250 is formed by electroplating through an organic mask after the BLM is formed. In one example BLM pad 245 is formed from multiple layers of metals, each layer selected from the group consisting of Cr, Cu, Au, Ni, Ti, TiN, Ta and TaN. In one example, BLM pad 245 comprises a layer of Cu over a layer of Cr in contact with terminal pad 215 and a layer of Au over the layer of Cu. In one example, BLM pad 245 comprises a layer of Ni over a layer of Cr in contact with terminal pad 215 and a layer of Au over the layer of Ni. In one example, solder bump 250 comprises a Pb/Sn alloy.
FIGS. 2A and 2B are top views of terminal pads according the first embodiment of the present invention. In FIG. 2A , wire 145 (see FIG. 1E or 1 F) is in itself a wiring pad 145 A having sides 260 A, 260 B, 260 C and 260 D. Terminal pad 215 has sides 265 A, 265 B, 265 C and 265 D. Sides 265 A, 265 B, 265 C and 265 D of terminal pad 215 are aligned within the perimeter formed by sides 260 A, 260 B, 260 C and 260 D of wiring pad 145 A. In FIG. 2A , BLM pad 245 overlaps sides 260 A, 260 B, 260 C and 260 D of wire pad 145 A as well as sides 265 A, 265 B, 265 C and 265 D of terminal pad 215 . Alternatively, BLM pad 245 may overlap sides 265 A, 265 B, 265 C and 265 D of terminal pad 245 but not overlap sides 260 A, 260 B, 260 C and 260 D of wire pad 145 A.
In FIG. 2B , wire 145 has sides 260 A, 260 C and an end 270 . Terminal pad 215 has sides 265 A, 265 B, 265 C and 265 D. Sides 265 A, 265 B, 265 C and 265 D of terminal pad 215 are aligned within respective sides 260 A, 260 C and end 270 of wire 145 . In FIG. 2B , BLM pad 245 overlaps sides 260 A, 260 C and end 270 of wire 145 as well as sides 265 A, 265 B, 265 C and 265 D of terminal pad 245 . However, side 265 B of terminal pad 215 does not extend across any side of wire 145 . Alternatively, BLM pad 245 may overlap sides 265 A, 265 B, 265 C and 265 D of terminal pad 215 but not overlap sides 260 A, 260 C and end 270 of wire 145 . Again, side 265 B of terminal pad 215 would not extend across any side of wire 145 A.
FIGS. 3A through 3F are cross-sectional views illustrating fabrication of a terminal pad structure according to a second embodiment of the present invention. FIG. 3A illustrates an exemplary integrated circuit chip prior to formation of a terminal pad according to the second embodiment of the present invention. FIG. 3A is identical to FIG. 1A . In FIG. 3B , an electrically conductive barrier layer 275 is formed on top surface 165 of dielectric layer 125 . An electrically conductive layer 280 is then formed on conductive barrier layer 275 .
In FIG. 3C , a terminal pad 285 is formed from conductive barrier layer 275 and conductive layer 280 subtractively. Terminal pad 285 may be formed by any number of well known photolithographic processes followed by any number of etch processes such as RIE or wet etching. In one example, conductive barrier layer 275 is a diffusion barrier to a material contained within wire 145 . In one example, conductive barrier layer 275 comprises Ti, TiN, Ta, TaN, W or combinations thereof. In one example, conductive layer 280 comprises Al or AlCu (not more than about 1% Cu). In the example, of conductive layer 280 containing aluminum and a chlorine based RIE etch is used, a passivation step using chromic-phosphoric acid may be performed in order to passivation exposed aluminum.
In FIG. 3D , a conformal lower dielectric layer 290 is formed in direct contact with top surface 165 of dielectric layer 125 and all exposed surfaces of terminal pad 285 . An intermediate dielectric layer 295 is formed on lower dielectric layer 290 and an optional electrically non-conductive upper layer 300 is formed on intermediate dielectric layer 295 . In one example, lower dielectric layer 290 comprises silicon dioxide and is between about 0.5 micron to about 2.0 microns thick. In one example, intermediate dielectric layer 295 comprises silicon nitride and is between about 0.5 micron to about 2.0 microns thick. In one example, optional upper layer 300 (if present) comprises polyimide or photosensitive polyimide and is between about 2 microns to about 10 microns thick.
In FIG. 3E , a via 305 is etched through lower dielectric layer 290 , intermediate dielectric layer 295 and upper layer 300 to a expose top surface 310 of terminal pad 285 . Via 305 may be formed by any number of well-known photolithographic processes followed by any number of well-known etch processes such as RIE. Terminal pad 285 extends under all edges 315 of via 305 . Via 305 is “fully landed” on terminal pad 305 . The fact that terminal pad 285 is overlapped by lower dielectric layer 290 , intermediate dielectric layer 295 and upper layer 300 adds strength to the overall terminal pad structure. The fact that via 305 is “fully landed” on terminal pad 285 seals wiring level 110 and all lower wiring levels from contamination and adds strength to the overall terminal pad structure. At this point wirebond connections may be made to terminal pad 285 as described supra in reference to FIG. 1E .
In FIG. 3F , further processing is performed in order to make a solder bump connection to terminal pad 285 . In FIG. 3F a BLM pad 320 is formed on terminal pad 285 . A solder bump 325 is then formed on BLM pad 320 . Solder bump 325 is illustrated after a thermal reflow process has been performed. In one example, BLM pad 320 and solder bump 325 are formed by evaporation through a metal mask. In a second example, BLM pad 320 is formed by evaporation through a metal mask and solder bump 325 is formed by electroplating through an organic mask after the BLM is formed. In one example BLM pad 320 is formed from multiple layers of metals, each layer selected from the group consisting of Cr, Cu, Au, Ni, Ti, TiN, Ta and TaN. In one example, BLM pad 320 comprises a layer of Cu over a layer of Cr in contact with terminal pad 285 and a layer of Au over the layer of Cu. In one example, BLM pad 320 comprises a layer of Ni over a layer of Cr in contact with terminal pad 285 and a layer of Au over the layer of Ni. In one example, solder bump 325 comprises a Pb/Sn alloy.
FIGS. 4A through 4B are top views of terminal pads according to the second embodiment of the present invention. FIGS. 4A and 4B are top views of terminal pads according the second embodiment of the present invention. In FIG. 4A , wire 145 (see FIG. 1E or 1 F) is in itself a wiring pad 145 A having sides 260 A, 260 B, 260 C and 260 D. Via 305 has sides 330 A, 330 B, 330 C and 330 D. Terminal pad 285 has sides 335 A, 335 B, 335 C and 335 D. Sides 260 A, 260 B, 260 C and 260 D of wire pad 145 A are aligned within the perimeter formed by sides 330 A, 330 B, 330 C and 330 D of via 305 . Sides 330 A, 330 B, 330 C and 330 D of via 305 are aligned within the perimeter formed by sides 335 A, 335 B, 335 C and 335 D of terminal pad 285 . In FIG. 4A , BLM 320 overlaps sides 335 A, 335 B, 335 C and 335 D of via 305 .
In FIG. 4B , wire 145 has sides 260 A, 260 C and an end 270 . Terminal pad 285 has sides 335 A, 335 B, 335 C and 335 D. Sides 335 A, 335 B, 335 C and 335 D of terminal pas 285 are aligned within respective sides 260 A, 260 C and end 270 of wire 145 . In FIG. 4B , BLM 320 overlaps sides 260 A, 260 C and end 270 of wire 145 as well as sides 330 A, 330 B, 330 C and 330 D of via 305 and sides 335 A, 335 B, 335 C and 335 D of terminal pad 285 . Alternatively, BLM 320 may overlaps sides 330 A, 330 B, 330 C and 330 D of via 305 but not overlap sides 335 A, 335 B, 335 C and 335 D of terminal pad 285 .
Thus the present invention provides cost performance terminal pad structures and fabrication processes having structural strength and contamination seal abilities.
The description of the embodiments of the present invention is given above for the understanding of the present invention. It will be understood that the invention is not limited to the particular embodiments described herein, but is capable of various modifications, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, it is intended that the following claims cover all such modifications and changes as fall within the true spirit and scope of the invention. | Terminal pads and methods of fabricating terminal pads. The methods including forming a conductive diffusion barrier under a conductive pad in or overlapped by a passivation layer comprised of multiple dielectric layers including diffusion barrier layers. The methods including forming the terminal pads subtractively or by a damascene process. | 7 |
This application is a division of Ser. No. 08/536,422, filed Sep. 29, 1995 now U.S. Pat. No. 5,738,057.
FIELD OF THE INVENTION
The invention relates generally to an internal combustion engine, and more particularly to such an engine having improved fuel efficiency and emissions characteristics.
BACKGROUND OF THE INVENTION
Internal combustion engines derive power from a controlled combustion of a mixture of a hydro-carbon based fuel and air inside a combustion chamber. A primary goal of any engine design is to increase fuel efficiency and performance while reducing emissions. A more complete combustion reduces emissions such as unburned hydrocarbons, (referred to herein "THC" emissions) as well as carbon dioxide (CO 2 ) and carbon monoxide (CO). Of course, while complete combustion is desired, design trade offs must be made since the processes leading to the most complete combustion may have negative side effects. For example, if the peak temperature of combustion is too high, undue NO X emissions will be formed during combustion and be exhausted. In addition, for a very hot flame front in the presence of cooler spots in the combustion chamber or compression end of the cylinder, so-called "knock" may occur, thus reducing engine performance. Of course, a myriad of other considerations go into the design of any engine.
One means of increasing fuel efficiency while reducing emissions is to provide a relatively fast burn of the combustion charge. The idea underlying such a design is that a faster burn will be more complete since the charge constituents (fuel and air) will preferably be close to the point at which combustion is initiated when they are burned. So-called fast burn is typically achieved by virtue of engine designs which seek to minimize the surface-to-volume ratio (S/V) of the combustion chamber. The smaller S/V thus promotes a fast burn. By "fast burn" it is meant that the combustion is such that most of the pressure exerted on the piston by combustion is exerted over a small portion of the piston's travel which occurs just following ignition of the charge. Thus, while the high heat of the fast burn is advantageous in that it gives a more complete burning of the hydrocarbons, it may have the disadvantage of leading to engine roughness and vibration by virtue of such a large force being exerted during a small portion of the piston travel. Moreover, such an engine must be designed such that the peak temperature of combustion is high enough to get the desired hydrocarbon burning, but not so high as to generate undue NO X .
Another approach to achieving more complete combustion for fuel efficiency and emissions purposes is to increase the homogeneity of the charge. A combustion charge may not be completely homogeneous, meaning that certain regions are more volatile than others leading to uneven combustion. In one engine, to prevent such problems, the fuel-air mixture was subjected to an induced swirling motion prior to ignition to increase the thoroughness of the mixture. As shown in U.S. Pat. No. 4,846,138 this swirling was induced by the valve stems extending across a thin, upstanding combustion chamber during the compression stroke of the flat-headed piston. The valve stems serve to induce a swirl in the fuel-air mixture being compressed leading to a more thorough mixing. Further, during the power stroke, the same configuration of the valve stems causes the flame front to swirl around these stems again improving the combustion. As discussed in that patent, the swirling induced by this configuration improved gas mileage and emissions for that engine.
The swirling during combustion in the engine according to the '138 patent was also beneficial in removing unburned hydrocarbons from the walls of the cylinder. Since the walls of the piston cylinder are typically cooler than the internal volume of the cylinder, unburned hydrocarbon molecules may cling to these walls during combustion. The swirling induced by the valve stems in the '138 patent help to sweep that charge around these cooler walls, thus assisting in removing unburned hydrocarbons. Such "scrubbing" of combustion chamber walls is thus a desirable feature for reducing such emissions.
While the extreme temperatures under which combustion typically occurs are advantageous in terms of burning the fuel efficiently, it has other draw backs which must be compensated for in the engine design. One example is in the valves associated with the combustion chamber. In a typical engine configuration, the intake and exhaust valves are disposed within the intake and exhaust ports which they are sealing. This is particularly disadvantageous in the case of the exhaust valve since that valve sits in the stream of hot exhaust gas as it leaves the combustion chamber and exits through the exhaust port to the exhaust manifold. Alternatively, the intake valve is almost continually subject to vacuum. Further, because of the configuration of conventional valves and their position relative to the cam shaft, typical valves are very long and have thin stems. Since flow to the stem away from the valve head is one means of heat transfer and dissipation, this means that a long thermal distance must be traversed to effectively draw heat away from the head in this manner. Further, the stems are typically very thin, meaning that only a small radiating surface is available for radiating heat in the stem. The other mechanism for cooling standard valves is flow from the head into the valve seat. Of course, this mechanism is unavailable when the valve is open and not in contact with the seat. Because typical valves are required to withstand incredibly high temperatures without having adequate mechanisms for withstanding such temperatures, they are typically formed of expensive and exotic materials so that they can successfully withstand the elevated temperatures. It would thus be desirable to avoid the undue expense and complexity of having to use such exotic materials for the valves.
A further consideration in regard to the valves is lubrication. A valve is generally actuated from a rotating cam shaft. In a typical single overhead cam, the cam contacts a cam pad at the end of a rocker arm. This contact causes the rocker arm to move the valve out of engagement with its respective port. The cam pads on the rocker arm, however, are typically located above the cam shaft, since the valves must be pulled out of engagement with their respective ports. As a result, lubricating this contact is problematic. Any oil that is thrown up to lubricate the cam/cam pad contact simply runs off due to gravity. A typical dual overhead cam arrangement suffers from similar problems. There, a cam engages the angled top surface of a bucket which houses the valve spring. Any oil thrown onto the top surface of the bucket also runs off due to gravity. While the cams are sufficiently lubricated to allow the engine to function, such lubrication is less than ideal and works against gravity, thus requiring an oversupply of oil to achieve lubrication.
The lubrication mechanism for the valve train itself is also less than ideal although it works for its intended purpose. Since the valves reciprocate in a bearing sleeve, there must be lubrication between the valve and the sleeve. This lubrication is typically carried out by a planned or intentional leakage of oil between the valve and the valve sleeve and past the valve seals. Thus, the valve seals are designed to have less than ideal sealing characteristics. In the case of the intake valve, the controlled leakage of oil in this manner is somewhat assisted by the fact that the intake port is constantly containing vacuum in the intake port. This assists in drawing lubricating oil between the bearing sleeve and the valve. Of course, this has the draw back of insuring that at least a small amount of oil is burned during each combustion cycle of a conventional engine. The exhaust valve, on the other hand, does not have such a mechanism for assisting in the movement of oil between the valve and the bearing sleeve. Because of the lack of such a mechanism this means that the exhaust valve and intake valve in a given engine typically see different amounts of oil, and are thus lubricated differently. Indeed, because of this, exhaust valves fail at a significantly higher rate than intake valves. In addition, the only way for oil in the bearing sleeve of an exhaust valve to exit is to be exhausted through the exhaust port during the exhaust strike of the piston with which a given valve is associated. This has negative impact in terms of emissions.
Lubrication of a typical valve train assembly is thus a difficulty which must be taken into account in engine design. Clearly, the system works, but extreme measures must be taken to compensate for the disadvantages of such systems.
SUMMARY OF THE INVENTION
It is thus a primary aim of the invention to improve upon the structure of the internal combustion engine disclosed in U.S. Pat. No. 4,846,138 to yield an engine that is more efficient than those provided heretofore, both in terms of combustion and valve performance.
In accord with that aim, it is a principal object of the present invention to provide a more complete combustion of the charge during the power stroke.
It is a related object to both improve the mixing of the charge prior to combustion, and to improve the removal of clinging fuel from the walls of the combustion chamber and cylinder during combustion.
Another related object is to provide both vertical and horizontal components to a swirling charge during combustion.
It is a further related object to provide a smooth and even burn of the charge.
Still another object is reducing emissions generated during the combustion process.
Another object of the invention is to provide for cooler valves than in existing engines.
It is a related object to provide valves with short, efficient heat paths.
It is a further related object to provide a circulating medium to carry heat away from the valves.
Another principal object of the invention is to provide a lubrication system for the valves and the valve-actuation mechanism that is assisted by the force of gravity.
A related object is to provide a system where the contact between the cam shaft and cam pad is adequately lubricated.
In accord with these and other objects of the invention, an internal combustion engine is provided that uses the geometry of a combustion chamber, cylinder head, piston crown and valve necks extending across the combustion chamber, to provide thorough mixing of the charge by a swirling action before combustion, and to provide a thorough and "smooth, even" burn of the charge after ignition by a complex vertical and horizontal swirling action that scrubs clinging fuel from the walls of the combustion chamber and cylinder and provides a burn that maintains a higher pressure over a longer period of piston travel. The piston crown in the internal combustion engine is tapered to a zenith which is coincident with the longitudinal axis of the piston. A complementary interior surface is present in the cylinder head at the compression end of the cylinder. Also provided is a thin upstanding combustion chamber disposed vertically above the compression end of the cylinder and including a throat in communication with the interior surface of the cylinder head. The combustion chamber is divided into two sections which are offset with respect to the longitudinal axis. The sectioning of the combustion chamber and the offsetting of those sections aids in inducing the complex swirling of the charge during the compression and power strokes of the piston. Associated with each section of the combustion chamber is a poppet valve which is disposed transversely to the longitudinal axis such that the stem of each valve extends across each combustion section. Each poppet valve also includes a head and neck region, with the head selectively engaging a port in the opposite wall of the combustion chamber section. A resilient member is coupled to each valve for biasing it into engagement with its respective port during the power and compression strokes to further induce swirling of the charge.
This configuration gives the advantageous functional characteristics referred to above during the compression and power strokes. During compression, the foregoing geometry results in the poppet valve necks serving as swirl sources to the compressing fuel-air mixture and thus inducing a substantially vertical swirling of that mixture. A similar swirling of the flame front occurs during combustion. At the same time, a complemental substantially horizontal swirling is induced and sustained by the two offset adjacent sections of the combustion chamber in combination with the tapered piston head and the complementally-shaped interior surface in the cylinder head. The separation of the chambers effectively divides the flame front into two sections during combustion. As the flame fronts emerge from the combustion chamber, they contact the tapered region of the crown. This causes the flame fronts to be thrown against the cylindrical walls of the cylinder, thereby aiding in providing a horizontal component to the swirl. As the piston withdraws, this complex swirling motion continues, thus scrubbing unburned hydrocarbons from the cylinder walls. Further, the initial restriction of the combustion to the two halves of the combustion chamber, followed by entry of the flame fronts into the cylinder, provides a slower, more even burning of the charge than in previous engines.
According to a further feature of the invention, hollow valves are advantageously provided. These valves are larger in diameter than stock valves and include an interior hollow region. Both the large exterior diameter, and the hollow interior provide substantial radiative cooling surfaces. Further, oil is circulated through and around the hollow valves to provide for removal of heat through the medium of the oil. Further, the valves are not located in the ports which they seal as in conventional engines. This also leads to cooler valves since, for example, the exhaust valve is exposed to the cool intake charge. Because of the enhanced cooling of these valves, exotic fabricating materials are not required.
Further according to the invention, an internal combustion engine is provided that uses the configuration and, optionally, the orientation, of the valve train to adequately lubricate the valve train and take advantage of the effects of gravity. In one embodiment, a rocker arm is mounted beneath the cam shaft for pivotal movement. One arm of the rocker arm includes a cam pad for engaging a cam on the cam shaft. Another arm includes a valve-engaging end, such that a pivotal motion of the rocker arm causes movement of the valve. The rocker arm is partially disposed in a rocker arm bracket mounted below the cam shaft. The bracket includes a central slot including sidewalls for receiving a portion of the rocker arm. The central slot and the enclosed portion of the rocker arm form an oil-receiving cavity for accumulating oil in the area of the cam pad. This cavity includes crevices so that the accumulated oil can leak out at a controlled rate by means of gravity. This leaking oil in turn flows into the respective valve associated with the rocker arm. The valve train may be disposed at a downward angle with reference to the combustion chamber to which it is coupled, thus allowing the lubricating oil in the valve to flow away from the combustion chamber, thus inhibiting the leakage of oil into the chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, partially cut-away view of the engine according to the invention;
FIG. 2 is a sectional view of the engine according to the invention;
FIG. 3 is a further sectional view, showing the engine according to the invention during the compression stroke;
FIG. 4 is a similar view to FIG. 3, but showing the engine according to the invention during the exhaust stroke;
FIG. 5 is an internal view of the combustion chamber according to one embodiment of the invention, shown from below;
FIG. 6 is a section view of the combustion chamber according to an embodiment of the invention, which also shows the piston head;
FIGS. 7-9 depict progressions of the combustion process through various stages;
FIG. 10 is a representation of the path taken by flame fronts as they exit the combustion chamber;
FIG. 11 is a representation of the swirling action induced in the flame front by the piston crown;
FIG. 12 is a further representation of continued swirling of the charge during combustion;
FIG. 13 is a representation of scrubbing of clinging fuel from the walls of the combustion chamber according to the invention;
FIG. 14 is a representation of the relative orientation between the combustion chamber and the piston crown;
FIG. 15 is a graph showing the comparative emission between an engine according to the invention and a stock engine;
FIG. 16 is a graph showing the percent of consumed charge (X) as a function of the crank angle (Θ) of the crank shaft for the inventive and stock engines;
FIG. 17 is a graph of the pressure volume curves comparing the inventive and stock engines;
FIG. 18 is a top cut-away view of the head according to one embodiment of the invention;
FIG. 19 is an isolated view of the valve train according to an embodiment of the invention;
FIG. 20 is an exploded view of the valve train of FIG. 19;
FIG. 21 is a section view of a valve according to an embodiment of the invention;
FIG. 22 is a representation of a piston crown according to an alternative embodiment of the invention;
FIG. 23 is a section view of an alternative embodiment of the invention;
FIG. 24 is a further section of an alternative embodiment of the invention, and showing a valve train in place;
FIG. 25 is a section view of a valve according to an alternative embodiment of the invention;
FIG. 26 is an isolated view of the valve train according to the alternative embodiment;
FIG. 27 is an end view showing the push rod saddle according the alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, FIG. 1 is a perspective view of an automotive engine according to one embodiment of the invention. The engine 10 includes a block 20, above which is disposed a cylinder head 30. Cylinder head 30 is roughly trapezoidal in cross section, having a wider base and narrower top. As the engine 10 is of a valve-in-head design, the cylinder head includes an intake port 40, and an exhaust port 50. According to a novel aspect of the invention, the cylinder head also includes side-mounted valve enclosures 60 and 70, which house valve assemblies. It will be noted from FIG. 1 that the valve enclosures 60 and 70 are mounted to the sidewall of the cylinder head at a depending angle. This mounting angle, and the resulting angled position of the enclosed valves form an aspect of the present invention. The valves contained within valve enclosures 60 and 70 are actuated by rocker arms driven by a cam shaft. The rocker arms are shown in FIG. 1, and bear reference numbers 65 and 75. The cam shaft is shown at 80. As is apparent in FIG. 1, the rocker arms 65 and 75 are disposed within rocker arm brackets 66 and 76. FIG. 1 also shows a head cover 90 which may be bolted in place over the head by means of bolts 91.
The sectional view of FIG. 2 shows the various components of the engine 10 in greater detail. In particular, FIG. 2 shows the valve structure 100 according to an aspect of the invention. As discussed in regard to the valve enclosure 70, valve 100 is preferably disposed at an upward angle within the cylinder head 30 in this embodiment of the invention. Valve 100 is essentially a poppet valve with a head 105, a stem 107 and an angular sealing region 108 on the head 105. Sealing region 108 is designed to engage on a seat 58 in the exhaust port 50. Valve seat 58 is formed in a sidewall of an upstanding combustion chamber, depicted generally in FIG. 2 by reference numeral 120. As will be appreciated by one skilled in the art, both exhaust valve 100 and an associated intake valve are associated with the combustion chamber 120. The valves are timed by means of the cam shaft 80 so that both valves are closed during the compression and power strokes, and so that the exhaust valve is open during the exhaust stroke, and that the intake valve is open during the intake stroke. Unlike a conventional engine, the neck of valve 100, and the neck of the associated intake valve extend across the combustion chamber to close the exhaust and intake ports respectively. As such, with the valve 100 closed, the valve neck 107 extends across the combustion chamber. As will be appreciated by those skilled in the art, valves are typically disposed within the ports which they seal. Accordingly, gases moving through those ports are impeded by the valves and, particularly in the case of the exhaust ports, unduly heat the valves. According to the present design, this does not occur. As seen in the exhaust stroke represented in FIG. 4, the valve 100 in no way impedes flow through the exhaust port and conduit. Moreover, a typical intake valve--in the intake conduit--is acted upon by vacuum almost constantly. In this design, the valve is only subjected to vacuum during the intake stroke, thus reducing the chance of vacuum leaks.
It will also be noted from FIG. 2 that the combustion chamber itself has a unique configuration. First of all, the combustion chamber 120 is relatively thin and upstanding. Moreover, the combustion chamber 120 according to the invention is divided into two halves or adjacent sections. The two adjacent sections are 121, shown in solid FIG. 2, and 122, shown in phantom in FIG. 2. They are offset or canted with respect to each other about a vertical or longitudinal axis. A further view of the two sections 121 and 122 can be seen in the bottom section view of FIG. 5. Just as the two adjacent sections of the combustion chamber are angled with respect to each other, so are each paired set of intake and exhaust valves associated with a given combustion chamber. As can be seen most clearly in FIG. 3, the exhaust valve 100 is tilted downwardly in one direction while the intake valve 109 is tilted downwardly in the opposite direction. Since the sections of the combustion chamber with which each valve are associated are also tilted, this tilting of the valves allows the longitudinal axis of the valve to be disposed perpendicularly to the port which is it designed to close.
Returning to FIG. 2, there is also shown, according to the invention, a piston 150. The piston 150 reciprocates within a cylinder within the block 20. The crown of piston 150, bearing reference numeral 160, is tapered. According to the invention, the crown 160 tapers toward a zenith coincident with a vertical or longitudinal axis of the piston 150. In the present embodiment, this tapering of crown 160 results in a wedge shape, although other tapering shapes may be used. The wedge-shape of the crown 160, according to this embodiment, can be seen by comparing FIG. 2, showing one side view and FIG. 6, showing the other side view.
Cylinder head 30 also includes an interior surface 130 which is adjacent to the compression end of the cylinder, and has a shape that is complemental to the wedge-shape of the piston crown 160. Thus, with the piston 150 at the top of its stroke, the wedge-shaped crown 160 and the complemental interior surface 130 are disposed adjacent to each other, as seen in FIG. 2. Furthermore, the interior surface is in communication with the thin upstanding combustion chamber through a throat 135, the contour of which can be seen most clearly in the section view of FIG. 5.
COMBUSTION
The configuration of the thin upstanding combustion chamber 120, the valve stems which extend across it in the closed position, and the configuration of the piston crown 160 and the complemental surface in the head, all combine to give the engine 10 improved performance and significant advantages in terms of emissions.
One advantage of this design is that the configuration of these components causes a controlled swirl of the charge during the compression stroke. In reference to FIG. 3, the flow of the fuel-air mixture into the combustion chamber 120 is represented. As the piston 190 nears the top of its stroke, the fuel-air mixture is forced or "squished" between the wedge-shaped piston crown 160 and the complementally shaped interior surface 130. The charge is then forced upwardly through the throat region 135 between the combustion chamber 120 and the interior surface 130. The compressed charge is thus channeled into the combustion chamber. As the charge enters the two adjacent sections 121, 122 of the combustion chamber it is forced generally upwardly parallel to the axis of the respective adjacent sections. As the charge rises, it encounters the necks of the exhaust and intake valves, which are extended across the respective chamber in their closed position as seen most clearly in FIG. 5. The valve necks thus serve as sources of intentionally induced swirling in the combustion chamber during the compression stroke and thus induce desirable turbulence in the combustion chamber. In particular, a swirling action of the compressed charge is induced in the charge as it attempts to circulate around the round valve stems, and as it comes in contact with the sidewalls of the combustion chamber, etc. This induced swirl of the compressed charge insures a more homogeneous mixture of fuel and air in the charge. The homogeneous nature of the charge helps to ensure upon ignition, a more homogenous, smooth and even burning of the charge.
The configuration of the combustion chamber, valve stems, piston head and cylinder head surface also effect positive action in the combustion chamber during the combustion cycle of the power stroke. Once the charge, which is under turbulence as discussed above, is fully compressed (i.e. the piston is at the top of the compression stroke) the spark plug 160 ignites the charge. As can be seen from both FIGS. 3 and 5, the spark plug, in this embodiment, is located along the horizontal line joining the tops of the two adjacent sections of the combustion chamber, and is also centrally located between the two chambers in a transverse direction. That is, the spark plug is centered at the top of the combustion chamber 120. As the charge ignites, the expanding flame front interacts with the valve stems extending across the adjacent sections 121, 122 of the combustion chamber. A series of theoretical drawings showing the progression of the combustion process according to the invention is shown in FIGS. 7-13. The interaction of the flame front F with the valve necks V (FIG. 7) forces the flame front to circulate around the necks V, thus inducing a swirling in the advancing flame front. Further, the flame front is effectively divided into three separate paths (labeled P1, P2 and P3 in FIG. 8). As the three flame fronts progress, they create a whirl path by pushing the unburned gases in front of them. The center front, following path P2, is not ready to collide and join with the fronts in paths P1 and P3 (see FIG. 9). At the same time, the flame fronts in paths P1 and P3 are in contact with the combustion chamber sections (C in FIG. 8) themselves, which are angled with respect to each other as previously discussed (an isolated view of the combustion chamber and piston of the invention is shown in FIG. 14). The separation and angling of the adjacent sections of the combustion chamber serves to divide the emerging flame front into two sections, each one directed along an adjacent section of the combustion chamber. The two halves of the flame front, however, do not remain separated. Rather, because of the configuration of the combustion chamber and the piston crown, they react and push on each other to induce a further complex swirling of the expanding flame front that includes a horizontal component.
It is believed that the interaction of the separated flame fronts to induce this horizontal component to the swirl initially occurs adjacent the throat area 135 between combustion chambers 120 and internal surface 130 (see FIG. 3). During the time the expansion of the flame front and swirling are occurring in the combustion chamber (described above), the increased pressure in front of the flame front is forcing the piston downward. As the wedge-shaped crown 160 of the piston 150 and the piston itself withdraw into the cylinder, the two halves of the flame front (one from each combustion chamber section) exit from the throat region 135 into the compression end of the cylinder. The divided and swirling flame front (indicated in FIG. 10 by references F1 and F2) then encounters the wedge-shaped crown 160 of the piston as depicted in FIG. 10. Indeed, the adjacent sections 121, 122 of the combustion chamber are angled so as to aim the separated flame fronts toward and respective faces of the crown 160 of the present embodiment (See FIG. 14). Because of the wedge-shape, the expanding flame front is again thrown outward toward the walls of the interior surface 130, and also toward the walls of the cylinder. The flame fronts thus assume a rotational motion having a significant horizontal as well as vertical component. This rotational motion is caused by the gases being thrown out to the cylinder sidewalls, and by the interaction of the gases with the piston head as shown in FIG. 11.
The swirling motion continues, having both a vertical and horizontal component, as the piston withdraws further into the cylinder. Because of inertia and the directing of the flame fronts according to the invention, each flame front which emerges from a combustion chamber section will follow a path like the exemplary one for flame front F1 shown in FIG. 12. This significant swirling and directing of the flame front during combustion not only assists in maintaining a slow, even burn of the charge, but also leads to reduced emissions by virtue of a "scrubbing" action on the unburned hydrocarbons which typically stick to the inner cylinder walls. The scrubbing action according to the invention is shown in FIG. 13. The swirling flame front F is subject to centrifugal loading, as indicated by the solid arrows. As the front F is pushed toward the cylinder wall W. it imparts sufficient energy to the molecules clinging to that surface to allow those molecules to liberate from the walls and be swept into the continuing combustion.
To summarize, a multiple flame front is initially created in the combustion chamber by means of the valve necks dividing the initial flame front and inducing a largely vertical swirl therein. As the same time, the angling of the two halves of the combustion chamber also serves to divide the flame front into two directed halves. These halves exit the combustion chamber and engage the tapered crown of the piston and are thrown out, to the walls of the cylinder thereby creating a horizontal component to the swirling, advancing flame front. The outward, rotational movement of the flame front also provides a scrubbing action to the cylindrical walls. A significant aspect of this combustion process is that the various swirling actions actually result from the expansion of the flame front itself, as guided and directed by the geometry of the combustion chamber according to the invention. In a conventional engine, the combustion initiates and accelerates the gases. In the present invention, the components are designed to also give the gas desirable direction and swirling to achieve enhanced performance and emissions levels.
It will be appreciated by one skilled in the art that the foregoing description of the combustion process represents an oversimplification. The variables affecting this process are too long to list. However, it is clear that the design of the combustion chamber, the valves, the piston head and the cylinder head are such that the vertical and horizontal components of the induced swirl referred to above will occur in the combusting charge. Indeed, close inspection of a prototype engine according to an embodiment of this invention exhibited swirl shaped burn marks on the crown of the piston, confirming the existence of swirling of the charge during combustion. Moreover, the existence of such a mechanism for increasing the thoroughness of the combustion is evident from the improved emission characteristics observed for an engine according to an embodiment of the present invention.
A graphical representation of those improved characteristics as compared to the same characteristics for stock automotive engine is shown in FIG. 15. As can be seen from that figure, the engine 10, according to the invention, shows improved emissions characteristics for CO 2 ; CO; and NO X . The graph also shows a poorer emission result in terms of unburned hydrocarbons (THC). It is believed that the superior CO and CO 2 emissions are a result of the swirling actions induced in the combustion chamber and the compression end of the cylinder as discussed above. The more thorough burning due to increased homogeneity of the charge and due to the scrubbing action of unburned charge from the walls contributes to this improvement. Although the actual emission levels for THC were higher in the engine according to the invention, the level still indicates an improvement over the stock engine. This is due to the fact that the present engine has a much larger surface-to-volume ratio (S/V) than a stock engine. Typically, a large S/V leads to a significant increase in THC--due mainly to the large surface area being generally cooler and reducing the combustion temperature. In the present engine, the S/V is around 3-4 times larger than the stock engine, but the THC emissions are comparable. This is an indication that the unique combustion properties of this engine greatly enhance the level of hydrocarbon burning during combustion--most probably due to the swirling of the charge sustaining the burn, and due to the scrubbing action of the swirling charge. Moreover, the prototype engine according to this embodiment exhibited superior mileage to the stock engine: 27.2 as opposed to 22:2 mpg. A modified stock engine was used to generate the "stock" data shown in FIG. 10. That engine was a Ford 2.3 liter SOHC 4-cylinder engine. The engine had a 9.5:1 compression ratio. The engine was operated with a Holley two barrel carburetor and Mallory after market points ignition. Standard Ford intake and exhaust manifolds were used, but the electronic ignition and fuel injection were deleted to make the stock engine and the engine according to the invention identical except for the cylinder heads.
It is also believed that the configuration of the combustion-related components leads to a smoother, even burn during combustion than in conventional engines. The smoothness of the burn, as compared to that of a stock engine, can be seen in FIG. 16. That plot shows the percent of consumed charge (X) as a function of the crank angle (Θ) of the crankshaft and was generated with the two engines running at 3800 RPM and 99% load. As will be appreciated by one skilled in the art, the shape of such curves will differ for different RPM and load conditions. The central curve (S) is the fuel consumption curve for the stock engine. The left dashed curve I1 is the actual fuel consumption curve of an engine according to the invention, and the second dashed curve I2 is the same as I1, but displaced in time so that the spark ignition time of I2 coincides with that of S. As this graph shows, the burn of the stock engine has a very steep slope, indicating that most of the combustion occurs over a small range of crank angles. Curve I2, however, shows a smoother, less steep curve, showing that the combustion in the inventive engine is more gradual and constant. It is believed that a primary cause of this smoother burn is the configuration of the combustion chamber and cylinder. While the combusting charge is in the combustion chamber, it is somewhat restricted by the small size of the chamber, and the presence of the valve necks. Upon exiting into the compression end of the cylinder, the flame front is less restricted and is subject to the swirling and scrubbing action discussed previously. These different phases of combustion apparently lead to the smoother burn characteristics shown in FIG. 16. Such a burn may also be referred to as a "long" burn, since more constant pressure is exerted on the piston over a longer portion of its travel, as compared to the burn of a conventional engine.
The smoother burn characteristics also mean that the pressure applied to the piston face in the engine according to the invention is more uniform. A pressure-volume curve comparing the stock engine and the inventive engine is shown is FIG. 17. This curve was generated with the two engines running at 3800 RPM and 99% load. As will be apparent to one of skill in the art, the shape of these curves will differ for different RPM and loading conditions. As can be seen, the curve for the inventive engine I is broader than that of the stock engine S. This is firstly an indication of the more even burning of the engine according to the invention.--i.e. more pressure is applied during a longer period of the combustion stroke. Further, the area under this curve represents the gross indicated work per cylinder--which is also higher in the engine according to the invention. The more even application of pressure the piston surface also introduces less undesirable vibration into the combustion process.
The smooth burn according to the invention also leads to reduced NO X emissions. As will be appreciated by one skilled in the art, the higher the peak temperature, the greater the possibility of NO X production. By maintaining the lesser peak temperature of combustion in the present engine, the NO X emissions are reduced as shown in FIG. 15. The configuration of this engine maintains this lower peak temperature, while still exhibiting THC emission valves comparable to the stock engines. Typically, however, this reduced peak temperature would lead to higher THC because lower temperature means a less efficient burn. The unique characteristics of the present combustion apparently leads to both lower peak temperature and complete burning of the charge. This may be due to the burn occurring over a longer period of the piston's stroke than a conventional engine, such that the potential exists for more crevice volume to be exposed to combustion, and to thus burn as well. This effect is further-enhanced by the scrubbing action, described previously.
VALVE LUBRICATION AND COOLING
The engine 10, according to the invention is also designed for improved valve lubrication, cooling and ease of servicing and adjustment. As discussed in regard to FIG. 1, the engine 10 includes L-shaped rocker arms 65 and 75, which are housed within generally P-shaped rocker arm brackets 66 and 76. Each rocker arm bracket is held in place by two bolts one disposed horizontally 77, and one disposed vertically 78. Assuming head cover 90 is removed, rocker arm bracket 76 and its associated rocker arm 75 can be easily removed by removing bolt 77 and 78 and simply lifting the bracket and arm out of the cylinder head. This makes the bracket and rocker arm easy to service.
The operation of a representative rocker arm 75 can be seen most clearly in reference to FIG. 2. The L-shaped arm 75 includes a cam pad 170 disposed at the end of arm 171. Unlike a conventional single overhead cam configuration, it should be noted that the cam pad 170 is disposed below the cam shaft 80. This leads to advantageous lubrication and functional features as will be described in greater detail below. The depending arm 172 of the bracket 75 engages the valve train of valve 100 at an actuating end 174. As the rocker arm in FIG. 2 is pivoted in the counter-clockwise sense by virtue of the cam shaft 80 rotating in a clockwise sense, the valve 100 is disengaged from the exhaust port 105 by the actuating end 174 pushing the valve train to the right in the sense of FIG. 2. A valve spring 195 biases valve 100 toward the closed position.
An isolated perspective view of the rocker arm 75 and valve 100 are shown in FIG. 19, and an exploded view is shown in FIG. 20. The actuating end 174 of the rocker arm 75 engages a valve shoe 200 which is entrained on stem 107. The valve shoe 200 is disposed on the valve stem 107 between a valve guide 205 and a rear bearing sleeve 210. Head 105 is disposed at the end of stem 107. As can be seen in FIGS. 3 and 4, the valve guide is stationary in the cylinder head, while the stem 107 reciprocates with respect to the guide 205. As can be seen most clearly in FIG. 19, the valve guide 205 includes a curved bearing surface for receiving the curved actuating end 174 of the rocker arm 75. Valve guide 205 includes the curved bearing surface for two reasons. First of all, it allows the guide to adequately support the rocker arm 75. Secondly, the extended bottom section of the guide serves as a reservoir for lubricating oil, insuring adequate lubrication between arm 75 and guide 205. The threaded end at stem 107 is fed through the central hole in valve shoe 200 and rear sleeve 210. Threaded bolt 220 fits within the central hole of rear sleeve 210, and is interior threaded to receive the threads of stem 107. A compression-type oil ring 230 is also disposed on the shaft 107. As will be appreciated by one skilled in the art, the oil ring is disposed on the stem to prevent leakage of oil out of the valve and into the combustion chamber. The various components of valve 100 are designed and made to be light weight. A stock spring 195 may be used to achieve necessary valve actuation.
The valve according to this embodiment also includes numerous features leading to improved valve cooling. The stem 107 has a thicker region 107a, which tapers to a thinner region 107b. The presence of the thicker region 107a gives the valve an increased radiating surface leading to better valve cooling. According to a further aspect of the invention, the valve 100 also includes a hollow interior region. A section view of valve 100 is shown is FIG. 21, and shows the hollow region 108. The presence of this region further increases the radiating area available for heat dissipation. Thus, unlike thinner, solid conventional valves, the valves according to the invention have both a larger outside diameter and radiating surface and a large inner radiating surface provided by hollow region 108. Furthermore, despite the fact that conventional valves have a theoretical cooling by virtue of heat flow from the head to the stem, this cooling is largely non-existent. Because of the significant length of conventional valve systems, that cooling mechanism is secondary to the cooling mechanism of heat flow from the valve head to the valve seat. Of course, this primary cooling mechanism is unavailable when the conventional valve is open, i.e. not in contact with the seat. Because of the shorter, thicker stems and the presence of the hollow region allowing both inner and outer radiating areas, the valves of the present invention include improved heat transfer mechanisms. These mechanisms are also always available to the valve, and are not dependent on the valve contacting a valve seat.
Further still, the valve 100 may also include oil ports 108a allowing communication of circulating oil into hollow region 108. The pressurized oil will enter region 108 through the ports 108a and contact the inner surface of the valve in order to carry away heat. The valves also stay cooler since they are shorter than stock valves, and thus have a shorter thermal distance from head to stem. Further, the valves are cooler because, at least in the case of the exhaust valve, the stem is retracted from the exhaust path during exhaust, keeping that valve cooler by preventing exposure of the stem to super hot exhaust gas. The same exhaust stem is then cooled by cold intake charge during the intake stroke. The valves according to the invention are thus light weight and exhibit improved temperature characteristics, leading to less thermal distortion.
The configuration of the rocker arm brackets, rocker arms and tilted valves leads to improved lubrication characteristics for this engine. As can be seen in FIG. 1, and the top view of FIG. 18, the rocker arm brackets include elongated central openings 250. These elongated central openings 250 receive the horizontally extending arms of the respective rocker arms. At the same time, the openings serve as oil reservoirs. The upstanding sidewalls of the central openings 250 and the top surface of the rocker arm define a reservoir for collecting oil and maintaining the rocker arm and its associated cam pad under more constant lubrication. On either side of the rocker arms within elongated central openings 250 are leak crevices indicated generally by reference numeral 255 in the top view of FIG. 18. These leak crevices allow lubricating oil to leak along the depending portion of the rocker arms and into the valve train assembly. Thus, lubrication of both the rocker arm and the valve train are assisted by gravity. This is in distinction to the conventional single overhead cam configuration where the cam pads are located above the cam shaft. In that case, oil must be thrown upward to lubricate the cam pad cam shaft surfaces. Of course, gravity works against such a lubrication system. Similarly, this structure represents an improvement over the conventional dual overhead cam arrangement. In such an arrangement the buckets which house the spring end of the valve train are located below their respective cam shafts. However, the dual overhead cam design does not provide for pooling of the lubrication oil as in the present design. Accordingly, run off due to gravity is also present in that design. Further, conventional valves rely on planned leakage of oil to adequately lubricate the valve stem/bearing sleeve interface. This is an imperfect, but workable system. It can lead, however to undesirable results. For example the leakage of oil through an intake valve is enhanced, as compared to that through an exhaust valve, by virtue of the fact that the intake valve must contain vacuum. In the present invention, however, valve lubrication is controlled as opposed to relying on designed-in leakage in the manner of conventional engines. For instance, because the present valves are not sitting in the manifold, the stems behind the compression rings can be bathed in oil--as opposed to receiving minimal, leakage oil as in standard valves. Moreover, the circulation of oil through the present valves not only enhances lubrication, but also serves a cooling function, described above. The present valves are thus both cooler and better lubricated than conventional valves.
Gravity also assists the lubrication system in the present invention by virtue of the fact that the valves may be tilted in a preferred embodiment. Accordingly, lubricating oil in the valve tends to run away from the rings and the combustion chamber. Accordingly, when the engine is shut down lubricating oil that may typically leak into the combustion chamber will be drawn by gravity away from the combustion chamber and into the spring end of the valve train. Of course, prevention of leakage of oil into the combustion chamber increases engine efficiency and also reduces hydrocarbon emissions generated by burning oil as opposed to a fuel-air mixture. Thus, instead of gravity working against the lubrication system as in conventional single and dual overhead cam configurations, the design according to the present invention uses gravity to enhance the lubrication system.
ENHANCEMENTS
While the engine just described has superior performance and emissions characteristics as compared to a stock engine, it is believed that further improvements to the engine would lead to even greater performance and emissions characteristics. As will be appreciated by one skilled in the art, the only meaningful way to analyze an the performance of an engine is to conduct empirical studies on a prototype. While a prototype was built according to the previous embodiment, no prototype, to date, has been built incorporating the following potential improvements. Accordingly, the asserted advantages are at present somewhat theoretical, although soundly based on existing engine design principles and experience gained by testing and analysis of the previous embodiment. Thus, these improvements are also included within the scope of the invention.
A first improved feature could be an increased compression ratio. High compression is important in an engine according to the invention since the engine features a high surface to volume ratio in the combustion chamber. It is believed that a higher compression ratio would result in even lower unburned hydrocarbon emissions. Modification of both a tapered piston crown and the thin upstanding combustion chamber sections will lead to this higher compression ratio.
Another possible improved feature of the engine would be reduction of crevice volumes. As is known to those skilled in the art, crevice volumes are small volumes that occur at the proximity or joining of any two entities within the combustion chamber. In the embodiment previously described, an example of such a crevice volume is the joint between the valves and the valves seat, where a significant crevice is formed because of the seating angles. Another crevice volume in the previously-described embodiment is the thin volume between the piston crown and the complemental interior surface of the cylinder head. Crevice volumes create a problem in that they form a very acceptable place for unburned charge to hide, thus preventing the charge from being thoroughly combusted. In the embodiment previously-described, the wedge-shaped piston crown resulted in two very large and isolated crevice volumes between the curved portions joining each crown face and the complementally-shaped surface in the head. These crevice volumes can be seen most clearly in FIG. 2. This problem could be potentially solved by use of a cone-shaped piston, as shown in FIG. 22. This design is consistent with the previous description of the piston crown tapering to a zenith along the central axis of the piston.
Such a design not only would reduce crevice volumes, but would also lead to increased combustion efficiencies. In the previously-described embodiment, it is believed that the wedge-shape of the piston crown may have adversely affected the horizontal component of the complex swirl pattern of the combusting charge. This is due to the fact that the axially extending joint line between the two wedge faces served as a barrier to the swirl which had to be surmounted during each period of circulation. Modification of the piston crown to be cone-shaped would eliminate this problem, while also helping to eliminate the crevice volume problem.
Modification of the piston head to a cone shape could further be combined with a modification to the combustion chamber, as shown in FIG. 23. In this design, the two halves, 501 and 502, of the combustion chamber are still offset about a longitudinal axis as in the previous embodiment, but they are joined at the bottom instead of the top. As a result, the two separate flame fronts generated in each half of the combustion chamber will not interact until just before the flame fronts enter the compression end 505 of the cylinder. Of course, such a design requires each chamber half to have its own spark plug 511, 512. It is believed that this design will further enhance the swirling and scrubbing action of the combusting charge. Each chamber will have a valve neck 503 associated therewith (FIG. 24) to serve as a source of swirl for the flame front, and the two halves of the exiting charge will be more accurately directed so as to be thrown out against the cylinder walls with even greater intensity leading overall to a more thorough burn, while maintaining the other advantageous combustion characteristics of the preferred embodiment.
A further potential improved feature in the engine would be a reduced surface to volume ratio. This could be achieved by having a more compact combustion chamber, as well as a reduced surface area at the piston crown. Since less surface area will be available for clinging, unburned hydrocarbons, the lower surface to volume ratio should produce less unburned hydrocarbons.
A possible improvement could also be realized by increasing the valve size, which brings the possibility of improved breathing. An example of such a valve is seen in FIG. 25. Valve 550 has an even larger diameter that in the previous embodiment. Further, the hollow central cavity 555 has been extended the entire length of the valve. This not only allows for a significant increase in the internal radiating surface area, but significantly decreases valve mass and also allows the valve actuation spring 560 to be housed within the valve, as seen in FIG. 24. This greatly simplifies the structure and actuation of the valve. Instead of the relatively heavy rocker arms from the previous embodiment, this valve can be actuated by a light-weight push rod 570 engaging a valve boot 575. FIG. 24 shows a simplified valve boot 575. An alternative embodiment of boot 575' is shown in FIGS. 26 and 27. Boot 575' engages a ring 580 disposed on the valve 550. The boot, including an angled camming surface 585, includes a cutout 577 to reduce its mass while providing enhanced valve actuation. The boot, having a larger diameter than the valve, would ride on linear tracks on the inside wall of the valve sleeve, thus ensuring that the boot exerts only axial force of the valve.
A reduced weight in the valve actuation system should result in lower reciprocating mass, better lubrication, adjustment capabilities, cooling, and RPM capability. A simple mechanism may also be included so that the valves rotate during actuation. Rotation of the valves allows for more uniform heating of the valves, thus preventing the formation of hot spots which can cause valve distortion and knock during combustion. Cooling of the valve may also be enhanced by directing pressurized oil in the large hollow central cavity 555, the oil contacting the interior surface and carrying away heat.
An improvement of the design of the intake manifold could also lead to improved performance. In the previously-described embodiment, the intake manifold was fabricated with the use of simple carburation as the fuel delivery system. As is common with such systems, the cylinder furthest from the carburetor ran lean, while the cylinder closest to the carburetor ran with the richest mixture. Improvement could be achieved by use of a more accurate, functional and runner-equalized intake manifold, as well as by use of electronic fuel injection as opposed to carburation.
Another possible improved feature would be a reduced piston mass. In the previously-described embodiment, a prototype was made using a modified and existing casting to obtain the necessary piston crown shape. As a result, the piston had a weight that represented a 50 percent increase over a stock piston. By using a cone-shaped piston of reduced mass, significant improvement should be realized.
Of course, as with any engine, improvements could also be realized by properly adjusting an optimizing the timing of the engine. Further, any modifications which improve the serviceability or access to parts of the engine is preferred. Prevention of oil leakage and improved cooling capabilities are also desirable modifications to make to any engine.
While the above described modifications may potentially improve the performance of an engine according to the invention, the previously-described embodiment realizes a significant advancement over stock engines, as shown graphically in FIG. 15. That engine was able to achieve better mileage, and reduced emissions because of the unique structure of the engine. This structure lead to the improved functional characteristics described. In particular, the structure of the engine leads to an improved squish and swirl of the charge during the compression stroke. The shape of the combustion chamber, the extension of the valve stems across that chamber the shape of the piston head and the complemental shape of the cylinder head combine to lead to a combustion-induced vertical and horizontal swirling of the charge during the power stroke. This leads to a smoother, more even burn as well as a scrubbing action for removing unburned hydrocarbons from the combustion chamber walls. The tapered piston crown contributes to the improved performance as the swirling charge exiting from the thin, upstanding combustion chamber sweeps outwardly by contact with that crown-shaped head to further induce swirl and lead to a more complete burn of the charge as well as scrubbing of the cylinder walls. The design disclosed herein also offer lighter valves with enhanced cooling, lubricating and actuating capabilities.
There has thus been disclosed an improved internal combustion engine. Potential improvements have also been disclosed, and are intended to be within the scope of the present invention. Indeed, the invention embraces all modifications and equivalents to the disclosed embodiment as fall within the scope of the following claims. | An internal combustion engine of the valve-in-head type having a low profile cylinder head which requires minimal head-room in the engine compartment of an automotive vehicle The cylinder head has a rectilinear configuration with the valve trains disposed on horizontal axes extending transversely of the cylinder head. Each valve train in the cylinder head is provided with precise axial support at both ends of the train. The engine has a relatively thin upstanding combustion chamber over each cylinder and one or more pairs of poppet valves per cylinder each having a sealing surface adjacent its outer edge for engagement with respective seats defined by axially aligned header tubes. Each valve has a relatively short neck extending through the combustion chamber during the intake and compression strokes and when the fuel-air mixture is fired. The valve spring of each valve train is situated between a fixed abutment attached to the side wall of the cylinder head and the end of the valve cage remote from the poppet valves. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Application No. 61/133,994, filed Jul. 7, 2008, the entirety of which is incorporated herein by reference and is to be considered part of this specification.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the use of thermostatic HVAC controls that are connected to a computer network. More specifically, the present invention pertains to application of specific adaptive waveforms to the setpoints programmed into thermostats in order to reduce energy consumption with out a subjective loss of comfort.
2. Background
Heating and cooling systems for buildings (heating, ventilation and cooling, or HVAC systems) have been controlled for decades by thermostats. At the most basic level, a thermostat includes a means to allow a user to set a desired temperature, a means to sense actual temperature, and a means to signal the heating and/or cooling devices to turn on or off in order to try to change the actual temperature to equal the desired temperature. The most basic versions of thermostats use components such as a coiled bi-metallic spring to measure actual temperature and a mercury switch that opens or completes a circuit when the spring coils or uncoils with temperature changes. More recently, electronic digital thermostats have become prevalent. These thermostats use solid-state devices such as thermistors or thermal diodes to measure temperature, and microprocessor-based circuitry to control the switch and to store and operate based upon user-determined protocols for temperature vs. time.
These programmable thermostats generally offer a very restrictive user interface, limited by the cost of the devices, the limited real estate of the small wall-mounted boxes, and the inability to take into account more than two variables: the desired temperature set by the user, and the ambient temperature sensed by the thermostat. Users can generally only set one series of commands per day, and in order to change one parameter (e.g., to change the late-night temperature) the user often has to cycle through several other parameters by repeatedly pressing one or two buttons.
Because the interface of programmable thermostats is so poor, the significant theoretical savings that are possible with them (sometimes cited as 25% of heating and cooling costs) are rarely realized. In practice, studies have found that more than 50% of users never program their thermostats at all. Significant percentages of the thermostats that are programmed are programmed sub-optimally, in part because, once programmed, people tend not to re-invest the time needed to change the settings very often.
A second problem with standard programmable thermostats is that they represent only a small evolutionary step beyond the first, purely mechanical thermostats. Like the first thermostats, they only have two input signals—ambient temperature and the preset desired temperature. The entire advance with programmable thermostats is that they can shift between multiple present temperatures at different times without real-time involvement of a human being.
Because most thermostats control HVAC systems that do not offer infinitely variable output, traditional thermostats are designed to permit the temperature as seen by the thermostat to vary above and below the setpoint to prevent the HVAC system from constantly and rapidly cycling on and off, which is inefficient and harmful to the HVAC system. The temperature range in which the thermostat allows the controlled environment to drift is known as both the dead zone and, more formally, the hysteresis zone. The hysteresis zone is frequently set at +/−1 degree Fahrenheit. Thus if the setpoint is 68 degrees, in the heating context the thermostat will allow the inside temperature to fall to 67 degrees before turning the heating system on, and will allow it to rise to 69 degrees before turning it off again.
Standard programmable thermostats are all designed with the same basic underlying premise: that the comfort of building occupants is maximized by maintaining a relatively constant temperature, at least for the duration of a given setpoint, and with the variations inherent in using a hysteresis band to trade comfort off against efficient operation and durability. That is, if a programmable thermostat has been programmed to maintain a temperature of 68 degrees Fahrenheit for 8 hours, it will cycle the HVAC system as needed to maintain that temperature.
However, academic research has shown that humans tend not to notice changes in temperature if (a) they are below a certain magnitude and (b) if the rate of change is sufficiently slow. For example a 1978 study found that people did not notice ramps less than 0.5° C./h (0.9° F./h). A 2004 study found that and that ramps up to 1.5° C./h (2.7° F./h) are unlikely to cause discomfort.
Because energy consumption is directly proportional to setpoint—that is, the further a given setpoint diverges from the balance point (the inside temperature assuming no HVAC activity) in a given house under given conditions, the higher energy consumption will be to maintain temperature at that setpoint), energy will be saved by any strategy that over a given time frame lowers the average heating setpoint or raises the cooling setpoint. It is therefore possible to save energy by adopting a strategy that takes advantage of human insensitivity to slow temperature ramping by incorporating a user's desired setpoint within the range of the ramp, but setting the average target temperature below the desired setpoint in the case of heating, and above it in the case of cooling. For example, a ramped summer setpoint that consisted of a repeated pattern of three phases of equal length set at 72° F., 73° F., and 74° F. would create an effective average setpoint of 73° F., but would generally be experienced by occupants as yielding equivalent comfort as in a room set at a constant 72° F. Energy savings resulting from this approach have been shown to be in the range of 4-6%.
It would be advantageous to create a temperature control system that would automatically generate optimized ramped setpoints that could save energy without compromising the comfort of the occupants. It would also be advantageous to create a temperature control system that could incorporate adaptive algorithms that could automatically determine when the ramped setpoints should not be applied due to a variety of exogenous conditions that make application of such ramped setpoints undesirable.
SUMMARY OF THE INVENTION
In one embodiment, the invention comprises a thermostat attached to an HVAC system, a local network connecting the thermostat to a larger network such as the Internet, and one or more additional thermostats attached to the network, and a server in bi-directional communication with a plurality of such thermostats. The server logs the ambient temperature sensed by each thermostat vs. time and the signals sent by the thermostats to their HVAC systems. The server preferably also logs outside temperature and humidity data for the geographic locations for the buildings served by the connected HVAC systems. Such information is widely available from various sources that publish detailed weather information based on geographic areas such as by ZIP code. The server uses this data to determine optimum application of an n-phase ramped setpoint algorithm in order to change the actual average setpoint over time without affecting the perceived temperature.
At least one embodiment of the invention comprises the steps of measuring the temperature inside a conditioned space; comparing said inside temperature to the desired setpoint for such conditioned space; evaluating the schedule for setpoint changes; determining whether the scheduled setpoint has been changed; setting the actual setpoint to the desired setpoint; determining the number of phases for actual setpoints; setting actual setpoints to increments away from the desired setpoint as additional phases, where each successive setpoint is further from said desired setpoint than the previous setpoint; and returning to the desired setpoint after said determined number of setpoints has been reached.
At least one embodiment of the invention comprises the steps of evaluating the temperature inside a conditioned environment; evaluating weather conditions outside the conditioned environment; setting a first target inside temperature for a specified time interval; setting at least a second target inside temperature for a specified time interval, where said second target temperature differs from said first target temperature by a specified amount; determining whether said variation of temperature setpoints is appropriate given said outside weather conditions; and cycling through said two or more target temperatures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of an overall environment in which an embodiment of the invention may be used.
FIG. 2 shows a high-level illustration of the architecture of a network showing the relationship between the major elements of one embodiment of the subject invention.
FIG. 3 shows an embodiment of the website to be used as part of the subject invention.
FIG. 4 shows a high-level schematic of the thermostat used as part of the subject invention.
FIG. 5 shows one embodiment of the database structure used as part of the subject invention
FIG. 6 shows the conventional programming of a programmable thermostat over a 24-hour period.
FIG. 7 shows the programming of a programmable thermostat over a 24-hour period using ramped setpoints.
FIG. 8 shows the steps required for the core function of the ramped setpoint algorithm.
FIG. 9 shows a flowchart listing steps in the process of deciding whether to implement the ramped setpoint algorithm.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an example of an overall environment 100 in which an embodiment of the invention may be used. The environment 100 includes an interactive communication network 102 with computers 104 connected thereto. Also connected to network 102 are one or more server computers 106 , which store information and make the information available to computers 104 . The network 102 allows communication between and among the computers 104 and 106 .
Presently preferred network 102 comprises a collection of interconnected public and/or private networks that are linked to together by a set of standard protocols to form a distributed network. While network 102 is intended to refer to what is now commonly referred to as the Internet, it is also intended to encompass variations which may be made in the future, including changes additions to existing standard protocols.
When a user of the subject invention wishes to access information on network 102 , the buyer initiates connection from his computer 104 . For example, the user invokes a browser, which executes on computer 104 . The browser, in turn, establishes a communication link with network 102 . Once connected to network 102 , the user can direct the browser to access information on server 106 .
One popular part of the Internet is the World Wide Web. The World Wide Web contains a large number of computers 104 and servers 106 , which store HyperText Markup Language (HTML) documents capable of displaying graphical and textual information. HTML is a standard coding convention and set of codes for attaching presentation and linking attributes to informational content within documents.
The servers 106 that provide offerings on the World Wide Web are typically called websites. A website is often defined by an Internet address that has an associated electronic page. Generally, an electronic page is a document that organizes the presentation of text graphical images, audio and video. Servers 106 also provide a variety of services other than serving websites. These services, such as communicating with and controlling remote devices as described below, may be delivered via Internet Protocol or other means for communicating across a network.
In addition to the Internet, the network 102 can comprise a wide variety of interactive communication media. For example, network 102 can include local area networks, interactive television networks, telephone networks, wireless data systems, two-way cable systems, and the like.
In one embodiment, computers 104 and servers 106 are conventional computers that are equipped with communications hardware such as modem or a network interface card. The computers include processors such as those sold by Intel and AMD. Other processors may also be used, including general-purpose processors, multi-chip processors, embedded processors and the like.
Computers 104 can also be handheld and wireless devices such as personal digital assistants (PDAs), cellular telephones and other devices capable of accessing the network.
Computers 104 utilize a browser configured to interact with the World Wide Web. Such browsers may include Microsoft Explorer, Mozilla, Firefox, Opera or Safari. They may also include browsers used on handheld and wireless devices.
The storage medium may comprise any method of storing information. It may comprise random access memory (RAM), electronically erasable programmable read only memory (EEPROM), read only memory (ROM), hard disk, floppy disk, CD-ROM, optical memory, or other method of storing data.
Computers 104 and 106 may use an operating system such as Microsoft Windows, Apple Mac OS, Linux, Unix or the like.
Computers 106 may include a range of devices that provide information, sound, graphics and text, and may use a variety of operating systems and software optimized for distribution of content via networks.
FIG. 2 illustrates in further detail the architecture of the specific components connected to network 102 showing the relationship between the major elements of one embodiment of the subject invention. Attached to the network are thermostats 108 and computers 104 of various users. Connected to thermostats 108 are HVAC units 110 . The HVAC units may be conventional air conditioners, heat pumps, or other devices for transferring heat into or out of a building. Each user is connected to the server 106 via wired or wireless connection such as Ethernet or a wireless protocol such as IEEE 802.11, a gateway 110 that connects the computer and thermostat to the Internet via a broadband connection such as a digital subscriber line (DSL) or other form of broadband connection to the World Wide Web. Server 106 contains the content to be served as web pages and viewed by computers 104 , as well as databases containing information used by the servers.
In the currently preferred embodiment, the website 200 includes a number of components accessible to the user, as shown in FIG. 3 . Those components may include a means to enter temperature settings 202 , a means to enter information about the user's home 204 , a means to enter the user's electricity bills 206 , means to calculate energy savings that could result from various thermostat-setting strategies 208 , and means to enable and choose between various arrangements 210 for demand reduction with their electric utility provider as intermediated by the demand reduction service provider.
FIG. 4 shows a high-level block diagram of thermostat 108 used as part of the subject invention. Thermostat 108 includes temperature sensing means 252 , which may be a thermistor, thermal diode or other means commonly used in the design of electronic thermostats. It includes a microprocessor 254 , memory 256 , a display 258 , a power source 260 , a relay 262 , which turns the HVAC system on and off in response to a signal from the microprocessor, and contacts by which the relay is connected to the wires that lead to the HVAC system. To allow the thermostat to communicate bi-directionally with the computer network, the thermostat also includes means 264 to connect the thermostat to a local computer or to a wireless network. Such means could be in the form of Ethernet, wireless protocols such as IEEE 802.11, IEEE 802.15.4, Bluetooth, cellular systems such as CDMA, GSM and GPRS, or other wireless protocols. The thermostat 250 may also include controls 266 allowing users to change settings directly at the thermostat, but such controls are not necessary to allow the thermostat to function.
The data used to generate the content delivered in the form of the website is stored on one or more servers 106 within one or more databases. As shown in FIG. 5 , the overall database structure 300 may include temperature database 400 , thermostat settings database 500 , energy bill database 600 , HVAC hardware database 700 , weather database 800 , user database 900 , transaction database 1000 , product and service database 1100 and such other databases as may be needed to support these and additional features.
The website 200 will allow users of connected thermostats 250 to create personal accounts. Each user's account will store information in database 900 , which tracks various attributes relative to users of the site. Such attributes may include the make and model of the specific HVAC equipment in the user's home; the age and square footage of the home, the solar orientation of the home, the location of the thermostat in the home, the user's preferred temperature settings, whether the user is a participant in a demand reduction program, etc.
As shown in FIG. 3 , the website 200 will permit thermostat users to perform through the web browser substantially all of the programming functions traditionally performed directly at the physical thermostat, such as temperature set points, the time at which the thermostat should be at each set point, etc. Preferably the website will also allow users to accomplish more advanced tasks such as allow users to program in vacation settings for times when the HVAC system may be turned off or run at more economical settings, and set macros that will allow changing the settings of the temperature for all periods with a single gesture such as a mouse click.
In addition to using the system to allow better signaling and control of the HVAC system, which relies primarily on communication running from the server to the thermostat, the bi-directional communication will also allow the thermostat 108 to regularly measure and send to the server information about the temperature in the building. By comparing outside temperature, inside temperature, thermostat settings, cycling behavior of the HVAC system, and other variables, the system will be capable of numerous diagnostic and controlling functions beyond those of a standard thermostat.
The system installed in a subscriber's home may optionally include additional temperature sensors at different locations within the building. These additional sensors may be connected to the rest of the system via a wireless system such as 802.11 or 802.15.4, or may be connected via wires. Additional temperature and/or humidity sensors may allow increased accuracy of the system, which can in turn increase user comfort or energy savings.
FIG. 6 represents the conventional programming of a thermostat and the resulting behavior of a home's HVAC system in the air conditioning context. The morning setpoint of 74 degrees 1002 remains constant from midnight until 9:00 AM, and the inside temperature 1004 varies more or less within the limits of the hysteresis band during that entire period. When the setpoint changes to 80 degrees 1006 , the inside temperature 1008 varies within the hysteresis band around the new setpoint, and so on. Whether the average temperature is equal to, greater or less than the nominal setpoint will depend on weather conditions, the dynamic signature of the structure, and the efficiency and size of the HVAC system. But in most cases the average temperature will be at least roughly equivalent to the nominal setpoint.
FIG. 7 represents implementation of three-phase ramped setpoint 1102 derived from the same user preferences as manifested by the settings shown in FIG. 6 . Because 74 degrees, the setpoint requested by the user 1104 is the lowest of the three discrete steps 1106 , 1108 , 1110 , rather than the middle step, the average inside temperature 1112 will be roughly one degree warmer than the average temperature without use of the ramped setpoints.
In order to implement such ramped setpoints automatically, algorithms may be created. These algorithms may be generated on remote server 106 and the setpoint changes can be transmitted to a given thermostat on a just-in-time basis or, if the thermostat 108 is capable of storing future settings, they may be transferred in batch mode to such thermostats. Basic parameters used to generate such algorithms include:
the number of discrete phases to be used;
the temperature differential associated with each phase; and
the duration of each phase
In order to increase user comfort and thus maximize consumer acceptance, additional parameters may be considered, including:
time of day
outside weather conditions
recent history of manual inputs
recent pre-programmed setpoint changes.
Time of day may be relevant because, for example, if the home is typically unoccupied at a given time, there is no need for perceptual programming. Outside weather is relevant because comfort is dependent not just on temperature as sensed by a thermostat, but also includes radiant differentials. On extremely cold days, even if the inside dry-bulb temperature is within normal comfort range, radiant losses due to cold surfaces such as single-glazed windows can cause subjective discomfort; thus on such days occupants may be more sensitive to ramping. Recent manual inputs (e.g., programming overrides) may create situations in which exceptions should be taken; depending on the context, recent manual inputs may either suspend the ramping of setpoints or simply alter the baseline temperature from which the ramping takes place.
FIG. 8 shows the steps used in the core ramped setpoint algorithm into the context of a remotely managed thermostat system. In step 1202 the application determines whether to instantiate the algorithm based upon external scheduling criteria. In step 1204 the application running on a remote server retrieves from the thermostat the data generated by or entered into the thermostat, including current temperature settings, HVAC status and inside temperature. The algorithm performs preliminary logical tests at that point to determine whether further processing is required. For example, in the heating context, if the inside temperature as reported by the thermostat 108 is more than 1 degree higher than the current setpoint, the algorithm may determine that running the ramped setpoint program will have no effect and therefore terminate. In step 1206 the algorithm advances to the next phase from the most recent phase; i.e., if the algorithm is just starting, the phase changes from “0” to “1”; if it has just completed the third phase of a three-phase ramp, the phase will change from “2” to “0”. In step 1208 the application determines if the current phase is “0”. If it is, then in step 1210 the algorithm determines whether current setpoint equals the setpoint in the previous phase. If so, which implies no manual overrides or other setpoint adjustments have occurred during the most recent phase, then in step 1212 the algorithm sets the new setpoint back to the previous phase “0” setpoint. If not, then in step 1214 , the algorithm keeps the current temperature setting as setpoint for this new phase. In step 1216 , the algorithm logs the resulting new setpoint as the new phase “0” setpoint for use in subsequent phases.
Returning to the branch after step 1208 , if the current phase at that point is not phase “0”, then in step 1220 , the algorithm determines whether the current setpoint is equal to the setpoint temperature in the previous phase. If not, which implies setpoints have been adjusted by the house occupants, thermostat schedules, or other events, then in step 1222 , the application resets the phase to “0”, resets the new setpoint associated with phase “0” to equal the current temperature setting, and sets the current setting to that temperature. Alternatively, if the current temperature setting as determined in step 1220 is equal to the setpoint in the previous phase, then in step 1224 new setpoint is made to equal current setpoint plus the differential associated with each phase change. In step 1226 the “previous-phase setpoint” variable is reset to equal the new setpoint in anticipation of its use during a subsequent iteration.
FIG. 9 shows one embodiment of the overall control application implementing the algorithm described in FIG. 8 . In step 1302 , the control application retrieves the current setting from the thermostat. In step 1304 , the setting is logged in database 300 . In step 1305 , the control program determines whether other algorithms that have higher precedence than the ramped setpoint algorithm are to be run. If another algorithm is to be run prior to the ramped setpoint algorithm, then the other program is executed in step 1306 . If there are no alternate algorithms that should precede the ramped setpoint application then in step 1308 , the control program determines whether the thermostat has been assigned to execute the ramped setpoint program. If not, the control program skips the remaining actions in the current iteration. If the program is set to run, then in step 1310 the algorithm retrieves from database 300 the rules and parameters governing the implementation of the algorithm for the current application of the program. In step 1312 , the algorithm determines whether one or more conditions that preclude application of the algorithm, such as extreme outside weather conditions, whether the home is likely to be occupied, etc. If any of the exclusionary conditions apply, the application skips execution of the ramped setpoint algorithm for the current iteration. If not, the application proceeds to step 1314 in which the application determines whether the setpoint has been altered by manual overrides, thermostat setback schedule changes, or other algorithms as compared to the previous value as stored in database 300 . If setpoint has been altered, the application proceeds to step 1320 discussed below. In step 1318 , the program described in FIG. 8 , is executed. In step 1320 , the application resets the phase to “0”. Certain temperature setting variables are reset in anticipation of their use in subsequent phases. These variables include the new phase 0 temperature setting which is anchored to the current actual temperature setting, and the new previous-phase setpoint which will be used for identifying setpoint overrides in the subsequent phase.
In step 1322 , the system records the changes to the thermostat settings to database 300 . In step 1324 , the system records the changes to the phase status of the algorithm to database 300 . In step 1326 , the application determines whether the new temperature setting differs from the current setting. If they are the same, the application skips applying changes to the thermostat. If they are different, then in step 1328 , the application transmits revised settings to the thermostat. In step 1330 , the application then hibernates for the specified duration until it is invoked again by beginning at step 1302 again. | The invention comprises systems and methods for ramping setpoints on thermostats controlling HVAC systems. At least one thermostat is located inside a structure and is used to control an HVAC system in the structure. At least one remote processor is in communication with said thermostat and at least one database stores data reported by the thermostat. At least one processor compares the outside temperature at least one location and at least one point in time to information reported to the remote processor from the thermostat. The remote processor ramps the setpoint on the thermostat so as to reduce the average spread between inside temperature and outside temperature in order to reduce energy consumption with affecting comfort. The remote processor takes into account the effect of weather conditions and occupant preferences in determining whether and when to ramp setpoints. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an electronic cigarette, especially to the electronic cigarette with a battery being fitted in an atomizing device thereof
[0003] 2. Related Art
[0004] An existing electronic cigarette comprises an atomizing device and a battery, the battery is set to one end of the atomizing device and electrically connected with the atomizing device, such configuration results a longer cigarette body, and inconvenient carrying.
SUMMARY OF THE INVENTION
[0005] An object of the present invention is to provide an electronic cigarette in a proper whole length and being easily carried.
[0006] To achieve the above object, an electronic cigarette of the present invention, comprises an atomizing device with a tobacco-liquid cup, and a battery electrically connected with the atomizing device; herein the tobacco-liquid cup defines a recessed cavity, and the battery is arranged in the recessed cavity.
[0007] Furthermore, the tobacco-liquid cup comprises an outer cup body and an inner cup body, a first end of the inner cup body and the outer cup body are tightly connected so that and the outer cup body enclose a liquid-storing space, and the inner cup body is hollow to form the recessed cavity for receiving the battery.
[0008] Furthermore, the tobacco-liquid cup is set with a mouthpiece near a second end of the inner cup body; the mouthpiece through its center defines an inhaling port to communicate with an air passageway for vapor mist to be drawn therethrough; the atomizing device further comprises an atomizer disposed between the mouthpiece and the battery to vaporize tobacco liquid into vapor mist.
[0009] Furthermore, the atomizer comprises an electric heat wire; the second end of the inner cup body is set with a first electrode assembly which is electrically connected with the electric heat wire and the battery; the first electrode assembly comprises a first seat and a first terminal post both of which are insulated from each other and respectively electrically connected to both ends of the electric heat wire to form positive and negative electrodes of the atomizer.
[0010] Furthermore, the battery rod is fitted outside of the battery; one end of the battery rod abutting against the first electrode assembly is set with a second electrode assembly coupled to the first electrode assembly; the second electrode assembly comprises a second seat and a second terminal post both of which are insulated from each other and respectively connected to positive and negative poles of the battery.
[0011] Furthermore, the battery rod and the tobacco-liquid cup are detachably connected.
[0012] Furthermore, the tobacco-liquid cup is set with a first magnetic part where it is interconnected with the battery rod; the battery rod is correspondingly set with a second magnetic part drawing the first magnetic part so that the tobacco-liquid cup and the battery rod are tightly interconnected.
[0013] Furthermore, the first seat is made from conductive magnet or magnetic materials to form the first magnetic part, or the first electrode assembly is set with a separate component made from magnet or magnetic materials to form the first magnetic part; the second seat is made from conductive magnet or magnetic materials to form the second magnetic part, or the second electrode assembly is set with a separate component made from magnet or magnetic materials to form the second magnetic part.
[0014] Furthermore, the first end of the inner cup body is tightly connected with the outer cup body by a end cap; the end cap is made from magnet or magnetic materials to form the first magnetic part, or the end cap is set with a separate component made from magnet or magnetic materials to form the first magnetic part; the battery rod is set with a battery cover away from the atomizer for enclosing the battery; the battery cover is made from magnet or magnetic materials to form the second magnetic part, or the battery cover is set with a separate component made from magnet or magnetic materials to form the second magnetic part.
[0015] Furthermore, the second seat is hollow and tubular, its end facing the battery defines an accommodating cavity for receiving the second terminal post; the second terminal post is fixed in the accommodating cavity by means of an insulation sleeve.
[0016] Furthermore, the insulation sleeve comprises a first insulation support and a second insulation support both of which are interconnected and define an inner chamber; the second terminal post is elastically fitted in center of the insulation sleeve by means of a compression spring fixed in the inner chamber; both the first insulation support and the second insulation support axially define a first terminal hole and a second terminal hole in their opposite end walls to communicate with the inner chamber for both ends of the second terminal post extending therethrough; the second terminal post forms a blocking ring in the inner chamber; the compression spring has both ends thereof respectively abutting against the blocking ring and an inner wall of the second insulation support, therefore, one end of the second terminal post facing the first electrode assembly remains extending outwards.
[0017] Furthermore, the atomizer is arranged between the mouthpiece and the first seat via a support; the support is hollow and tubular, its center forms an atomizing chamber to communicate with the air passageway and receive the atomizer.
[0018] Furthermore, the atomizer further comprises a liquid-delivery rod with both ends thereof extending into the tobacco-liquid cup to absorb tobacco liquid; the electric heat wire winds round the liquid-delivery rod; the support defines openings radially through its side wall for fitting the liquid-delivery rod.
[0019] Furthermore, one end of the first seat extends into the support to form a brace tightly fitted with the first seat; a sealing bush is set where the mouthpiece and the support are connected.
[0020] Furthermore, the outer cup body is partly or wholly transparent or semitransparent.
[0021] The present invention has advantages as: the tobacco-liquid cup defines a recessed cavity, and the battery is received in the recessed cavity, the whole length of the cigarette is effectively reduced, therefore, the electronic cigarette is more conveniently taken and used; magnetic parts are set where the tobacco-liquid cup and the battery-rod are interconnected so as to impart a magnetic connection therebetween, via which assembly and disassemble thereof are convenient, and it is convenient to replace the battery as well. The tobacco-liquid cup is transparent or semitransparent, the reminder of tobacco liquid in the tobacco-liquid cup can be observed any time, thereby tobacco liquid can be refilled in time.
[0022] Embodiments of the present invention will now be further described in detail with reference to the attached Figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is a front view of an electronic cigarette in accordance with an embodiment of the present invention;
[0024] FIG. 2 is a cross-sectional view of the electronic cigarette in accordance with the first embodiment of the present invention;
[0025] FIG. 3 is an exploded view of the electronic cigarette in accordance with the first embodiment of the present invention;
[0026] FIG. 4 is a cross-sectional view of the electronic cigarette in accordance with the second embodiment of the present invention;
[0027] FIG. 5 is an exploded view of the electronic cigarette in accordance with the second embodiment of the present invention;
[0028] FIG. 6 is a cross-sectional view of an atomizing device in accordance with an embodiment of the present invention;
[0029] FIG. 7 is a cross-sectional view of a battery rod in accordance with the first embodiment of the present invention; and
[0030] FIG. 8 is a cross-sectional view of a battery rod in accordance with the second embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] As shown in FIGS. 1 to 8 , an electronic cigarette in accordance with embodiments of the present invention, comprises an atomizing device 10 for vaporizing tobacco-liquid into vapor mists, and a battery 20 which is electrically connected with the atomizing device 10 so as to supply power source for the atomizing device 10 .
[0032] The atomizing device 10 comprises a tobacco-liquid cup 11 and an atomizer 12 fixed in the tobacco-liquid cup 11 .
[0033] The tobacco-liquid cup 11 is used for storing tobacco liquid and configured as main body of the electronic cigarette in accordance with this embodiment, and has one end defined a recessed cavity 111 ; the battery 20 is received in the cavity 111 .
[0034] Specifically, as shown in FIG. 6 , the tobacco-liquid cup 11 comprises an outer cup body 112 and an inner cup body 113 . Both the outer cup body 112 and inner cup body 113 are hollow and tubular. The inner cup body 113 is set in the outer cup body 112 with the first end thereof tightly connected with the outer cup body 112 and the second end unconnected with the outer cup body 112 so as to form an opening for filling tobacco liquid, the annular space enclosed between the two forms a liquid-storing space 116 , and the inner cup body 113 has its hollow part configured as the cavity 111 for receiving the battery 20 .
[0035] The outer cup body 112 and the inner cup body 113 are separately set in accordance this embodiment, the first end of the inner cup body 113 is tightly connected with the outer cup body 112 by an end cap 114 . The end cap 114 , the outer cup body 112 and the inner cup body 113 are tightly fitted among the three, and a first seal ring 115 is placed at their connection to ensure a tight connection therebetween. As one embodiment, the first end of the inner cup body 113 and the corresponding end of the outer cup body 112 may also be manufactured in-mold.
[0036] The atomizer 12 comprises an electric heat wire 121 and a liquid-delivery rod 122 , and the electric heat wire 121 winds round the liquid-delivery rod 122 . The electric heat wire 121 is electrically connected with the battery 20 , so as to vaporize tobacco liquid into vapor mist after a supply of electricity thereto. The liquid-delivery rod 122 is made from glass fiber or other high temperature resistant fiber, and is used for absorbing and delivering tobacco liquid for the electric heat wire 122 hearting.
[0037] The second end of the inner cup body 113 is set with a first electrode assembly 30 , the first electrode assembly 30 is electrically connected both ends of the electric heat wire 121 as positive and negative electrodes of the atomizer 12 , and is further electrically connected with positive and negative poles of the battery 20 .
[0038] Specifically, as shown in FIGS. 2 to 6 , the first electrode assembly 30 comprises a first seat 31 and a first terminal post 32 , both the first seat 31 and the first terminal post 32 are made from metal conductive materials, and insulation is obtained by setting a first insulation sleeve 33 between the two. The first seat 31 and the first terminal post 32 are respectively electrically connected both ends of the electric heat wire 121 so as to form the positive and negative electrodes of the atomizer 12 .
[0039] The first seat 31 is hollow in accordance with this embodiment, the first terminal post 32 is tightly fitted in the first seat 31 and insulated from the first seat 31 in use of the first insulation sleeve 33 . The first terminal post 32 is hollow as well, and its hollow center forms a first air inlet port 321 for environmental air to enter the atomizing device 10 .
[0040] Referring to FIGS. 7 and 8 , outside of the battery 20 is fitted with a battery rod 21 . One end of the battery rod 21 contacting the first electrode assembly 30 is set with a second electrode assembly 40 , and the second electrode assembly 40 is coupled to the first electrode assembly 30 , via which the battery 20 and the atomizing device 10 are electrically connected.
[0041] Moreover, the other end of the battery rod 21 is set with a battery cover 22 , via which the battery 20 is enclosed in the battery rod 21 . The battery cover 22 and the end cap 114 have coupled periphery in accordance with this embodiment, and while the battery rod 21 is placed in the cavity 111 , the battery cover 22 and the end cap 114 abut against each other with their peripheries aligned.
[0042] Referring to FIGS. 2 , 7 , 8 , the second electrode assembly 40 comprises a second seat 41 and a second terminal post 42 insulated from each other; the second seat 41 and the second terminal post 42 are made from metal conductive materials, and correspondingly connected with positive and negative electrodes of both the battery 20 and the atomizer 12 . The second seat 41 and the second terminal post 42 are set with a second insulation sleeve 43 therebetween, and retain insulated from each other in use of the second insulation sleeve 43 .
[0043] Referring to FIGS. 7 and 8 , the second seat 41 is hollow as well; its end facing the battery 20 defines an accommodating cavity for receiving the second terminal post 42 . The second insulation sleeve 43 comprises a first insulation support 431 and a second insulation support 432 ; the first insulation support 431 and the second insulation support 432 are interconnected, and are tightly fitted in the accommodating cavity of the second seat 41 . The first insulation support 431 and the second insulation support 432 are internally coupled so as to define an inner chamber 44 , and the second terminal post 42 is elastically fitted in center of the second insulation sleeve 43 by means of a compression spring 45 fixed in the inner chamber 44 . Both the first insulation support 431 and the second insulation support 432 have their opposite end walls axially defined a first terminal hole and a second terminal hole to communicate the inner chamber 44 for both ends of the second terminal post 42 extending outwards therefrom. The second terminal post 42 forms a blocking ring 421 in the inner chamber 44 , and the compression spring 45 has both ends thereof respectively abutting against the blocking ring 421 and an inner wall of the second insulation support 432 , so that the end of the second terminal post 42 facing the first electrode assembly 30 remains extending outwards. The second terminal post 42 is hollow as well, and defines a second air inlet port 422 through its center to communicate with the first air inlet port 321 so that an air passageway is connected.
[0044] When assembling the electronic cigarette, the power rod 21 is inserted in the recessed cavity 111 of the inner cup body 113 ; the first seat 31 and the second seat 41 abut against each other; the first terminal post 32 and the second terminal post 42 abut against each other; the second terminal post 42 is pushed by the first terminal post 32 , overcomes the elastic force from the compress spring 45 , then goes forward to the battery 20 and finally is tightly fitted between the first terminal post 32 and the battery 20 , therefore, the second terminal post 42 is well electrically connected with the first terminal post 32 and the battery 20 . When the first electrode assembly 30 is separated from the second electrode assembly 40 , the external force is removed from the second terminal post 42 , thus the compression spring 45 restores the second terminal post 42 .
[0045] The tobacco-liquid cup 11 is detachably connected with the battery rod 21 in accordance with this embodiment. As shown in FIGS. 2 and 4 , the tobacco-liquid cup 11 and the battery rod 21 is preferably magnetically connected. Specifically, the tobacco-liquid cup 11 is set with a first magnetic part where it connects the battery rod 21 ; the battery rod 21 is correspondingly set with a second magnetic part for attracting the first magnetic part so that the tobacco-liquid cup and the battery rod 21 are tightly interconnected.
[0046] The first electrode assembly 30 is set at one end of the tobacco-liquid cup 11 near the battery 2 , the second electrode assembly 40 is set at one end of the battery 20 near the atomizing device 10 , and the first electrode assembly 30 and the second electrode assembly 40 are coupled. Therefore, When the first and second magnetic parts are designed, considering to reduce components and to simplify the structure of the electronic cigarette, the first seat 31 may be directly made from conductive magnet or magnetic materials so as to form the first magnetic part, or the first electrode assembly 30 is set with an separate component made from magnet or magnetic materials as the first magnetic part; accordingly, the second seat 41 may be directly made from conductive magnet or magnetic materials so as to be used as the second magnetic part, or the second electrode assembly 40 is set with an separate component made from magnet or magnetic materials as the second magnetic part.
[0047] In accordance with the embodiment as shown in FIGS. 2 and 3 , the first magnetic part is the first seat 31 from metal conductive materials, while the second magnetic part is a first permanent magnet 46 in the second seat 41 . Referring to FIG. 7 , the first permanent magnet 46 has an annular shape, and is fitted round an end of the first insulation support 431 facing the first seat 31 .
[0048] In accordance with another embodiment, the first magnetic part and the second magnetic part may also be configured at the other connecting ends of the tobacco-liquid cup 11 and the battery rod 21 , that is, the end cap 114 is made from magnet or magnetic materials so as to form the first magnetic part, or the end cap 114 is set with an separate component made from magnet or magnetic materials as the first magnetic part; accordingly, the battery cover 22 is made from magnet or magnetic materials so as to form the second magnetic part, or the battery cover 22 is set with an separate component made from magnet or magnetic materials as the second magnetic part.
[0049] In accordance with the embodiment as shown in FIGS. 3 and 4 , the end cap 114 is made from metal as the first magnetic part, while the battery cover 22 is set with a second permanent magnet 23 as the second magnetic part; or the end cap 114 is set with an separate component made from magnet or magnetic materials as the first magnetic part; the second permanent magnet 23 has an annular shape as well, and is mounted in the battery cover 22 by a tightening cap 24 .
[0050] It is understood that the tobacco-liquid cup 11 and the batter rod 21 may be interconnected by a thread connection, clamping means or the like; for instance, the end cap 114 and the battery cover 22 are correspondingly set with outer threads and inner threads at their joining position to form a thread connection therebetween.
[0051] As shown in FIGS. 1 to 5 , the tobacco-liquid cup 11 is set with a mouthpiece 50 at its end away from the battery 20 , and the mouthpiece 50 defines an inhaling port 51 along its center and communicating with the air passageway for vapor mist being drawn therethrough.
[0052] Referring to FIGS. 2 , 4 , 6 , the atomizer 12 is fixed between the mouthpiece 50 and the first seat 31 by a support 13 . The support 13 is hollow and tubular, and defines an atomizing chamber in its center for communicating with the air passageway and receiving the atomizer 12 .
[0053] The atomizer 12 is radially fitted in the atomizing chamber; the liquid-delivery rod 122 has both ends thereof extending outwards the atomizing chamber to the tobacco-liquid cup 11 so as to absorb the tobacco liquid, the support 13 radially defines openings 131 through its sidewall for fitting the liquid-delivery rod 122 .
[0054] The support 13 is rested on the first seat 31 in accordance with this embodiment, one end of the first seat 31 abutting against the support 13 extends into the support 13 to form a brace, and the support 13 is tightly fitted round the brace. The other end of the support 13 is fitted with a sealing bush 14 ; the sealing bush 14 has one end thereof tightly abutting against the liquid-delivery rod 122 , and has the other end thereof extending into the mouthpiece 30 to form a protrusion; the mouthpiece 30 has one end thereof fitted round the protrusion and tightly abutting against the sealing bush 14 , so that the tobacco-liquid cup 11 is internally sealed by means of the sealing bush 14 , therefore, tobacco liquid in the tobacco-liquid cup 11 is prevented from leaking from the inhaling port 31 . The sealing bush 14 correspondingly defines a through hole along its center to communicate with both the atomizing chamber and the inhaling port 31 so as to connect the air passageway.
[0055] Meanwhile, for observing the remaining tobacco liquid in the liquid-storing space 111 and filling tobacco liquid in time so that the electronic cigarette is regularly used, the outer cup body 112 is partly or wholly configured to be transparent or semitransparent in accordance with this embodiment.
[0056] As shown in FIGS. 2 to 5 , the battery rod 21 has an atomizing control unit therein, the atomizing control unit is respectively electrically connected with the battery 20 and the atomizing device 10 so as to control the atomizing device 10 powered on or off. The atomizing control unit may be set between the atomizing device 10 and the battery 20 , or be set at one end of the battery 20 away from the atomizing device 10 .
[0057] The atomizing control unit is preferably set at the end of the battery 20 away from the atomizing device 10 in accordance with this embodiment, and comprises an atomizing control circuit and an atomizing control switch which is connected with the atomizing control circuit.
[0058] The atomizing control switch is a sensor switch 71 in accordance with this embodiment; and the sensor switch 71 is mounted in the battery rod 21 by means of a switch holder 72 . Specifically, the sensor switch 71 is a capacitive sensor switch, when the user smokes in use of the electronic cigarette, the capacitive sensor switch senses the inhaling air flow and thereafter its electric capacity is changed, which controls the atomizing control circuit to switch on the power supply, and thus the electronic cigarette starts work. As an embodiment, the sensor switch 71 may be an airflow sensor switch, when the user inhales by the mouthpiece 50 ; a negative pressure is generated in the electronic cigarette, thus the air sensor switch produces pulsing signals, which controls the atomizing control circuit to switch on the power supply.
[0059] Because the sensor switch 71 itself is accurately manufactured, and it generally has a special built-in controller, the atomizing control circuit may be directly integrated into the controller of the sensor switch 71 in accordance with this embodiment. As an embodiment, the atomizing control circuit may also be integrated to a sensor control circuit board which is separately set outside of the sensor switch 71 and respectively electrically connected with the sensor switch 71 and the battery 20 .
[0060] As an embodiment, the atomizing control switch may also be a traditional key switch, the key switch is electrically connected with the battery 20 by means of a key control circuit board so that the atomizing control circuit is controlled by key operations for electrically connecting or disconnecting the atomizing device 10 .
[0061] Still referring to FIGS. 2 to 5 , the end of the battery rod 21 near the battery cover 22 is further set with a light device; the light device is used as a working indicator of the electrode cigarette, and has a light emitting unit electrically connected with the battery 20 . The light emitting unit is a red lighter in accordance with this embodiment, when the user smoke by the electronic cigarette, the end of the electronic cigarette away from the mouthpiece 30 forms red light ring like a cigarette burning, which improves a real visual sense of the user. The battery cover 22 is set with a transparent or semitransparent light cap 23 at its end for the light emitting unit to send out light. As an embodiment, the battery cover 22 may also be wholly transparent or semitransparent.
[0062] It is understood that, the electronic cigarette in accordance with the embodiments of the present invention is not limited to such embodiments as shown in FIGS. 1 to 8 , and various technical characteristics of each embodiment may be combined each other to form new embodiments.
[0063] While the embodiments of the present invention have been illustrated and described, it will be understood that various amendments and modifications can be made by those skilled in the art without departing from the principle and the spirit of the present invention, and those amendments and modifications shall also be deemed in the scope of the invention. | The invention is related to an electronic cigarette, including an atomizing device with a tobacco-liquid cup, and a battery electrically connected with the atomizing device, herein, the tobacco-liquid cup forms a recessed cavity, the battery is received in the cavity. The battery of the present invention is set in the atomizing device, so that the whole length of the electronic cigarette is effectively reduced, and it is more convenient to take the electronic cigarette. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to apparatus for changing screen devices which are utilized with plastics extrusion mechanisms and, more particularly, to apparatus which automatically performs screen-changing functions associated with the use of screen devices for filtering extruded plastic materials.
2. Description of the Prior Art
The use of screen devices for filtering extruded plastic materials is well known. Screening is particularly useful when extruding recycled plastics, in order to remove particles of dirt or other foreign matter from the recycled material. Screen devices, however, are particularly subject to clogging up when utilized in plastics recycling operations. Accordingly, the changing of screen devices at frequent intervals is necessary.
Mechanisms for changing screen devices, associated with plastics extruders, are known. For example, U.S. Pat. No. 3,059,276 to L. D. Yokana discloses apparatus wherein each of two parallel paths from an extruder cylinder contains a screen device, and wherein a valving arrangement conducts extruded plastic material alternatively to one or the other of the parallel paths, such that the screen device located in a currently idle path may be changed manually, while the screen device in a currently active path is performing the required filtering operation. In addition, U.S. Pat. No. 3,007,199 to J. E. Curtis discloses apparatus wherein two screen devices are located on a piston, which may be moved between two positions, each locating a different one of the screen devices in line with an extrusion head, such that one screen device may be removed for replacement while the other filters plastic material which is discharged from the extrusion head. The piston of the Curtis patent is power-operated between its two positions. However, each removal of an old screen device from the piston, and each replacement of a new screen device onto the piston, is done manually.
The various screen changing steps required by the prior art mechanisms, as just discussed, involving the manual performance of various functions, are considered unduly time consuming and excessively high in labor costs. This is particularly true in the case of large scale plastics recycling operations, where screen devices must be changed quite frequently, and where the rapid changing of screen devices would be quite advantageous economically.
SUMMARY OF THE INVENTION
The invention contemplates apparatus for changing screen devices in a plastics extrusion mechanism which discharges an extruded plastic material along a direction of advance or discharge from a discharge end thereof. The apparatus comprises a slide assembly housing, which may be mounted at the discharge end of the plastics extrusion mechanism, and which includes a slide chamber. The slide chamber has an axis of elongation disposed perpendicularly to the aforementioned direction of advance or discharge. The slide assembly housing has an inlet opening and an outlet opening disposed along opposite surfaces of the slide chamber in linear alignment with the direction of advance or discharge, such that the extruded plastic material advancing along the direction of advance or discharge may enter the inlet opening, pass through the slide chamber perpendicularly to the slide chamber axis, and exit through the outlet opening. A slide assembly, which is slidably moveable within the slide chamber along the slide chamber axis, includes first and second apertured recesses at respective first and second spaced locations therealong for receiving a first screen device and a second screen device, respectively, therein. The first recess is located in alignment with the direction of advance or discharge between the inlet and outlet openings of the slide chamber in a first position of the slide assembly, while the second recess is located in alignment with the direction of advance or discharge between the inlet and outlet openings of the slide chamber in a second position of the slide assembly. The apparatus also includes first means for sliding the slide assembly alternatingly between the first and second positions thereof; second means, responsive to the slide assembly entering into the first position of the slide assembly, for generating a screen-change signal; and third means, responsive to the screen-change signal, for removing a used screen device from the second recess and introducing a new screen device into the second recess.
In addition, apparatus in accordance with the invention preferably also includes fourth and fifth means, corresponding to the aforementioned second and third means, respectively, and effective to change screen devices in the first recess upon entry of the slide assembly into its second position.
The described screen-changing apparatus may constitute an integral part of a novel plastics extrusion mechanism. Alternatively, the screen-changing apparatus may be a separate unit which is adapted for mounting at the discharge end of any standard, commercially available, plastics extruder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 of the drawing is an isometric view of apparatus, constructed in accordance with the principles of the invention, for changing screen devices which are utilized to filter a plastic material discharged from a plastics extrusion mechanism;
FIGS. 2 and 3 are, respectively, a plan view and an end elevational view of the apparatus of FIG. 1, depicting additional aspects of the screen-changing apparatus;
FIG. 4 is an illustration of a screen device which may be employed in the apparatus of FIGS. 1-3; and
FIGS. 5-8 are enlarged vertical views, partly in section and with parts broken away, showing the sequence of operation of various elements of the apparatus of FIGS. 1-3 in performing their screen-changing functions.
DETAILED DESCRIPTION
Referring initially to FIGS. 1-4 of the drawing, an apparatus 10 operates automatically to change screen devices 11. Such screen devices 11 serve to filter out foreign matter from extruded plastic materials being discharged from a plastics extrusion mechanism 12. The apparatus 10 may constitute a separate unit, adapted for mounting at a discharge end 13 of the extrusion mechanism 12. Alternatively, the apparatus 10 may be an integral part of the extrusion mechanism 12.
The apparatus 10 includes a slide assembly housing 14 which surrounds a slide chamber 16 (FIG. 2). A slide assembly 17 is adapted for reciprocating sliding movement within the slide chamber 16, along a longitudinal axis 18, under the control of a first piston and cylinder assembly 19. The slide assembly 17 includes first and second spaced, apertured recesses 21 and 22, respectively, each of which recesses is adapted to retain a screen device 11 therein.
In a first position of the slide assembly 17 (FIGS. 1 and 2), the first recess 21 is so located within the slide chamber 16 (FIG. 2) as to be aligned between an inlet opening 23 and an outlet opening 24 of the slide assembly housing 14 along a direction of advance or discharge of extruded plastic material from the extruder 12, which direction is identified by an arrow 26 in FIGS. 1 and 2 of the drawing. Meanwhile, the second recess 22 in the slide assembly 17 is located outside of the slide assembly housing 14 at a first side thereof, in a first screen-changing station 27. In a second position of the slide assembly 17 (not shown), the second recess 22 is so located within the slide chamber 16 as to be aligned between the inlet and outlet openings 23 and 24 of the slide assembly housing 14 along the direction of advance or discharge indicated by the arrow 26. Meanwhile, the first recess 21 in the slide assembly 17 is located outside of the slide assembly housing 14 at a second side thereof, in a second screen-changing station 28. A pair of limit switches 29 and 31 (FIG. 1) may be employed, in conventional manner, to indicate that the slide assembly 17 is in its first position or its second position, respectively.
The various mechanisms located at the first and second screen-changing stations 27 and 28 are identical. Accordingly, only one such station, the first screen-changing station 27, will be described in detail hereinafter. The first screen-changing station 27 includes, generally, a screen device ejection mechanism 32 (FIGS. 5-8) operated by a second piston and cylinder assembly 33 (FIGS. 1 and 2), a slidably mounted screen device carrier 34 (FIGS. 1, 3 and 5-8), a third piston and cylinder assembly 36 (FIGS. 1 and 3) for sliding the screen device carrier 34 between a screen device introducing position (FIGS. 6 and 7) and a screen device reloading position (FIGS. 5 and 8) thereof, a screen device introducing mechanism 37 (FIGS. 5-8) operated by a fourth piston and cylinder assembly 38 (FIGS. 1 and 3), and a screen device reloading mechanism 39 (FIGS. 5-8) operated by a fifth piston and cylinder assembly 41 (FIGS. 1-3). Like mechanisms which are located at the second screen-changing station 28 are labeled in the drawing with corresponding numerals, each followed by the suffix "A," e.g., the piston and cylinder assembly 33A.
The screen device ejection mechanism 32 includes a number of projecting fingers 42,42, which are aligned for entry into the second recess 22 in the slide assembly 17 through a like number of apertures 43,43. Such entry of the fingers 42,42 into the second recess 22, so as to eject a used, clogged screen device 11 from the second recess 22 as shown in FIG. 5, may be initiated by a screen-change signal from the limit switch 29, i.e., a signal that the slide assembly 17 has entered into its first position, as illustrated in FIG. 1. The screen-change signal may be applied through any conventional electro-pneumatic or electro-hydraulic control mechanism (not shown) to actuate the second piston and cylinder assembly 33.
The screen device carrier 34 is shown in its screen device introducing position in FIGS. 6 and 7 of the drawing, and in its screen device reloading position in FIGS. 5 and 8. The screen device carrier 34 includes an aperture 44 which is adapted to house temporarily a single screen device 11. The screen device carrier 34 is aligned in its screen device reloading position with the screen device reloading mechanism 39 such that a screen device 11 may be fed into the aperture 44 from a magazine 46 (FIG. 8) upon the operation of the fifth piston and cylinder assembly 41. The screen device carrier 34 may thereafter be moved, by operation of the third piston and cylinder assembly 36, into the screen device introducing position, where the aperture 44 in the screen device carrier 34 is aligned with the screen device introducing mechanism 37 (FIG. 6). The fourth piston and cylinder assembly 38 may then be operated, with the screen device carrier 34 in such screen device introducing position and the slide assembly 17 in its first position (FIG. 7), in such manner as to move the screen device introducing mechanism 37 toward the second recess 22 in the slide assembly 17, thereby pushing the screen device 11 carried within the aperture 44 in the screen device carrier 34 out of such aperture 44 and into the second recess 22 in the slide assembly 17 (FIG. 7), whereupon the fourth piston and cylinder assembly 38 may operate to withdraw the screen device introducing mechanism from the second recess 22 and the aperture 44, in the slide assembly 17 and screen device carrier 34, respectively (FIG. 8).
The operation of the apparatus 10 will next be described with reference to a single cycle of operations, beginning with the slide assembly 17 entering into its first position (FIGS. 1 and 2). The extrusion mechanism 12 is currently functioning to discharge an extruded plastic material along the direction of the arrow 26 in FIGS. 1 and 2 of the drawing. Thus, the extruded plastic material may now begin to advance from the inlet opening 23 in the slide assembly housing 14 (FIG. 2) through a clean screen device 11 retained within the first recess 21 in the slide assembly 17, such that a filtered plastic material may pass through the apertures 43,43 and exit through the outlet opening 24 in the slide assembly housing 14.
Meanwhile, as the slide assembly 17 enters into its first position, the limit switch 29 is operated, generating a screen-change signal indicative of such repositioning of the slide assembly 17. The apparatus 10 is presently in the condition indicated in FIGS. 1-3 and 8 of the drawing, with the screen device carrier 34 in its screen device reloading position and with a new screen device 11 located in the aperture 44 of the screen device carrier 34.
The screen-change signal generated by the limit switch 29 actuates the second piston and cylinder assembly 33, causing the screen device ejection mechanism 32 to move to the right, as illustrated in the drawing, from the position of FIG. 8 to the position of FIG. 5. Thus, the projecting fingers 42,42, are extended through the apertures 43,43 in the slide assembly 17 and into the second recess 22, forcing the used screen device 11 to fall from the second recess 22 into a suitably positioned receptacle, e.g., for cleaning and subsequent reuse. The second piston and cylinder assembly 33 thereupon completes its cycle of operation by withdrawing the screen device ejection mechanism 32 toward the left, as illustrated in the drawing, from the position of FIG. 5 to that of FIG. 6.
The third piston and cylinder assembly 36 is next operated to move the screen device carrier 34 from its screen device reloading position (FIG. 5) to its screen device introducing position (FIG. 6), so as to locate the new screen device 11, carried within the aperture 44 of the screen device carrier 34, in alignment with the now empty second recess 22 in the slide assembly 17. Such operation of the third piston and cylinder assembly 36 may be initiated by any conventional mechanism, e.g., a limit switch (not shown), which indicates that the screen device ejection mechanism 32 is approaching, or has entered into, its withdrawn position, as shown in FIG. 6 of the drawing.
The fourth piston and cylinder assembly 38 is next operated to move the screen device introducing mechanism 37 to the left, as illustrated in the drawing, from the position of FIG. 6 to that of FIG. 7 and then further to the left, so as to force the new screen device 11 from the aperture 44 in the screen device carrier 34 into the second recess 22 in the slide assembly 17, where the new screen device 11 is thereupon retained. Such operation of the fourth piston and cylinder assembly 38 may be initiated by any conventional mechanism, e.g., a limit switch (not shown), which indicates that the screen device carrier 34 has entered into its screen device introducing position, as shown in FIG. 6 of the drawing. The fourth piston and cylinder assembly 38 thereupon completes its cycle of operations by withdrawing the screen device introducing mechanism 37 toward the right, as illustrated in the drawing, from the position of FIG. 7 to that of FIG. 8.
The third piston and cylinder assembly 33 is next operated to return the screen device carrier 34 from its screen device introducing position (FIG. 7) to its screen device reloading position (FIG. 8) so as to align the aperture 44 in the screen device carrier 34 with the magazine 46. Such operation of the third piston and cylinder assembly may be initiated by any conventional mechanism, e.g., a limit switch, which indicates that the screen device introducing mechanism 37 has entered into its withdrawn position, as shown in FIG. 8 of the drawing.
The fifth piston and cylinder assembly 41 may now be operated to force another new screen device from the magazine 46 so as to reload the aperture 44 in the screen device carrier 34. Such operation of the fifth piston and cylinder assembly 41 may be initiated by any conventional mechanism, e.g., a limit switch, which indicates that the screen device carrier 34 has re-entered its screen device loading position (FIG. 8).
The slide assembly 17 currently has the new screen device 11 retained within the second recess 22. The extrusion mechanism 12 is meanwhile functioning to discharge the extruded plastic material along the direction of the arrow 26 in FIGS. 1 and 3 of the drawing. Thus, the screen device 11 retained within the first recess 21 in the slide assembly 17 is gradually becoming clogged with foreign matter filtered from the extruded material.
At a suitable time, an operation of the first piston and cylinder assembly 19 is initiated, causing the slide assembly 17 rapidly to enter into its previously described second position. The new screen device 11 within the second recess 22 in the slide assembly 17 thereupon commences immediately to filter out further foreign matter from the extruded material, with the first recess 21 in the slide assembly 17 now being located at the second screen-changing station 28. Such operation of the first piston and cylinder assembly 19 may be initiated by any suitable mechanism, e.g., a timing device or a facility for sensing that the screen device 11 within the first recess 21 in the slide assembly 17 is becoming clogged.
The various mechanisms located at the second screen-changing station 28 meanwhile begin operating, in response to a screen-change signal from the limit switch 31 upon the entry of the slide assembly 17 into its second position, to replace the used screen device 11 in the first recess 21 of the slide assembly 17, in similar manner to the described operation of the corresponding mechanisms at the first screen-changing station 27. Thus, the apparatus 10 may continue to function with the slide assembly 17 in its second position until such time as the first piston and cylinder assembly 19 may be operated to return the slide assembly 17 to its first position for replacement of the screen device 11 in the second recess 22 of the slide assembly, completing a full cycle of operations of the apparatus 10.
As shown in phantom lines in FIG. 1 of the drawing, the magazines 46 and 46A may be removed occasionally, at appropriate times, for reloading of screen devices 11 therein, e.g., screen devices 11 which have been cleaned for reuse in the apparatus 10.
It is to be understood that the described apparatus is simply illustrative of a preferred embodiment of the invention. In other embodiments, the various piston and cylinder assemblies might be replaced by other, equivalent devices for operating the various mechanisms of the apparatus. Many other modifications may, of course, also be made in accordance with the principles of the invention. | The disclosure concerns apparatus which automatically performs screen-changing functions associated with the use of screen devices for filtering extruded plastic materials. The apparatus includes a slide assembly with two apertured recesses for receiving screen devices, and mechanisms for aligning the recesses alternatingly with a direction of advance of the extruded plastic material. A screen device is replaced within one recess, as a screen device within the other recess filters the extruded plastic material. Such screen device replacement is provided through the automatic, sequential operations of screen device ejection, screen device carrier, screen device introducing and screen device reloading mechanisms. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a sponge cake using a fructooligosaccharide.
BACKGROUND ART
[0002] A sponge cake is a cake based on eggs, saccharides such as sugar, and flour, which is prepared by making dough by utilizing the foaming properties of eggs, and baking the dough. The sponge cake is characterized in that the baked dough has a cross section with a structure wherein an infinite number of bubbles are present like sponges. The sponge cake either becomes concave or bulges in the center depending on the condition of the bubbles upon baking. The phenomenon of a sponge cake becoming concave in the center is referred to as “the shrinkage after baking” (“Kamaochi”); such a sponge cake is regarded as an undesirable product, and thus, defective. Moreover, a sponge cake for use as a cake base for a decorated cake or the like preferably has a thickness as uniform as possible, because it is undesirable for such a cake having an excessively large bulge in the center.
[0003] Oligosaccharides in which one or more fructose residues are bound to sucrose by β2→1 bonds are collectively referred to as fructooligosaccharides. Examples of fructooligosaccharides include 1-kestose in which one fructose residue is bound to a sucrose unit, nistose in which two fructose residues are bound to a sucrose unit, and fructosylnystose in which three fructose residues are bound to a sucrose unit. Among currently marketed fructooligosaccharides are mixtures of 1-kestose, nistose, and fructosylnystose; and crystalline 1-kestose obtained by crystallization of 1-kestose with a high purity. It has been revealed that fructooligosaccharides have various physiological functions, such as decay resistance, the effect of promoting bifidobacterium growth, the effect of improving the metabolism of lipids such as cholesterol, the effect of regulating immunity, and the effect of inhibiting a rise in blood sugar level. These physiological functions make fructooligosaccharides industrially very useful as functional food ingredients.
[0004] Foods such as sponge cakes containing various oligosaccharides have been so far reported.
[0005] For example, Japanese Patent Laid-Open Publication No. 49383/1993 discloses a sponge cake in which 30% or more of the saccharide has been substituted with a branched-chain oligosaccharide. However, the publication discloses neither a sponge cake using a fructooligosaccharide nor a water-soluble polymer as used in the present invention.
[0006] Japanese Patent Laid-Open Publication No. 346644/1999 discloses a sponge cake containing maltooligosaccharide. The publication relates to freezing resistance, and therefore discloses neither a sponge cake using a fructooligosaccharide nor a water-soluble polymer as used in the present invention.
[0007] Furthermore, Japanese Patent Laid-Open Publication No. 96942/1986 discloses bread containing a fructooligosaccharide. Although both sponge cakes and bread use flour and have structures containing an infinite number of bubbles, the publication aims to improve the percentage of residual fructooligosaccharide by using a baker's yeast that hardly digests fructooligosaccharides and does not suggest a sponge cake. The patent publication neither discloses a water-soluble polymer used in the present invention.
SUMMARY OF THE INVENTION
[0008] The present inventors have found that when a sponge cake is made using a fructooligosaccharide in a proportion of 25% by weight or more in total saccharide ingredients, the sponge cake becomes concave-shaped in the center (i.e., shrinks after baking) (Study 1 ). On the other hand, the inventors have found that sponge cakes do not become concave-shaped in the center when various saccharides other than fructooligosaccharides are used (Study 2 ).
[0009] The inventors have also found that when a sponge cake is made using a fructooligosaccharide, the addition of a water-soluble polymer selected from collagen peptide, xanthan gum, and guar gum can prevent the sponge cake from becoming concave in the center (Studies 3 and 4 ).
[0010] Accordingly, the present invention recognizes the heretofore-unknown problem that a sponge cake made using a fructooligosaccharide becomes concave in the center, and also solves this problem.
[0011] An object of the present invention is to provide a sponge cake that has excellent physiological functions of a fructooligosaccharide and is prevented from becoming concave in the center.
[0012] According to the present invention, there is provided a sponge cake comprising a saccharide comprising a fructooligosaccharide and a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum.
[0013] According to the present invention, there is provided a method for making the sponge cake according to the present invention, which comprises preparing sponge cake dough by mixing a saccharide comprising a fructooligosaccharide with a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum, and baking the dough.
[0014] The fructooligosaccharide used in the present invention has physiological functions such as decay resistance, the effect of promoting bifidobacterium growth, the effect of improving the metabolism of lipids such as cholesterol, the effect of regulating immunity, and the effect of inhibiting a rise in blood sugar level. Therefore, the sponge cake according to the present invention advantageously has the excellent physiological functions of the fructooligosaccharide, and can provide a product of high value that is prevented from becoming concave in the center.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a cross section of the sponge cake of Example
[0016] FIG. 2 is a cross section of the sponge cake of Example 4.
[0017] FIG. 3 is a cross section of the sponge cake of Comparative Example 1.
DETAILED DESCRIPTION OF THE INVENTION
Sponge Cake
[0018] The term “sponge cake” as used herein means a cake made of flour, eggs, and saccharides as ingredients, which is prepared by making dough by utilizing the foaming properties of eggs, and baking the dough.
[0019] A sponge cake can be made by suitably employing a conventionally used method. For example, a sponge cake can be made by preparing sponge cake dough by mixing the above-mentioned ingredients, and baking the dough. After the preparation of the sponge cake dough, the dough may be poured into a mold and baked to make a sponge cake of a desired shape.
[0020] Examples of the methods for making a sponge cake include a method of beating whole eggs together (a “Tomodate” method) and a method of beating and mixing egg yolks and egg whites separately (a “Betsudate” method).
[0021] A starch ingredient other than flour can be added to the sponge cake dough according to the present invention. Examples of the starch ingredient other than flour include rice powder, corn powder, cornstarch, tapioca starch, potato starch, and processed starches.
[0022] In the sponge cake according to the present invention, the amount of eggs in the total ingredients can be 50 to 400 parts by weight, preferably 80 to 200 parts by weight, and more preferably 100 to 150 parts by weight, based on 100 parts by weight of the starch ingredients (including flour). The eggs used can be whole eggs or egg whites only, but are preferably whole eggs.
[0023] In the sponge cake according to the present invention, the amount of the saccharide in the total ingredients can be 50 to 300 parts by weight, preferably 80 to 200 parts by weight, and more preferably 100 to 150 parts by weight, based on 100 parts by weight of the starch ingredients (including flour).
[0024] In the sponge cake according to the present invention, the proportions of the starch ingredients (including flour), eggs, and saccharide in the total ingredients, based on a total weight of 100 of the starch ingredients (including flour), eggs, and saccharide, can be 10 to 50, 25 to 60, and 15 to 50, respectively; preferably 15 to 45, 30 to 55, and 20 to 45, respectively; and more preferably 20 to 35, 30 to 50, and 30 to 40, respectively.
[0025] In addition to the flour, eggs, and saccharide, the sponge cake according to the present invention uses, as an ingredient, a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum.
[0026] The sponge cake according to the present invention can optionally contain other ingredients commonly used in the production of sponge cakes singly or in appropriate combinations, in amounts such that a sponge cake can be made. Examples of the other ingredients that can be added include dairy products such as whole milk powder, dried skim milk, milk, condensed milk, yogurt, cheese, and whey; fats and oils such as butter, margarine, and shortening; fruit juices such as orange juice and lemon juice; nuts such as almonds and macadamia nuts; cocoa; chocolate; dried fruits; jams; fillings; sweeteners such as aspartame, sucralose, acesulfame potassium, and stevia; leavening agents such as baking soda, ammonium carbonate, and baking powder; emulsifiers such as sugar esters, monoglycerol esters, and sorbitan esters; acidulants such as citric acid and malic acid; flavors; colorants; dietary fibers; salt; vitamins; and minerals.
[0027] The expression “the sponge cake is concave-shaped in the center” as used herein means that the sponge cake upon baking is not uniform in thickness, and is concave in the center. Whether or not the sponge cake is concave in the center can be determined by measuring a difference between the thickness of an edge portion and the thickness of a central portion of the sponge cake. Specifically, a sponge cake can be determined to be concave in the center when the difference between the thickness of the thickest portion of the edge portion (the maximum thickness) and the thickness of the thinnest portion of the central portion (the minimum thickness) of the sponge cake exceeds 10% of the thickness of the thickest portion of the edge portion.
[0028] The sponge cake according to the present invention may have a shape that bulges in the center (thickness), as long as it is prevented from becoming concave in the center. However, when the sponge cake is used as a cake base, it preferably has a shape with a substantially uniform thickness upon baking, i.e., the difference between the thickness of the thickest portion and the thinnest portion of the sponge cake is 10% or less of the thickness of the thickest portion of the sponge cake.
[0029] [Fructooligosaccharide]
[0030] In the production of the sponge cake according to the present invention, at least a fructooligosaccharide is used as a saccharide ingredient.
[0031] Examples of the fructooligosaccharide include a single saccharide and mixtures of two or more saccharides selected from 1-kestose, nistose, and fructosylnystose.
[0032] The fructooligosaccharide is preferably 1-kestose, and more preferably crystalline 1-kestose. Because of its little hygroscopicity, crystalline 1-kestose is very easy to handle.
[0033] The fructooligosaccharides or a single component thereof used in the present invention may be a commercially available product.
[0034] The fructooligosaccharides or a single component thereof used in the present invention can be prepared according to a known method. For example, crystalline 1-kestose can be prepared according to the method described in WO97/021718.
[0035] In the sponge cake according to the present invention, when the proportion of the saccharide in the total ingredients, based on a total weight of 100 of the starch ingredients (including flour), eggs, and saccharide, is 25 or more, preferably 30 or more, and more preferably 33 or more, the amount of the fructooligosaccharide in the total saccharide ingredients can be 25 to 100% by weight. To provide the physiologically active functions of the fructooligosaccharide, the amount of the fructooligosaccharide in the total saccharide ingredients is preferably 30 to 100% by weight, more preferably 35 to 100% by weight, still more preferably 45 to 100% by weight, and even more preferably 50 to 100% by weight.
[0036] Examples of the saccharides other than fructooligosaccharides include monosaccharides such as fructose and glucose; disaccharides such as sucrose, lactose, maltose, and trehalose; oligosaccharides such as galactooligosaccharides, xylooligosaccharides, and lactulose; and sugar alcohols such as maltitol, lactitol, erythritol, reduced palatinose, xylitol, sorbitol, and palatinit.
[0037] When a fructooligosaccharide only or a fructooligosaccharide and a sugar alcohol only is used as the saccharide or saccharides contained in the sponge cake, an abrupt rise in the blood sugar level after the ingestion of the sponge cake can be inhibited. A preferred sugar alcohol is maltitol in view of its shape-retaining ability.
[Water-Soluble Polymer]
[0038] As will be described in the Examples, it has been found that a sponge cake made using a fructooligosaccharide as a saccharide ingredient becomes concave-shaped in the center; however, the addition of a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum as an ingredient when making a sponge cake can effectively prevent this phenomenon.
[0039] The term “collagen peptide” as used herein means a peptide having an average molecular weight of about 10,000 or less, which is prepared by hydrolysis of collagen into lower molecules.
[0040] The collagen peptide used in the present invention may be a commercially available product.
[0041] The collagen peptide used in the present invention can be prepared according to a known method (for example, the method described in Japanese Patent Laid-Open Publication No. 241013/2006). Collagen peptide can be prepared by, for example, hydrolysis of the collagen contained in fish, cows, pigs, chickens, or the like into lower molecules, or by hydrolysis of gelatin obtained by heat denaturation of collagen into lower molecules.
[0042] As compared to gelatins and polysaccharide thickeners that can be difficult to dissolve without using hot water, or difficult to dissolve in high concentrations, collagen peptide is very easy to handle because it easily dissolves in cold water, and can be dissolved in high concentrations. Furthermore, since collagen peptide is not a food additive, a sponge cake not using a food additive can be made by adding collagen peptide without using other thickeners, emulsifiers, leavening agents, and the like.
[0043] In the sponge cake according to the present invention, the amount of collagen peptide in the total ingredients can be 0.3 to 15 parts by weight, preferably 0.5 to 10 parts by weight, more preferably 0.5 to 1 part by weight, and particularly preferably 0.5 to 0.8 part by weight, based on 100 parts by weight of the starch ingredients (including flour).
[0044] Collagen peptide can be added to the ingredients in its original powder form, or as a solution obtained by dissolving the collagen peptide in water, but is preferably added as a solution to provide a uniform mixture.
[0045] The term “xanthan gum” as used herein means a polysaccharide having an average molecular weight of millions to tens of millions, which contains repeating units consisting of two glucose molecules, two mannose molecules, and glucuronic acid. The term “xanthan gum” includes alkali metal salts (for example, sodium salt and potassium salt) of xanthan gum, and alkaline earth metal salts (for example, calcium salt) of xanthan gum.
[0046] The xanthan gum used in the present invention may be a commercially available product.
[0047] The term “guar gum” as used herein means a polysaccharide having an average molecular weight of 200,000 to 300,000, which has a linear bond of two mannose molecules and a side chain of one galactose molecule.
[0048] The guar gum used in the present invention may be a commercially available product.
[0049] In the sponge cake according to the present invention, the amount of xanthan gum or guar gum in the total ingredients can be 0.01 to 0.5 part by weight, preferably 0.03 to 0.5 part by weight, and more preferably 0.06 to 0.2 part by weight, based on 100 parts by weight of the starch ingredients (including flour). These ranges enhance the effect of preventing the sponge cake from becoming concave in the center, and make the texture of the sponge cake desirable.
[0050] The term “average molecular weight” as used herein means a molecular weight (a number average molecular weight) calculated as an average molecular weight of a polymer (collagen peptide, xanthan gum, or guar gum) based on the number of molecules of the polymer.
[0051] The average molecular weight can be measured, for example, according to the following method.
[0052] First, gel filtration analysis is conducted by the HPLC method, and a calibration curve is prepared using Multistation GPC-8020 Software Ver. 4.0 (manufactured by TOSOH CORPORATION), based on the retention time of the molecular weight marker. Next, using this calibration curve, the average molecular weight can be calculated based on the average retention time of the target polymer.
[0053] In the case of, for example, collagen peptide, the analysis conditions may be as follows.
[0000] Analysis conditions:
Column: TSK-GEL3000PW XL (300×7.8 mm)
[0054] Eluent: 45% acetonitrile (containing 0.1% TFA)
Flow rate: 0.5 ml/min
Detection condition: 215 nm
[0055] In the present invention, the “water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum” may be a combination of two or more water-soluble polymers selected from the group consisting of collagen peptide, xanthan gum, and guar gum.
[0056] In the present invention, the “water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum” is preferably collagen peptide.
[0057] According to a preferred embodiment of the sponge cake according to the present invention, there is provided a sponge cake comprising a saccharide comprising a fructooligosaccharide, and collagen peptide, wherein, when the proportion of the saccharide in the total ingredients, based on a total weight of 100 of starch ingredients (including flour), eggs, and saccharide, is 25 or more, preferably 30 or more, and more preferably 33 or more, the proportion of the fructooligosaccharide in the saccharide is 25 to 100% by weight (preferably 30 to 100% by weight); and the amount of the collagen peptide in the total ingredients is 0.3 to 15 parts by weight (preferably 0.5 to 10 parts by weight, more preferably 0.5 to 1 part by weight, and particularly preferably 0.5 to 0.8 part by weight) based on 100 parts by weight of the starch ingredients (including flour).
[0058] According to a preferred embodiment of the sponge cake according to the present invention, there is also provided a sponge cake comprising a saccharide comprising a fructooligosaccharide, and xanthan gum or guar gum, wherein, when the proportion of the saccharide in the total ingredients, based on a total weight of 100 of starch ingredients (including flour), eggs, and saccharide, is 25 or more, preferably 30 or more, and more preferably 33 or more, the proportion of the fructooligosaccharide in the saccharide is 25 to 100% by weight (preferably 30 to 100% by weight); and the amount of xanthan gum or guar gum in the total ingredients is 0.01 to 0.5 part by weight (preferably 0.03 to 0.5 part by weight, and more preferably 0.06 to 0.2 part by weight) based on 100 parts by weight of the starch ingredients (including flour).
[0059] According to a further preferred embodiment of the sponge cake according to the present invention, there is provided a sponge cake comprising a saccharide comprising 1-kestose, and collagen peptide, wherein, when the proportion of the saccharide in the total ingredients, based on a total weight of 100 of starch ingredients (including flour), eggs, and saccharide, is 25 or more, preferably 30 or more, and more preferably 33 or more, the proportion of 1-kestose in the saccharide is 25 to 100% by weight (preferably 30 to 100% by weight); and the amount of collagen peptide in the total ingredients is 0.3 to 15 parts by weight (preferably 0.5 to 10 parts by weight, more preferably 0.5 to 1 part by weight, and particularly preferably 0.5 to 0.8 part by weight), based on 100 parts by weight of the starch ingredients (including flour).
[0060] According to a further preferred embodiment of the sponge cake according to the present invention, there is also provided a sponge cake comprising a saccharide comprising 1-kestose, and xanthan gum or guar gum, wherein, when the proportion of the saccharide in the total ingredients, based on a total weight of 100 of starch ingredients (including flour), eggs, and saccharide, is 25 or more, preferably 30 or more, and more preferably 33 or more, the proportion of 1-kestose in the saccharide is 25 to 100% by weight (preferably 30 to 100% by weight); and the amount of xanthan gum or guar gum in the total ingredients is 0.01 to 0.5 part by weight (preferably 0.03 to 0.5 part by weight, and more preferably 0.06 to 0.2 part by weight), based on 100 parts by weight of the starch ingredients (including flour).
[0061] According to the present invention, there is provided a method for making a sponge cake which comprises preparing sponge cake dough by mixing a saccharide comprising a fructooligosaccharide with a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum, and baking the dough.
[0062] According to the present invention, there is provided a sponge cake comprising a saccharide comprising a fructooligosaccharide, and collagen peptide, wherein the collagen peptide is added in an amount of 0.1 to 10 parts by weight, and preferably 0.5 to 10 parts by weight, based on 100 parts by weight of water-based ingredients (for example, eggs, milk, fruit juice, water, yogurt, and whey).
[0063] According to the present invention, there is provided a sponge cake comprising a saccharide comprising a fructooligosaccharide, and xanthan gum or guar gum, wherein the xanthan gum or guar gum is added in an amount of 0.03 to 0.5 part by weight, and preferably 0.05 to 0.5 part by weight, based on 100 parts by weight of water-based ingredients.
EXAMPLES
[0064] The present invention will be described in greater detail with reference to the following examples; however, the scope of the invention is not limited to these Examples.
Study 1
[0065] After 150 g of a saccharide and 150 g of whole eggs were mixed with stirring, 150 g of flour was added. The mixture was further stirred to prepare sponge cake dough. The saccharides were prepared using sugar and 1-kestose (a crystalline powder containing 97% or more of 1-kestose; trade name: Meioligo CR, manufactured by Meiji Seika Kaisha, Ltd.) according to the formulations listed in Table 1.
[0066] Into a 18 cm round mold on which glassine was placed, 400 g of the sponge cake dough was poured, and the dough was baked at 180° C. for 40 minutes to prepare a sponge cake. The sponge cake was removed from the mold and cut along the center. The thicknesses of the edge and the center of the sponge cake were measured.
[0067] The results are shown in Table 1.
[0000]
TABLE 1
Substituted
Substituted
Substituted
Only
with 25%
with 50%
with 75%
Sugar
1-Kestose
1-Kestose
1-Kestose
Flour (g)
150
150
150
150
Whole Eggs (g)
150
150
150
150
Sugar (g)
150
112.5
75
37.5
1-Kestose (g)
—
37.5
75
112.5
Thickness
5.2 cm
4.4 cm
3.7 cm
2.4 cm
(Center)
Thickness
5.1 cm
4.9 cm
4.7 cm
4.5 cm
(Edge)
[0068] The sponge cake containing sugar only as the saccharide was uniform in thickness. In contrast, the sponge cakes containing 25% by weight or more of 1-kestose were concave-shaped in the center.
[0069] The foregoing results have confirmed that sponge cakes containing 25% by weight or more of 1-kestose as a saccharide become concave in the center. The present inventors confirmed that similar results were also obtained when a fructooligosaccharide mixture was used instead of 1-kestose (the data omitted).
Study 2
[0070] After 150 g of a saccharide and 150 g of whole eggs were mixed with stirring, 150 g of flour was added. The mixture was further stirred to prepare sponge cake dough. The various saccharides listed in Table 2 were used as the saccharides.
[0071] Into a 18 cm round mold on which glassine was placed, 400 g of the sponge cake dough was poured, and the dough was baked at 180° C. for 40 minutes to prepare a sponge cake. The sponge cake was removed from the mold and cut along the center. The thicknesses of the edge and the center of the sponge cake were measured.
[0000] The results are shown in Table 2.
[0000]
TABLE 2
Xylooligo-
Reduced
saccharide
Lactulose
Maltitol
Erythritol
Palatinose
Flour (g)
150
150
150
150
150
Whole Eggs (g)
150
150
150
150
150
Saccharide (g)
150
150
150
150
150
Thickness
7.2 cm
6.0 cm
5.1 cm
1.9 cm
4.2 cm
(Center)
Thickness
5.6 cm
5.3 cm
5.1 cm
2.6 cm
1.9 cm
(Edge)
[0072] The sponge cakes using the various oligosaccharides other than a fructooligosaccharide instead of sugar did not become concave-shaped in the center. Moreover, the sponge cake using maltitol as a sugar alcohol underwent similar expansion to that of the sponge cake using sugar.
[0073] The foregoing results have confirmed that the use of a fructooligosaccharide as a saccharide results in a sponge cake that is concave in the center.
Study 3
[0074] After 150 g of a saccharide, 150 g of whole eggs, and a 50% by weight aqueous solution of collagen peptide (manufactured by Nitta Gelatin Inc.) dissolved and hydrated in hot water were mixed with stirring, 150 g of flour was added. The mixture was further stirred to prepare sponge cake dough. The saccharides were prepared using 1-kestose, a fructooligosaccharide mixture (an amorphous powder containing 95% or more of a mixture of 1-kestose, nistose, and fructosylnystose; trade name: Meioligo P, manufactured by Meiji Seika Kaisha, Ltd.), and maltitol (manufactured by Roquette K.K.) according to the formulations listed in Table 3. The collagen peptide was prepared to give each of the amounts shown in Table 3.
[0075] Into a 18 cm round mold on which glassine was placed, 400 g of the sponge cake dough was poured, and the dough was baked at 180° C. for 40 minutes to prepare a sponge cake. The sponge cake was removed from the mold and cut along the center. The thickness of the thickest portion and the thinnest portion of the sponge cake were measured. The shape of the sponge cake was determined as follows: “convex” represents a shape that bulges in the center in appearence; “concave” represents a shape that is concave in the center; and “flat” represents a shape that is substantially uniform in thickness, i.e., the difference between the thickest portion and the thinnest portion is 10% or less of the thickness of the thickest portion.
[0000] The results are shown in Tables 3 and 4.
[0000]
TABLE 3
Example
Example
Example
Example
Example
Example
1
2
3
4
5
6
Flour (g)
150
150
150
150
150
150
Whole Eggs (g)
150
150
150
150
150
150
1-Kestose (g)
150
150
—
—
150
50
Fructooligosaccharide
—
—
150
150
—
—
Mixture (g)
Maltitol (g)
—
—
—
—
—
100
50% Aqueous
1.5
2
3
10
30
3
Collagen Solution (g)
Shape
Flat
Flat
Convex
Convex
Convex
Convex
Minimum Thickness
3.5 cm
3.9 cm
3.6 cm
2.6 cm
3.0 cm
3.6 cm
Maximum Thickness
3.7 cm
4.0 cm
4.2 cm
3.8 cm
3.4 cm
4.3 cm
[0000]
TABLE 4
Compar-
Compar-
Compar-
ative
ative
ative
Comparative
Example 1
Example 2
Example 3
Example 4
Flour (g)
150
150
150
150
Whole Eggs (g)
150
150
150
150
1-Kestose (g)
150
—
50
—
Fructooligosaccharide
—
150
—
50
Mixture (g)
Maltitol (g)
—
—
100
100
50% Aqueous
—
—
—
—
Collagen Solution (g)
Shape
Concave
Concave
Concave
Concave
Minimum Thickness
2.7 cm
2.6 cm
3.6 cm
2.7 cm
Maximum Thickness
4.2 cm
4.2 cm
4.4 cm
4.2 cm
[0076] The amount by weight of the 50% aqueous collagen solution in Tables represents the amount by weight calculated as the aqueous solution.
[0077] The results have shown that the sponge cakes using 1-kestose or the fructooligosaccharide mixture became concave in the center (Comparative Examples 1 to 4; FIG. 3 ); however, the addition of collagen peptide prevented the sponge cakes from becoming concave in the center (Examples 1 to 6; FIGS. 1 and 2 ). Particularly the sponge cakes according to Examples 1 and 2 were substantially uniform in thickness.
Study 4
[0078] After 150 g of a saccharide, 150 g of whole eggs, and an aqueous solution of each of various water-soluble polymers (manufactured by San-Ei Gen F.F.I., Inc.) dissolved and hydrated in hot water were mixed with stirring, 150 g of flour was added. The mixture was further stirred to make sponge cake dough. The saccharides were prepared using 1-kestose, a fructooligosaccharide mixture, and maltitol according to the formulations listed in Table 5. The various water-soluble polymers were prepared to give the amounts shown in Table 5.
[0079] Into a 18 cm round mold on which glassine was placed, 400 g of the sponge cake dough was poured, and the dough was baked at 180° C. for 40 minutes to prepare a sponge cake. The sponge cake was removed from the mold and cut along the center. The thickness of the thickest portion and the thinnest portion of the sponge cake were measured. The shape of the sponge cake was determined according to Study 3 .
[0000] The results are shown in Table 5.
[0000]
TABLE 5
Example
Example
Example
Comparative
Comparative
7
8
9
Example 5
Example 6
Flour (g)
150
150
150
150
150
Whole Eggs (g)
150
150
150
150
150
1-Kestose (g)
150
150
—
150
150
Fructooligosaccharide
—
—
50
—
—
Mixture (g)
Maltitol (g)
—
—
100
—
—
1% Xanthan Gum
30
—
10
—
—
Aqueous Solution (g)
1% Guar Gum
—
30
—
—
—
Aqueous Solution (g)
5% Pullulan Aqueous
—
—
—
30
—
Solution (g)
5% Gum Arabic
—
—
—
—
30
Aqueous Solution (g)
Shape
Flat
Flat
Flat
Concave
Concave
Minimum Thickness
3.2 cm
3.4 cm
3.7 cm
2.2 cm
2.0 cm
Maximum Thickness
3.2 cm
3.7 cm
3.7 cm
4.4 cm
4.1 cm
[0080] The amount by weight of each of the various polymer aqueous solutions in Tables represents the amount by weight calculated as the aqueous solution.
[0081] The results have shown that the sponge cakes using 1-kestose or the fructooligosaccharide mixture were prevented from becoming concave in the center by the addition of xanthan gum or guar gum (Examples 7 to 9); however, similar effects were not observed with pullulan and gum arabic (Comparative Examples 5 and 6). | An object of the present invention is to provide a sponge cake that does not become concave-shaped in the center even when it uses a fructooligosaccharide having physiological functions, such as decay resistance, the effect of promoting bifidobacterium growth, the effect of improving the metabolism of lipids such as cholesterol, the effect of regulating immunity, and the effect of inhibiting a rise in blood sugar level. According to the present invention, there is provided a sponge cake comprising a saccharide comprising a fructooligosaccharide, and a water-soluble polymer selected from the group consisting of collagen peptide, xanthan gum, and guar gum. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a biodegradable polymer composition that exhibits good resistance to thermal decomposition, resulting from molding or radiation sterilization. It has been found that it is possible to control the reduction in weight-average molecular weight caused by thermal decomposition to within 30% of the initial molecular weight after molding and radiation sterilization, by adding a free radical scavenger to the biodegradable polymer.
In this invention, the biodegradable polymer has sufficiently mild properties so that it is suitable for medical treatment of parts of the body and their environment, while maintaining its shape and properties for a necessary period. After such treatment, the polymer may be caused to disappear by hydrolyzing with an enzyme or non-enzyme.
2. Description of the Related Art
The biodegradable polymer may be natural or synthetic, and an enzyme is capable of hydrolyzing almost all natural polymers. For example, collagen which is a polypeptide, is representative of the natural polymers and is hydrolyzed by collagenase, while a polyglycoside composed of combined glycosides such as cellulose, starch, hyaluromic acid, chitin and chitosan is also contemplated, with cellulose, for example being hydrolyzed by cellulase enzyme.
In spite of the fact that a natural polyester produced by a microbe was known as a biodegradable polymer since 1920, such knowledge was not utilized for a long time. However, as a result of recent progress in biotechnology, many kinds of natural polyesters have been researched and developed as biodegradable materials, including poly β-hydroxybutylate.
Many kinds of synthetic biodegradable polymers are capable of being hydrolyzed by a non-enzyme. However, polypeptides such as poly glutamic acid are hydrolyzed by peptide decomposition enzymes similar to natural polypeptides.
Almost all biodegradable synthetic polyesters such as polyglucolic acid, polylactic acid or copolymers of glycolic and lactic acids, are hydrolyzed by non-enzymes and find frequent clinical use as medical materials.
There are many medical applications of biodegradable polymers employed as medical materials, but these are almost always restricted to surgical use such as suture or bone fixation materials. Other industrial uses of these polymers include PLLA film molded products such as a garbage bags, agricultural film, storage bags, or textiles, since PLLA is decomposed by microbes under a natural environment.
The production of biodegradable polymers useful as medical and industrial materials is accomplished by such methods as extrusion of heated meltdown, injection, and pressed molding. However, heating processes are usually avoided in the course of production, since a drop in molecular weight inevitably occurs in products after such heating process, because biodegradable polymers generally have poor heat stability. In addition, sterilization is inevitably necessary for medical use in contrast with industrial use, because biodegradable polymers are applied in surgical use such as surgical sutures or bone fixation materials. Ethylene-oxide gas is generally utilized for the sterilization process, because biodegradable polymers show poor durability against radiation exposure. In this process, since ethylene-oxide gas utilized for the sterilization, is intended to eliminate toxicity in the living body, it is inevitably necessary to remove residual gas after the sterilization process, by applying vacuum for an extended period, but it is nevertheless impossible to completely remove the gas. Sterilization methods by radiation are therefore employed in many cases when biodegradable polymers are utilized for medical uses. Moreover, only specified kinds of biodegradable polymers are generally irradiated, but some strength deterioration inevitably occurs, caused by radiation decomposition.
It is the object of this invention to treat biodegradable polymers so as to avoid or restrict molecular weight reduction in the course of heat treatment processes, and strength deterioration, caused by sterilization, and to improve the properties of the composition containing the treated polymer.
SUMMARY OF THE INVENTION
In this invention, the production of a biodegradable polymer composition showing good resistance to thermal decomposition, wherein a drop of weight-average molecular weight is controlled within 30% of the initial molecular weight after molding and radiation sterilization process, is accomplished by adding a free radical scavenger to the biodegradable polymer.
Biodegradable polymer compositions of the invention, notwithstanding thermal and radiation decomposition, are applicable for medical and many industrial uses. Moreover, this processing method may be applied to non-biodegradable polymers such as nylon or polypropylene when subjected to thermal casting and sterilization by irradiation.
DETAILED DESCRIPTION OF THE INVENTION
For treatment of the biodegradable polymer compositions of the invention, the free radical scavenger is selected from the oxidation resistant agent group consisting of polyphenols, tannic acids, or gallic acids, the vitamin group consisting of Vitamin E or Vitamin C, or triarylisocianulate, such free radical scavenger being added to the biodegradable polymer composition, to improve its properties after thermal, mechanical and irradiation treatments.
When the biodegradable polymer is heated until its temperature is 50-degrees Centigrade higher than its melting temperature, radicals are generated from the polymer. Moreover, the polymer begins to deteriorate by an oxidizing reaction caused by ambient oxygen. The molecular weight of the polymer is substantially reduced by a high dose (of 2 to 3 MRad) applied radiation similar in effect to heating, generating radicals in molecular chains of the polymer, causing breaks in the chains and substantially reducing the molecular weight.
In order to prevent the molecular chains from being broken by the generated radicals as a result of heating and irradiation, the free radical scavenger can be previously added to the polymer composition in order to inactivate the generated radicals.
The volume of the free radical scavenger added to the composition is preferably in the range of 0.01 to 10 wt. %, more preferably a range of 0.01 to 2 wt. %, based on the weight of the polymer. If the volume of scavenger is less than 0.01 wt. %, the time necessary to obtain desired results will be undesirably long. If volume is more than 10 wt. %, the added scavenger may have a negative rather a positive effect on the molecular weight of the polymer.
There is no special method or process for adding and mixing free radical scavenger with the biodegradable polymer composition. For example, when adding vitamin E, it is possible not only to directly add the vitamin E to the polymer in the mentioned volume range, but also at first mix and dissolve the vitamin E in an organic solvent such as acetone, causing a mixture of the polymer and vitamin E to remain at final drying of the resulting solution.
In order to obtain additional uniform mixture, the biodegradable polymer composition may be absorbed to form a complex with an inorganic compound such as apatite, zeolite or titanium dioxide.
Operations involving the application of heat including extrusion, injection and heat pressing may be part of the manufacturing process for producing a biodegradable polymer composition by adding and mixing a free radical scavenger with the polymer. It is preferred that the composition is produced at a temperature not more than 50-degree Centigrade higher than the melting temperature of the biodegradable polymer, because such temperature is the upper limited temperature for generating free radicals. There is no restriction with respect to a lower limit of the temperature for generating free radicals, but it is preferred to produce such radicals at a higher temperature than the softening point of the biodegradable polymer because of greater ease of production.
The biodegradable polymer composition prepared by adding and mixing the free radical scavenger with the polymer is sterilized with radiation such as 60 Co-γ ray by a conventional method. It is preferred that the radiation is produced in a dose range of 1.0 to 3.0 Mrad. If the radiation is less than 1.0 Mrad dose, the sterilization effect is poor, and if more than 3.0 Mrad dose, the molecular weight of the polymer begins to deteriorate.
There is no special procedure for carrying out the steps involving heating and radiation sterilization. However, it is preferred that the heating step is carried out first, because of greater ease of production.
The biodegradable polymer of this invention is composed of any of natural and synthetic polymers, and free radicals are generated during steps of heating and radiation sterilization. The polymer includes, for example any of the group consisting of poly-glycolic acid, poly-lactic acid, poly-dioxanon, gelatin, hyaluronic acid, collagen, poly-amino acid, poly-caprolacton, copolymer of lactic and glycolic acid, copolymer of lactic acid and caprolacton, copolymer of glycolic acid and caprolactone, poly-hydroxybutylate, chitin, albumin, or chitosan. The biodegradable polymer composition of the invention is applicable for medical and many industrial uses.
By this invention, the biodegradable polymer is prevented from an occurrence of molecular weight loss caused by heating and by radiation sterilization. This results in the production of high quality polymer compositions.
In conclusion, products of biodegradable polymer compositions produced by this invention such as sutures for operations and bone fixation material maintain their mechanical properties and have other improved properties due to the prevention of molecular weight loss caused by heating and radiation sterilization.
Other polymers which may be added to the biodegradable polymer, such as polyethylene for artificial joint friction parts, that require heating and radiation sterilization, can also be treated by this invented method, in order to prevent molecular weight loss from accelerating.
EXAMPLES
The following examples illustrate the invention, but do not restrict the scope of such invention as claimed herein.
The weight-average molecular weights shown in the examples are measured by Shimazu GPC.
Example 1
To poly-L-lactide(PLLA) having a weight-average molecular weight of 340 thousand was added 0.1 wt. % Vitamin E(Tocopherol). From this composition, a molded rod sample of 10 cm length and 10 mm diameter was formed using an injection machine (Nisshou Jushi Ind. Ltd., NS40-A).
While the weight-average molecular weight of the PLLA rod having no Vitamin E additive declined to about 180 thousand after molding, the weight-average molecular weight of PLLA rod having Vitamin E additive showed almost no molecular weight drop, at about a 330 thousand molecular weight.
Example 2
To PLLA having a weight-average molecular weight of about 280 thousand was added 1.0 wt. % of Vitamin E. Pellets of this composition were spun into thread using a simplified melt spinner. The molecular weight after spinning was about 260 thousand, indicating a small molecular weight drop.
In contrast, PLLA thread similarly spun but with no Vitamin E additive had a reduced molecular weight of about 140 thousand, about half the molecular weight of the Vitamin E-containing PLLA after spinning
Example 3
PLLA pellets of weight-average molecular weight of about 280 thousand were modified by treated samples composed of 100 parts of titanium dioxide (WakoJunyaku Co.) and 10 parts of tannin (WakoJunyaku Co.) that was absorbed in the titanium dioxide. A PLLA rod was then fabricated from polymer pellets containing 0.5 parts of treated samples per tannin unit.
The molecular weight after molding the rod was about 260 thousand, indicating a relatively small molecular weight drop, while the molecular weight of the PLLA rod having no tannin additive declined to about 140 thousand.
Example 4
To a copolymer of L-lactide(75 mol %) and caprolactone (25 mol %) having a weight-average molecular weight of about 340 thousand was, added Vitamin E in the amount of 0.2 wt. % and the copolymer was used to spin thread with a simplified melt spinner. The weight-average molecular weight of the copolymer was about 330 thousand and indicated a small molecular weight drop from that of the copolymer containing no Vitamin E.
Example 5
The melt-spun thread of Example 4 was packed in a bag laminated with aluminum and polyethylene film, the air in the bag was replaced by nitrogen gas, and the thread was irradiated by exposure to radioactive rays ( 60 Co-γ ray) of 2.5 Mrad. The weight-average molecular weight of the thread after radiation was about 300 thousand.
Example 6
To PLLA pellets of weight-average molecular weight of about 280 thousand was added triarylisocianulate in an amount of 0.2 wt. %, and the composition was extruded to a rod of 2 mm diameter. The weight-average molecular weight of the extruded PLLA was slightly increased to 290 thousand.
The product was vacuum-packed and irradiated, by exposure to radioactive rays ( 60 Co-γ ray) of 2.0 Mrad, to obtain a cross-linked product having improved mechanical properties.
Example 7
A treated specimen was prepared composed of 100 parts hydroxy-apatite and 1 part Vitamin E absorbed in the hydroxy-apatite. A mixture composed of 100 parts of PLLA pellets of weight-average molecular weight of about 280 thousand was mixed with 30 parts of the treated specimen in apatite and molded by injector. The molecule weight of PLLA in the resulting composite was about 330 thousand. After forming the composite by means of a hydrostatic pressure type extruder in order to orientate the molecular chains, the composite was irradiated with 60 Co-γ radiation of 2.5 MRad to obtain the finished PLLA/apatite composite which had a molecular weight of about 300 thousand and superior mechanical properities, for example, high tenacity and high modulus. | A biodegradable polymer composition having good resistance to thermal decomposition, wherein it is possible to control the weight-average molecular weight to within 30% of the initial molecular weight after molding and radiation sterilization, by adding a free radical scavenger to the biodegradable polymer.
Biodegradable polymer compositions of the invention, which withstand thermal and radiation decomposition are effective for medical and many industrial uses. Moreover, this inventive method is applicable for the treatment of many non-biodegradable polymers such as nylon or polypropylene which are subjected to thermal casting and radiation sterilization. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing felts for vinyl flooring or gasketing material, and specifically to the use of a latex binder for papermaking fibers which also removes contaminating dissolved ions from the process water.
2. Brief Description of Prior Art
Chrysotile asbestos has found widespread use in the manufacture of felts for vinyl flooring and gasketing materials. The fibers of chrysotile have a cationic electrostatic charge. It is convenient to use a styrene-butadiene rubber latex, the particles of which are negatively charged, to bond the fibers into a uniform sheet. Due to the difference in electrostatic charge, the particles of latex are quantitatively adsorbed on the fibers within seconds.
Unfortunately, chrysotile contains mineral salts which dissolve in the process water during the mechanical dispersion of the fibers. As these minerals become more concentrated in the process water, the drainage of water from the asbestos stock is reduced, slowing the felt-making machinery. Fresh water must then be added to the process water. As a result, part of this process water must continually be discarded. Closing of the process water system would result in a savings of fuel and raw materials and eliminate objectionable effluents.
Fibrous substitutes for asbestos which have been proposed, such as cellulose, fiberglass, rockwool and polypropylene are relatively inert and do not readily adsorb latex particles. These asbestos substitutes must be pre-treated with agents such as alum or polymeric flocculants and/or used with mineral fillers such as kaolinite or wollastonite to promote the precipitation of latex particles in the formation of a felt. The accumulation of dissolved mineral salts in the process water will be as much a hindrance to the closure of the process water system with these asbestos-free compositions as it is with asbestos-containing felt compositions.
Conventional styrene butadiene latices used in felt-making are usually prepared in a batch polymerization. All of the monomer is in the reactor at the start of the polymerization and must be emulsified by copious amounts of surfactants. These surfactants are also needed to prevent coagulation of the latex particles during storage and handling. Adsorption of the latex particles onto asbestos in the felt-making process releases the surfactants to the process water adding to the dissolved salts originating from the mineral component. In addition, these surfactants, particularly those of non-ionic type, enter the air-water interface causing the formation of a stable foam, requiring the continuous introduction of an antifoam composition.
If it were not for the surfactants, the surface of the particles of the styrene-butadiene latices, containing copolymerized carboxylic and sulfate acid groups, would provide ion exchange capacity which would aid in the purification of process water. "Low Emulsifier" synthetic styrene-butadiene latices were prepared in a two-step polymerization in U.S. Pat. No. 3,784,498. Stability was obtained by pH adjusting the latices in the second step with ammonia to between 7 and 10. Styrene-butadiene latices prepared by a similar two-step polymerization with N-methylol acrylamide in U.S. Pat. No. 3,882,070 had a final pH of greater than 5. The pH of these latices is too high to be useful for precipitation of cationic fibers in felt manufacture and to adequately demonstrate the ion exchange capability.
SUMMARY OF THE INVENTION
It has been found that the problems of the prior art can be overcome through the use of a latex containing the least possible amount of surfactants. A polymerization process involving continuous addition of monomers is uniquely suited to preparing latices which are virtually surfactant-free. Initially, the reactor has no monomers in it to be emulsified. Carboxylic acids and the persulfate catalyst which are present, while not normally considered emulsifiers, are sufficient to stabilize the monomer droplets during a continuous monomer addition process.
The latices manufactured according to the foregoing process provide a plurality of advantages. These latices have excellent stability and freedom from foam when subjected to mechanical agitation as during pumping. Some of the characteristics required for felt manufacture, such as drainage and tensile strength, are improved when the latices of this invention are employed. Furthermore, these latices exhibit an inherent ion exchange capability as evidenced by removal of dissolved salts from the felt-making process water.
DESCRIPTION OF THE DRAWINGS
The invention will become better understood and its advantages more apparent from the following detailed description, especially when read in light of the drawings wherein:
FIG. 1 is a plot of the specific conductance of process water which is continually recycled from felts made with the binder latex of the invention; and
FIG. 2 shows the change in the concentration of various dissolved metal ions in the process water during continuous felt manufacture.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Asbestos sheets suitable for use as a substrate for vinyl flooring are generally produced with fibers ranging in length from 1/32 to 1/8 inch. Fibers with these lengths are classified by the Quebec Producers Association as Grades 5, 6 and 7. These grades and mixtures thereof are generally used in the manufacture of asbestos sheets but other fibers, e.g., cellulose, are occasionally introduced.
The desired amount of asbestos fiber, generally from 0.3 to 8% by weight of the total slurry, is added to the water. The slurry is then refined in a Hydropulper, Jordan engine, beater, disc refiner or the like. The water at this point is hot (about 38° C.) and it is recycled from the wet end of the papermaking machinery. After the fiber bundles are broken down the slurry is transferred to a tank where binder latex is added. The mixture is then formed into sheets and the sheets are then pressed and dried.
The purposes of this invention are achieved by utilizing the carboxylic acids and initiator to provide emulsification of monomer droplets during polymerization and stability of the finished latex during storage and handling. In this case, nuclei for polymerization are provided by a seed latex rather than by micelles as in batch polymerizations. While the theory behind the effectiveness of the method is not fully understood, for the purpose of completeness of disclosure, it is noted that in the continuous monomer addition polymerization process, a low molecular weight styrene-butadiene polymer having sulfate and carboxyl groups may initially be created. Such a polymer could have sufficient sulfate and carboxyl groups for it to function as a surfactant.
The seed and the binder latices used in this invention may be, in principle, a copolymer of a diolefin with 4 to 8 carbon atoms, for example: 1,3-butadiene; 1,3-dimethyl-1,3-butadiene; 1,4-dimethyl-1,3-butadiene; and isoprene, with styrene. The seed latex may be prepared with the same initiators, carboxylic acids and chelating agents which are described below as being appropriate for making the subject latex of this invention. The seed and binder latices of this invention are typically carboxylated styrene-diene latices containing from about 40 to about 70 weight percent styrene, from about 30 to about 60 weight percent of a diene monomer and from 0.5 to about 5 weight percent of a carboxylic acid monomer such as, for example, acrylic acid, methacrylic acid, fumaric or itaconic acid. Additionally, the latices can also contain initiators, chain transfer agents, preservatives and other modifiers which are well known to those skilled in the art.
The stabilization of the seed latex can be obtained with anionic surface active agents such as sodium lauryl sulfate, sodium dodecyl benzene sulfonate, sodium alkyl sulfosuccinates or alkyl phenoxy poly(ethyleneoxy)ethanols such as as octyl or nonylphenoxy poly(ethyleneoxy)ethanols, including the full range of ethylene oxide contents available. Nonionic surface active agents such as alkyl phenoxy poly(ethyleneoxy)ethanols, including the full range of ethylene oxide contents available may also be used.
The surface active agent used to stabilize the seed latex is restricted to amounts that will result in a seed latex with an average particle size of between about 0.0005 and 0.1 microns. Seeds with an average particle size of 0.01 to 0.08 are preferred. The amount of surfactant stabilizer which will result in seed particles within the specified size range is from about 0.5 to about 4% by weight depending on the amount of initiator used.
Continuous monomer addition, when used in the preparation of the seed latex, results in smaller particles than would result from a batch process with the same amount of surfactants. Initially, the reactor contains the aforementioned surfactants, water and optionally buffers, chain transfer and chelating agents. This solution is brought up to a temperature of between 160° and 210° F., preferably between 175° and 190° F. A solution of the initiators, a detailed description of which appears below, is mixed into the hot surfactant solution. A mixture of styrene, diene monomer and unsaturated carboxylic acid is pumped into the reactor at a rate that will bring about complete addition of the monomer with 21/2 hours. The reaction mixture is kept at this temperature for 2 hours longer. A preservative may be added if the seed latex is to be stored for any length of time.
Continuous monomer addition, when applied to the preparation of binder latices, results in reduced amounts of surfactant and, consequently, higher surface tension of the finished latex. A carboxylic acid, chelating agent, seed latex and chain transfer agent are charged to a stirred reactor. The reactor is heated to temperatures as described for the making of seed latex, typically 180° F. Seed latex can be used in an amount such that the seed solids comprises from about 0.05 to about 8 percent of the weight of polymer in the binder latex. A solution of initiator in water is charged to the reactor contents at 180° F. Styrene, a diene monomer and unsaturated carboxylic acid monomer are blended in a separate tank, referred to as a monomer tank. Initiator, a small amount of hydroxide base and water are mixed in an aqueous tank. The contents of the monomer tank and the aqueous tank are simultaneously and uniformly fed to the reactor continuously over a four hour period. The reaction is then continued for two hours at 190° F. The reactants are cooled, discharged and stripped with a chemical stripping formulation which consists of 0.1% t-butyl hydroperoxide, 0.1% erythorbic acid and 0.01% ferrous sulfate.
Sources of radicals to initiate the polymerization of the latices of this invention can be selected from any of the initiators known in the art including those which undergo scission by heating or reaction with reducing agents. Water-soluble type initiators are preferred including sodium persulfate, potassium persulfate, ammonium persulfate, hydrogen peroxide and others which are familiar to those skilled in the art. The amount of initiator used may range from about 0.1 percent to about 4.0 percent of the polymer weight depending on the rate of polymerization desired. The initiator, and the redox agent if used, can be supplied to the aqueous composition in various ways. For example, the entire amount an aqueous solution initiator used can be added at the beginning of the polymerization, or an initial portion can be followed by a continuous or addition of portions of the remainder during the reaction, or the entire amount can be added continuously throughout the period of the reaction. The seed latex typically requires about twice the amount of initiator needed for the binder latex of this invention. When reducing agents are used it is again preferred to use water-soluble materials such as sodium metabisulfite, sodium hydrosulfite and ascorbic acid.
Unsaturated carboxylic acids useful in the manufacture of the latices of this invention are those which have the formula: ##STR1## This includes α,β-ethylenically unsaturated monocarboxylic acids where R 1 is hydrogen and R 2 can be hydrogen, methyl, ethyl or like alkyl groups as in acrylic, methacrylic, and ethacrylic acids, respectively. Ethylenically unsaturated dicarboxylic acids where R 1 is a carboxyl group and R 2 is hydrogen in formula I such as maleic and fumaric acid, may also be selected. Ethylenically unsaturated dicarboxylic acids where R 1 is hydrogen and R 2 is a methylene carboxylic acid group in formula I, such as itaconic acid, can also be selected. The latices of this invention may contain from about 0.5 to about 15 percent of polymer weight of an unsaturated carboxylic acid, preferably from 3 to 6 percent.
Chain transfer agents can be used to regulate the average molecular weight of the polymer. Preferred agents are mercaptans such as t-dodecylmercaptan.
The aqueous solutions of this invention may contain small amounts of water-soluble compounds to maintain the pH of the solution at desired levels. Such compounds include alkali metal or ammonium salts or bases such as sodium or potassium carbonate, sodium bicarbonate, trisodium phosphate, sodium citrate, ammonium or potassium hydroxide and the like.
Latices for asbestos felts are evaluated by preparing hand sheets and subjecting them to conventional paper testing. A blend of 25 parts of Quebec grade 5 and 75 parts of Quebec grade 7 asbestos is dispersed in water (38° C.) to about a 5% consistency. The slurry is agitated using a 2.5 inch split disc impeller at 1000 rpms for 8 minutes. Sufficient latex is added to give 15 parts of polymer in 100 parts of asbestos and the stirring continued for 7 minutes. The resulting slurry is uniform and homogeneous and suitable for forming sheets in a Williams sheet mold after being diluted to a 3% consistency. The sheets are then pressed on a Williams hydraulic press and dried on the Williams standard sheet dryer.
Water (35° C.) is added to the stock to bring the consistency to 2%. The drainage of water from the asbestos slurries is measured with a Schopper-Riegler freeness tester. Low numbers indicate fast drainage.
The tensile strengths are determined by pulling 1 inch strips of the sheet on an Instron 1130 test instrument at a crosshead speed of 2 in/min. A cold test is done at room temperature (21° C.); a hot test is done by heating the strip to 190° C.; a plasticizer tensile is run after the sample is soaked for 18 hours in butyl benzyl phthalate to simulate the plasticizers which may be used in some vinyl coatings in flooring manufacture.
For a fuller understanding of the nature and objects of this invention, reference may be made to the following examples. These examples are given merely to illustrate the invention and are not to be construed in a limiting sense.
EXAMPLE 1
This example illustrates the preparation of a seed latex.
A clean stirred pressure vessel was charged with 1020.0 grams of deionized water, 62.3 grams of a 25% solution of Siponate DS-10 (trademark of Alcolac, Inc.), 1.95 grams of sodium bicarbonate and 0.6 grams of a 42% solution of Hampene 100 (an EDTA chelating agent). The mixture was stirred and the reactor was heated to the polymerization temperature of 176° F. At 176° F., solution of 7.1 grams of ammonium persulfate catalyst in 55 grams of deionized water was charged to the reaction vessel. The monomer mixture, 389.5 grams of styrene and 389.5 grams of butadiene, was pumped into the reactor at a constant rate over a period of 2.5 hours. The reaction temperature of 176° F. was maintained for 2 hours longer.
EXAMPLE 2
This example illustrates the preparation of a binder latex.
A clean stirred pressure reactor was charged with 945.0 grams of deionized water, 100 grams of the seed latex of Example 1, 31.7 grams of fumaric acid, 4.7 grams of Hampene 100 and 3.0 grams of dodecyl mercaptan. Temperature of the mixture was increased to 180° F. while agitating the reaction mixture. At 180° F., a solution of 1.2 grams of ammonium persulfate in 50 grams of deionized water was added to the reactor. A monomer mixture of 704.0 grams of styrene, 468.0 grams of butadiene, 14.8 grams of methacrylic acid and 4.2 grams of dodecyl mercaptan was prepared. A catalyst mixture of 5.4 grams of ammonium persulfate and 200.0 grams of deionized water was prepared. The catalyst and the monomer mixtures were both pumped continuously to the reactor at a rate such that the mixtures were both completely added in a period of 4 hours. The pressure in the reactor did not exceed 100 psi during the polymerization. After the temperature had been maintained at 190° F. for 2 more hours, chemical stripping additives, 3 grams of t-butyl hydroperoxide (70%) and 7 grams of isopropyl alcohol, were added followed by the addition of 10 grams of erythorbic acid (5% solution). After one additional hour at 190° F., the reaction mixture was cooled to ambient temperature.
This latex had a solids content of 49.0%, only 0.2% coagulum, a pH of 2.65 and a surface tension of 63.8 dyne cm -1 . The last two characteristics, low pH and high surface tension, allow the full development of the ion exchange capability of this type of latex.
The particle size of latices made according to this invention ranged from 0.12 to 0.25 microns with an average of 0.16 microns. The ionic groups which are bound to the surface of the polymer particle provide less than 0.7 milliequivalent of charge per gram of polymer in the latex. It is preferred that the binder latex of this invention have a charge bound to the polymer of from about 0.2 to 0.4 milliequivalents per dry gram. These "bound charges" originate from the copolymerization of a monomer containing an ionizable group, such as a carboxylic acid, or from the incorporation of the initiating sulfate groups into the polymer, such as from the persulfate catalyst. These ionizable groups are "bound to the polymer" in the sense that they are not desorbed from the polymer particle upon dilution or mechanical shear. Thus, the bound charges provide latex stability, sites for bonding the polymer particle onto asbestos on other mineral fillers and the added capability of scavenging metallic ions from the aqueous phase. These and other capabilities of the latex of this invention will be amply demonstrated in the following examples.
EXAMPLE 3
A drum of high ionic strength process water was obtained from an asbestos felt mill. A pair of hand sheets were prepared according to the aforementioned procedure with the latex of Example 2. The water drained from the hand sheets was collected and sparged with nitrogen for 5 minutes at 24° C. to remove dissolved gases. The conductivity of the collected process water was measured with a cell whose constant was 0.61 cm -1 . Another pair of hand sheets was prepared with the process water collected from the preceding pair, the procedure being repeated until five pairs of hand sheets were made. In FIG. 1, the lower line shows a gradual decrease in specific conductance, for a total 9% decrease after 4 pairs of hand sheets had been made. Hand sheets were made with a conventional felt latex, GAF 400-76E, without benefit of the continuous monomer addition method of this invention. The upper line in FIG. 1 illustrates the increase in specific conductance--6% after 5 pairs of hand sheets--encountered with a conventional batch polymerized type of latex.
EXAMPLE 4
A slurry of asbestos fibers, 4 part Johns Manville 7M57 to 1 parts of Paperbestos 5, was prepared at 10 percent consistency in a Black Clawson Hydrapulper. The slurry is pumped to a batch chest where the latex of Example 2, diluted to 10% solids, was added. The amount of polymer was 12.8 percent of fiber by weight. The resulting stock is pumped through the stock value where white water from the later stages of the process is returned to the system between the stock valve and the fan pump so that the consistency is maintained at 3.5% in the headbox. The furnish from the headbox is fed onto a 4 meter wide plastic Fourdrinier wire moving at 125 feet per minute. As soon as the stock containing the latex of Example 2 arrived at the machine the drainage improved so that one half of the suction boxes were turned off and the speed increased to 131 feet per minute.
The conductivity of the process water was 3650 micromhos at the beginning of Example 4 since the system was closed. After the machine had been running for 10 hours, the conductivity was decreased to 3300 micromhos. Samples of process water were taken at about one hour intervals during this time and analyzed by Atomic Absorption Spectroscopy. The metallic ions contributing to the conductivity of the process water are shown in FIG. 2. Significant decreases in the concentration of magnesium, sodium and calcium ions were observed. These ions were replaced with potassium in an ion exchange process in which the insoluble acidic polymeric ion exchange resin is the binder latex particle, an integral part of the moving fibrous felt.
Within 6 hours after the stock containing the latex of Example 2 was replaced by stock containing a conventional batch polymerized latex the conductivity had increased to 3600 micromhos.
The physical properties of felts produced during the course of Example 4 are summarized in Table 1.
TABLE 1______________________________________ Before Example 4 After______________________________________Latex (%) 13.5 12.8 14.3Density (lb/ft.sup.3) 63.4 62.1 63.2Cold Tensile (lb/in) 54.8 50.7 53.2Hot Tensile (lb/in) 22.5 26.0 22.0Smoothness, felt side 466. 506. 460.wire 893. 961. 939.______________________________________
The hot tensile strength was noticeably higher and the density was lower during Exhibit 4 than with the conventional latex (Before and After). Both of these properties are beneficial to felt usage. The other felt properties, strength and smoothness, were equal to those with conventional latex. | A carboxylated latex is added to an aqueous slurry of fibers to remove metal ions contained in solution. The water is removed to form a felt. The demetallized water removed during felt formation is recycled in a closed process water system. The carboxylated latex is formed by polymerizing an unsaturated carboxylic acid on a substantially surfactant free styrene-diene polymer latex. | 3 |
[0001] The present application claims priority under 35 U.S.C. 119 to Korean Patent Application No. 10-2007-0072639 (filed on Jul. 20, 2007), which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Photolithography processes are essential for manufacturing semiconductor devices. In a photolithography process, after coating a relatively uniform photoresist layer over a wafer, the wafer is subject to an exposure process using a photomask having a predetermined layout. Then the exposed photoresist layer is developed to form a pattern having a predetermined shape.
[0003] In semiconductor photolithography technologies used for manufacturing semiconductor devices, a mask may be precisely designed such that the amount of light passing through the mask can be precisely adjusted. As semiconductor devices have become more highly integrated, design rules for smaller scale devices have been introduced. At smaller scales, sidelobes may occur between adjacent patterns due to constructive interference of light.
[0004] FIG. 1A is a plan view illustrating a part of a related mask, FIG. 1B is a view illustrating an aerial image of light passing through the mask of FIG. 1A , and FIG. 1C is a view illustrating patterns formed using the mask of FIG. 1A . As shown in FIG. 1A , the related mask 10 has mask patterns 11 , such as hole patterns or blocking patterns, corresponding to photoresist patterns to be formed. When mask 10 includes hole patterns 11 , as shown in FIG. 1B , sidelobe 23 may occur in the aerial image of light, which passes through mask patterns 11 , due to constructive interference of light. As shown in FIG. 1C , an undesired sidelobe pattern 33 may be generated between the photoresist patterns 31 to be formed over a substrate 30 through the mask 10 . Thus, when the photoresist patterns 31 are etched using the mask 10 , an undesirable result may be generated by the sidelobe pattern 33 on the substrate 30 .
SUMMARY
[0005] Embodiments relate to a mask capable of preventing sidelobes from being formed in a photoresist pattern used for forming a semiconductor device, and a manufacturing method thereof. A mask according to embodiments includes a substrate and a phase delay material layer formed over the substrate. At least one mask pattern including a hole pattern may be formed on the phase delay material layer, the hole pattern allowing light to pass through the mask pattern. Assist patterns compensate for constructive interference of the light occurring between the mask patterns.
[0006] A method for manufacturing a mask according to embodiments includes preparing a base substrate and forming a phase delay material layer over the base substrate. The method includes forming at least one mask pattern including a first hole pattern, which allows light to pass through the hole pattern, by patterning the phase delay material layer. The method includes forming at least one assist pattern including a second hole pattern located between the mask patterns, thereby compensating for constructive interference of the light between portions of the first hole pattern.
[0007] A phase shift mask having a light phase delay part and light transmitting parts according to embodiments includes at least one hole pattern formed on a light phase delay part between the light transmitting parts in a phase shift mask, the hole pattern causing destructive interference of a portion of the light passing through the light transmitting parts.
[0008] Embodiments can prevent undesirable sidelobes, which may be formed in a dense photoresist pattern, from occurring, so that desirable patterns may be formed. Embodiments may prevent sidelobes from occurring by inserting an assist pattern into a mask, so that defects in semiconductor devices can be prevented.
DRAWINGS
[0009] FIG. 1A is a plan view illustrating a part of a related mask.
[0010] FIG. 1B is a view illustrating an aerial image of light passing through the mask of FIG. 1A .
[0011] FIG. 1C is a view illustrating patterns formed using the mask of FIG. 1A .
[0012] FIG. 2 is a sectional view illustrating a mask according to embodiments.
[0013] FIG. 3A is a sectional view illustrating a pattern formed using the mask of FIG. 2 according to embodiments.
[0014] FIG. 3B is a sectional view illustrating a pattern formed using the mask of FIG. 2 according to embodiments.
[0015] FIG. 4A is a plan view illustrating a part of a mask according to embodiments.
[0016] FIG. 4B is a view illustrating an aerial image of light passing through the mask of FIG. 4A .
[0017] FIG. 4C is a view illustrating a pattern formed using the mask of FIG. 4A .
[0018] FIG. 5A is a plan view illustrating a mask according to embodiments.
[0019] FIG. 5B is a plan view illustrating a comparison mask compared with a mask according to embodiments.
[0020] FIG. 6 is a graph illustrating intensity of light, which passes through the mask of FIGS. 5A and 5B , as a function of positions “a-b” of the mask.
DESCRIPTION
[0021] Hereinafter, a mask and a manufacturing method thereof according to embodiments will be described with reference to the accompanying drawings. FIG. 2 is a sectional view illustrating a mask according to embodiments. FIG. 3A is a sectional view illustrating a pattern formed using the mask of FIG. 2 according to embodiments. and FIG. 3B is a sectional view illustrating a pattern formed using the mask of FIG. 2 according to embodiments. As shown in FIG. 2 , the mask 100 according to embodiments includes a base substrate 110 , mask patterns 111 and assist patterns 121 . The mask patterns 111 and the assist patterns 121 may be formed on a base substrate 110 . The mask 100 may include a PSM (Phase Shift Mask). The mask pattern 111 may include a hole pattern or a blocking pattern.
[0022] Referring to FIG. 2 , the mask pattern 111 includes a hole pattern to serve as a light transmitting part. A peripheral area of the mask pattern 111 may serve as a light phase delay part. The light phase delay part may include a phase delay material layer. The phase delay material layer may be a compound, for example, compounds containing transition metals. The transition metal may include one selected from the group consisting of Cr, Mo, Hf, W, Pt, Co, Ni, Ta and Ti. Further, the compound including the transition metal may include Si.
[0023] The assist pattern 121 prevents one or more sidelobes which may occur due to constructive interference generated between the mask patterns 111 . The assist pattern 121 may cause destructive interference, which compensates for the constructive interference, by allowing light to pass through a place where the sidelobe occurs. When the mask pattern 111 includes a hole pattern, the assist pattern 121 may be formed with a hole pattern. Further, when the mask pattern 111 includes a blocking pattern, the assist pattern 121 may be formed with a blocking pattern. The assist pattern 121 may have a size corresponding to 20% to 60% of that of the mask pattern 111 . Further, an interval between the assist patterns 121 may correspond to 50% to 200% of the size of the assist pattern 121 .
[0024] An arrangement interval of the mask patterns 111 may be larger than a width of the mask pattern 111 by one to ten times. The assist pattern 121 may have a circular or polygonal shape. Further, by way of example, the assist pattern 121 may also have a triangular, rectangular or pentagonal shape. The assist pattern 121 may include slits. In other words, the assist pattern 121 may have various shapes which may effectively remove the sidelobe(s).
[0025] As shown in FIGS. 3A and 3B , when the photolithography process is performed using the mask 100 , good photoresist patterns 131 can be formed over the substrate 130 . FIG. 3A is a sectional view illustrating a mask when positive photoresist is used and FIG. 3B is a sectional view illustrating the mask when negative photoresist is used. Since destructive interference occurs in the mask due to the assist pattern 121 formed between the mask patterns 111 , a sidelobe pattern is not generated between the photoresist patterns 131 formed by the mask patterns 111 .
[0026] FIG. 4A is a plan view illustrating a part of the mask according to embodiments. FIG. 4B is a view illustrating an aerial image of light passing through the mask of FIG. 4A . FIG. 4C is a view illustrating a pattern formed using the mask of FIG. 4A . As shown in FIG. 4A , the mask 100 according to embodiments includes mask patterns 111 , such as hole patterns or blocking patterns, corresponding to the photoresist pattern 131 to be formed. Further, the mask 100 includes the assist pattern 121 between the mask patterns 111 . Light diffraction may occur when the light passes through the assist pattern 121 , so that destructive interference of light may occur.
[0027] As shown in FIG. 4B , in view of the aerial image of light passing through the mask patterns 111 and the assist patterns 121 , the light passes through the mask patterns 111 , but the light forms a minimal image 123 corresponding to the assist patterns 121 due to the destructive interference of light. Thus, as shown in FIG. 4C , an undesirable sidelobe pattern, except for patterns formed by the mask patterns 111 , is not formed between the photoresist patterns 131 formed over the substrate 130 through the mask 100 .
[0028] FIG. 5A is a plan view illustrating the mask according to embodiments. FIG. 5B is a plan view illustrating a comparison mask compared with the mask according to embodiments. FIG. 6 is a graph illustrating the intensity of light, which passes through the mask of FIGS. 5A and 5B , as a function of positions along the line shown between points “a” and “b” on the masks. As shown in FIG. 5A , the mask 100 according to embodiments includes mask patterns 111 formed with hole patterns and the assist patterns 121 . As shown in FIG. 5B , the comparison mask 200 includes comparison mask patterns 211 identical to the mask patterns 111 of the mask 100 according to embodiments, and does not include assist patterns.
[0029] The graphs with curves indicated by P and Q in FIG. 6 can be obtained by measuring the intensity of light passing through the mask 100 and the comparison mask 200 , respectively. As shown on curve P of the mask 100 , the maximum intensity of light is obtained at the position corresponding to the mask patterns 111 , and intensity of light is lowered at the position P′ corresponding to the assist patterns 121 due to the destructive interference of the light. As shown on curve Q of the comparison mask 200 , the maximum intensity of light is obtained at the position corresponding to the comparison mask patterns 211 , and a relatively lower local maximum intensity of light is obtained by the constructive interference of the light at the position Q′ corresponding to the mask between the comparison mask patterns 211 .
[0030] In view of photoresist corresponding to the comparison mask 200 , light does not physically pass through the mask between the comparison mask patterns 211 . From an optical point of view, a sufficient amount of light is irradiated onto the photoresist, so that an undesirable sidelobe pattern may be formed over the substrate. However, in view of photoresist corresponding to the mask 100 according to embodiments, light physically passes through the assist patterns 121 . From an optical point of view, destructive interference occurs when the light passes through the assist patterns 121 , so that the sidelobe pattern is not formed on the photoresist. Consequently, only desired patterns may be formed over the substrate.
[0031] It will be obvious and apparent to those skilled in the art that various modifications and variations can be made in the embodiments disclosed. Thus, it is intended that the disclosed embodiments cover the obvious and apparent modifications and variations, provided that they are within the scope of the appended claims and their equivalents. | A mask according to embodiments includes a substrate and a phase delay material layer formed over the substrate. At least one mask pattern including a hole pattern may be formed on the phase delay material layer, the hole pattern allowing light to pass through the mask pattern. Assist patterns compensate for constructive interference of the light occurring between the mask patterns. Embodiments may prevent sidelobes from occurring by inserting an assist pattern into a mask, so that defects in semiconductor devices can be prevented. | 6 |
[0001] This application claims the benefit of U.S. Provisional Application No. 60/977,115, filed Oct. 3, 2007, the entire contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to tetraaza phenalen-3-one compounds which inhibit poly (ADP-ribose) polymerase (PARP).
BACKGROUND
[0003] The present invention relates to inhibitors of the nuclear enzyme poly(adenosine 5′-diphospho-ribose) polymerase [“poly(ADP-ribose) polymerase” or “PARP”, which is also referred to as ADPRT (NAD:protein (ADP-ribosyl transferase (polymerising)) and PARS (poly(ADP-ribose) synthetase) and provides compounds and compositions containing the disclosed compounds. Moreover, the present invention provides methods of using the disclosed PARP inhibitors to treat cancer.
[0004] There is considerable interest in the development of PARP inhibitors as chemosensitizers for use in cancer therapy and to limit cellular damage after ischemia or endotoxic stress. In particular, potentiation of temozolomide cytotoxicity observed in preclinical studies with potent PARP-1 inhibitors reflects inhibition of base excision repair and subsequent cytotoxicity due to incomplete processing of N 7 -methylguanine and N 3 -methyladenine. There is now a body of preclinical data demonstrating that the cytotoxicity of temozolomide is potentiated by coadministration of a PARP inhibitor either in vitro or in vivo. Plummer, et al., Clin. Cancer Res., 11(9), 3402 (2005).
[0005] Temozolomide, a DNA methylating agent, induces DNA damage, which is repaired by O 6 -alkylguanine alkyltransferase (ATase) and poly(ADP-ribose) polymerase-1 (PARP-1)-dependent base excision repair. Temozolomide is an orally available monofunctional DNA alkylating agent used to treat gliomas and malignant melanoma. Temozolomide is rapidly absorbed and undergoes spontaneous breakdown to form the active monomethyl triazene, 5-(3-methyl-1-triazeno)imidazole-4-carboxamide. Monomethyl triazene forms several DNA methylation products, the predominate species being N 7 -methylguanine (70%), N 3 -methyladenine (9%), and O 6 -methylguanine (5%). Unless repaired by O 6 -alkylguanine alkyltransferase, O 6 -methylguanine is cytotoxic due to mispairing with thymine during DNA replication. This mispairing is recognized on the daughter strand by mismatch repair proteins and the thymine excised. However, unless the original O 6 -methylguanine nucleotide in the parent strand is repaired by ATase-mediated removal of the methyl adduct, thymine can be reinserted. Repetitive futile rounds of thymine excision and incorporation opposite an unrepaired O 6 -methylguanine nucleotide causes a state of persistent strand breakage and the MutS branch of mismatch repair system signals G2-M cell cycle arrest and the initiation of apoptosis. The quantitatively more important N 7 -methylguanine and N 3 -methyladenine nucleotide alkylation products formed by temozolomide are rapidly repaired by base excision repair. Plummer, et al., Clin. Cancer Res., 11(9), 3402 (2005).
[0006] Chemosensitization by PARP inhibitors is not limited to temozolomide. Cytotoxic drugs, generally, or radiation can induce activation of PARP-1, and it has been demonstrated that inhibitors of PARP-1 can potentiate the DNA damaging and cytotoxic effects of chemotherapy and irradiation. Kock, et al., 45 J. Med. Chem. 4961 (2002). PARP-1 mediated DNA repair in response to DNA damaging agents represents a mechanism for drug resistance in tumors, and inhibition of this enzyme has been shown to enhance the activity of ionizing radiation and several cytotoxic antitumor agents, including temozolomide and topotecan. Suto et al., in U.S. Pat. No. 5,177,075, disclose several isoquinolines used for enhancing the lethal effects of ionizing radiation or chemotherapeutic agents on tumor cells. Weltin et al., “Effect of 6(5H)-Phenanthridinone, an Inhibitor of Poly(ADP-ribose) Polymerase, on Cultured Tumor Cells”, Oncol. Res., 6:9, 399-403 (1994) disclose the inhibition of PARP activity, reduced proliferation of tumor cells, and a marked synergistic effect when tumor cells are co-treated with an alkylating drug. PARP-1 is thus a potentially important therapeutic target for enhancing DNA-damaging cancer therapies.
[0007] PARP inhibitors can also inhibit the growth of cells having defects in the homologous recombination (HR) pathway of double-stranded DNA repair. See Bryant et al., “Specific killing of BRCA2-deficient tumours with inhibitors of poly(ADP-ribose) polymerase,” Nature 434, 913 (2005); Farmer et al., “Targeting the DNA repair defect in BRCA mutant cells as a therapeutic strategy,” Nature 434, 917 (2005). This effect operates without the presence of chemosensitizers. Id. Known states associated with HR defects include BRCA-1 defects, BRCA-2 defects, and Fanconi anemia-associated cancers. McCabe et al., “Deficiency in the Repair of DNA Damage by Homologous Recombination and Sensitivity to Poly(ADP-Ribose) Polymerase Inhibition,” Cancer Res. 66. 8109 (2006). Proteins identified as associated with a Fanconi anemia include FANCA, FANCB, FANCC, FANCD2, FANCE, FANCF, FANCG, FANCL, and FANCM. Id. For reviews, see Zaremba et al., “PARP Inhibitor Development for Systemic Cancer Targeting,” Anti - Cancer Agents in Medicinal Chemistry 7, 515 (2007) and Lewis et al., “Clinical poly(ADP-ribose) polymerase inhibitors for the treatment of cancer,” Curr. Opin. Investigational Drugs 8, 1061 (2007).
[0008] Large numbers of known PARP inhibitors have been described in Banasik et al., “Specific Inhibitors of Poly(ADP-Ribose) Synthetase and Mono(ADP-Ribosyl)-Transferase”, J. Biol. Chem., 267:3, 1569-75 (1992), and in Banasik et al., “Inhibitors and Activators of ADP-Ribosylation Reactions”, Molec. Cell. Biochem., 138, 185-97 (1994). However, effective use of these PARP inhibitors, in the ways discussed above, has been limited by the concurrent production of unwanted side-effects. See Milam et al., “Inhibitors of Poly(Adenosine Diphosphate-Ribose) Synthesis; Effect on Other Metabolic Processes,” Science, 223, 589-91 (1984).
[0009] In addition to the above, PARP inhibitors have been disclosed and described in the following international patent applications: WO 00/42040; WO 00/39070; WO 00/39104; WO 99/11623; WO 99/11628; WO 99/11622; WO 99/59975; WO 99/11644; WO 99/11945; WO 99/11649; and WO 99/59973. A comprehensive review of the state of the art has been published by Li and Zhang in IDrugs 2001, 4(7): 804-812 (PharmaPress Ltd ISSN 1369-7056).
[0010] The ability of PARP-inhibitors to potentiate the lethality of cytotoxic agents by chemosensitizing tumor cells to the cytotoxic effects of chemotherapeutic agents has been reported in, inter alia, US 2002/0028815; US 2003/0134843; US 2004/0067949; White A W, et al., 14 Bioorg. and Med. Chem. Letts. 2433 (2004); Canon Koch S S, et al., 45 J. Med. Chem. 4961 (2002); Skalitsky D J, et al., 46 J. Med. Chem. 210 (2003); Farmer H, et al, 434 Nature 917 (14 Apr. 2005); Plummer E R, et al., 11(9) Clin. Cancer Res. 3402 (2005); Tikhe J G, et al., 47 J. Med. Chem. 5467 (2004); Griffin R. J., et al, WO 98/33802; and Helleday T, et al, WO 2005/012305.
[0011] The induction of peripheral neuropathy is a common factor in limiting therapy with chemotherapeutic drugs. Quasthoff and Hartung, J. Neurology, 249, 9-17 (2002). Chemotherapy induced neuropathy is a side-effect encountered following the use of many of the conventional (e.g., Taxol, vincritine, cisplatin) and newer chemotherapies (e.g. velcade, epothilone). Depending on the substance used, a pure sensory and painful neuropathy (with cisplatin, oxaliplatin, carboplatin) or a mixed sensorimotor neuropathy with or without involvement of the autonomic nervous system (with vincristine, taxol, suramin) can ensue. Neurotoxicity depends on the total cumulative dose and the type of drug used. In individual cases neuropathy can evolve even after a single drug application. The recovery from symptoms is often incomplete and a long period of regeneration is required to restore function. Up to now, few drugs are available to reliably prevent or cure chemotherapy-induced neuropathy.
[0012] There continues to be a need for effective and potent PARP inhibitors which enhance the lethal effects of chemotherapeutic agents on tumor cells while producing minimal side-effects.
[0013] In addition, PARP inhibitors have been reported to be effective in radiosensitizing hypoxic tumor cells and effective in preventing tumor cells from recovering from potentially lethal damage of DNA after radiation therapy, presumably by their ability to prevent DNA repair. U.S. Pat. Nos. 5,032,617; 5,215,738; and 5,041,653.
[0014] Recent publications suggest that PARP inhibitors kill breast cancer cells that are deficient in breast cancer associated gene-1 and -2 (BRCA1/2). These studies suggest that PARP inhibitors may be effective for treating BRCA1/2-associated breast cancers. [Farmer et al., Nature 2005, 434, 917; DeSoto and Deng, Intl. J. Med. Sci. 2006, 3, 117; Bryant et al., Nature, 2005, 434, 913.]
[0015] There continues to be a need for effective and potent PARP inhibitors which enhance the lethal effects of ionizing radiation and/or chemotherapeutic agents on tumor cells, or inhibit the growth of cells having defects in the homologous recombination (HR) pathway of double-stranded DNA repair, while producing minimal side-effects.
SUMMARY OF INVENTION
[0016] The present invention provides compounds described herein, derivatives thereof and their uses to inhibit poly(ADP-ribose) polymerase (“PARP”), compositions containing these compounds and methods for making and using these PARP inhibitors to treat the effects of the conditions described herein.
[0017] The present invention also provides a tetraaza phenalen-3-one compound of Formula (I), or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R is
(a) NR 1 R 2 , wherein R 1 is selected from the group consisting of hydrogen, Q-Ce straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy,
NR A R B (C 1 -C 6 straight or branched chain alkyl), NR A R B (C 2 -C 6 straight or branched chain alkenyl), (C 1 -C 6 straight or branched chain alkyl)carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 3 -C 8 cycloalkyl)carbonyl,
(C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl, (C 3 -C 8 cycloalkyl)oxycarbonyl,
arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl),
aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl),
(C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl,
heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl); wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, and wherein each of R A and R B are independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl;
and R 2 is selected from the group consisting of C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy, NR X R Y (C 1 -C 6 straight or branched chain alkyl), NR X R Y (C 2 -C 6 straight or branched chain alkenyl), (C 1 -C 6 straight or branched chain alkyl)carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 3 -C 8 cycloalkyl)carbonyl, (C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl,
(C 3 -C 8 cycloalkyl)oxycarbonyl, arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl), aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl), (C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl,
heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl); wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, and wherein each of R X and R Y are independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl;
wherein R 1 and R 2 are independently substituted with between 0 and 4 substituents, each independently selected from halo, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, and amino; and provided that R 1 and R 2 may not both be methyl, and R 2 may not be (phenyl)prop-1-yl when R 1 is hydrogen; or
(b) aryloxy, substituted with between 0 and 4 substituents, each independently selected from the group consisting of halo, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, NR C R D , NR C R D (C 1 -C 6 straight or branched chain alkyl), and NR C R D (C 2 -C 6 straight or branched chain alkenyl), wherein each of R C and R D is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; and when more than one substituent is of the form NR C R D , each occurrence of R C and R D is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; or
(c) a heterocyclyl having between 1 and 7 heteroatoms independently selected from O, N, or S; and having between 0 and 4 substituents independently selected from the group consisting of halo, haloalkyl, hydroxyl, nitro, trifluoromethyl, trifluoroethyl, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy, amino, thiocarbonyl, cyano, imino, NR E R F (C 1 -C 6 straight or branched chain alkyl), NR E R F (C 2 -C 6 straight or branched chain alkenyl) sulfhydryl, thioalkyl, dioxa-spiroethyl, (C 1 -C 6 straight or branched chain alkyl) carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl, arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl), aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl), (C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl, heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl), wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, wherein each of R E and R F is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; and when more than one substituent is of the form NR E R F each occurrence of R E and R F is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; wherein each of said 0-4 substituents is independently substituted with between 0 and 4 further substituents, and each said further substituent is independently selected from halo, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, and amino; provided that R has at least one substituent when R is an N-piperidinyl, N-pyrrolidinyl or an N-morpholinyl group.
[0018] In some embodiments each ring of each heterocyclyl of Formula (I) is independently 5-7 atoms in size.
[0019] Some embodiments include one, two or three nitrogen atoms in at least one ring of the heterocyclyl of Formula (I).
[0020] In some embodiments, the heterocyclyl of Formula (I) comprises 1-3 rings. In some embodiments, the heterocyclyl has 1-7 heteroatoms independently selected from O, N, and S. In some embodiments, the heterocyclyl comprises 1-2 rings. In some embodiments, the heterocyclyl comprises one ring. In some embodiments, the various occurrences of the heterocyclyl of Formula (I) each independently comprise 1-3 rings. In some embodiments, the various occurrences of the heterocyclyl of Formula (I) each independently comprise 1-2 rings. In some embodiments, the various occurrences of the heterocyclyl of Formula (I) each independently comprise one ring.
[0021] In some embodiments, the heterocyclyl of Formula (I) is selected from the group consisting of piperidinyl, piperazinyl, pyridazinyl, dihydropyridyl, tetrahydropyridyl, pyridinyl, pyrimidinyl, dihydropyrimidinyl, tetrahydrophyrimidinyl, hexahydropyrimidinyl, dihydropyrazinyl, tetrahydropyrazinyl, pyrrolidinyl, imidazolidinyl, pyrazolidinyl, pyrrolyl, dihydropyrolyl, imidazolyl, dihydroimidazoyl, pyrazolyl, dihydropyrazolyl, azepanyl, [1,2]diazepanyl, [1,3]diazepanyl, [1,4]diazepanyl, indolyl, dihydroindolyl, isoindolyl, dihydroisoindoly, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, and tetrahydroisoquinolyl; or subsets thereof.
[0022] The present invention also relates to a pharmaceutical composition comprising (i) a therapeutically amount of a compound of Formula (I) and (ii) a pharmaceutically acceptable carrier.
[0023] The present invention provides compounds which inhibit the in vitro and/or in vivo polymerase activity of poly(ADP-ribose) polymerase (PARP), and compositions containing the disclosed compounds.
[0024] The present invention provides methods to inhibit, limit and/or control the in vitro and/or in vivo polymerase activity of poly(ADP-ribose) polymerase (PARP) in solutions cells, tissues, organs or organ systems. In one embodiment, the present invention provides methods of limiting or inhibiting PARP activity in a mammal, such as a human, either locally or systemically.
[0025] In one embodiment, the invention provides a chemosensitization method for treating cancer comprising contacting the cancer cells with a cytotoxicity-potentiating tetraaza phenalen-3-one compound of Formula (I) or a pharmaceutically acceptable salt thereof and further contacting the tumor or cancer cells with an anticancer agent.
[0026] An embodiment of the present invention provides a chemosensitization method wherein a first dose of at least one compound of Formula (I) or a pharmaceutically acceptable salt thereof is administered singly or repeatedly to a patient in need thereof, and wherein subsequently a second dose of at least one chemotherapeutic agent is administered singly or repeatedly to said patient after a time period to provide an effective amount of chemosensitization.
[0027] An aspect of the present invention provides a pharmaceutical formulation comprising the compound of Formula (I) in a form selected from the group consisting of Non-limiting examples of such chemotherapeutic agents are recited below, pharmaceutically acceptable free bases, salts, hydrates, esters, solvates, stereoisomers, and mixtures thereof. According to a further aspect, the pharmaceutical formulation further comprises a pharmaceutically acceptable carrier and, optionally, a chemotherapeutic agent. The following embodiments are for illustrative purposes only and are not intended to limit in any way the scope of the present invention. In one embodiment, a pharmaceutical formulation of the invention comprises a compound of the invention in a pharmaceutically acceptable carrier. In another embodiment, a pharmaceutical formulation of the invention comprises a pharmaceutically acceptable salt of a compound of the invention in a pharmaceutically acceptable carrier. In another embodiment, a pharmaceutical formulation of the invention comprises a compound of the invention and one or more chemotherapeutic agents in a pharmaceutically acceptable carrier. In another embodiment, a pharmaceutical formulation of the invention comprises a pharmaceutically acceptable salt of a compound of the invention and one or more chemotherapeutic agents in a pharmaceutically acceptable carrier. Non-limiting examples of such chemotherapeutic agents are recited below.
[0028] According to additional aspects of the invention, the chemosensitizing compound and the chemotherapeutic agent are administered essentially simultaneously.
[0029] According to an aspect of the invention, the chemotherapeutic agent is selected from the group consisting of temozolomide, adriamycin, camptothecin, carboplatin, cisplatin, daunorubicin, docetaxel, doxorubicin, interferon-alpha, interferon-beta, interferon-gamma, interleukin 2, irinotecan, paclitaxel, a taxoid, dactinomycin, danorubicin, 4′-deoxydoxorubicin, bleomycin, pilcamycin, mitomycin, neomycin and gentamycin, etoposide, 4-OH cyclophosphamide, a platinum coordination complex, topotecan, therapeutically effective analogs and derivatives of the same, and mixtures thereof. According to a specific aspect, the chemotherapeutic agent is temozolomide.
[0030] In another embodiment, the present invention provides methods of treating the effect of cancer and/or to radiosensitize cancer cells to render the cancer cells more susceptible to radiation therapy and thereby to prevent the tumor cells from recovering from potentially lethal damage of DNA after radiation therapy, comprising administering to a subject an effective amount of a compound of Formula (I) or a pharmaceutically acceptable salt thereof. A method of this embodiment is directed to specifically and preferentially radiosensitizing cancer cells rendering the cancer cells more susceptible to radiation therapy than non-tumor cells.
[0031] The present invention also provides a method of treatment of cancer in a subject in need thereof comprising administering to the subject a therapeutically effective amount of a compound of Formula (I) or a pharmaceutically acceptable salt thereof, wherein the cancer cells have a defect in repair of double-stranded DNA scission. In one embodiment, the defect in repair of double-stranded DNA scission is a defect in homologous recombination. In one embodiment, the cancer cells have a phenotype selected from the group consisting of a BRCA-1 defect, a BRCA-2 defect, a BRCA-1 and BRCA-2 defect, and Fanconi anemia.
[0032] In another embodiment, the present invention provides methods of treating BRCA1/2-associated breast cancer comprising administering a compound of Formula (I) or a pharmaceutically acceptable salt thereof.
[0033] According to one embodiment of the invention, the compound for use in the chemosensitization method of the invention, the radiosensitization method of the invention, or the treatment of cancer wherein the cancer cells have a defect in repair of double-stranded DNA scission method of the invention, is a compound selected from Formula (I) or a pharmaceutically acceptable salt thereof. In another aspect, the compound is selected from the group consisting of
[0000]
[0000] and pharmaceutically acceptable salts thereof.
[0034] The present invention also provides means to treat chemotherapy-induced peripheral neuropathy. According to an aspect of the invention, the compounds of the present invention are administered prior to, or together with, the administration of at least one chemotherapy agent to prevent the development of neuropathy symptoms or to mitigate the severity of such symptoms. According to a further aspect, the compounds of the present invention are administered after the administration of at least one chemotherapeutic agent to treat a patient for the symptoms of neuropathy or to mitigate the severity of such symptoms. In another aspect, the present invention provides a method to retard, delay, or arrest the growth of cancer cells in a mammal, comprising the administration of a chemotherapeutic agent, and further comprising the administration of a compound of Formula (I) or a pharmaceutically acceptable salt thereof in an amount sufficient to potentiate the anticancer activity of said chemotherapeutic agent.
[0035] Still other aspects and advantages of the present invention will become readily apparent by those skilled in the art from the following detailed description, wherein it is shown and described preferred embodiments of the invention, simply by way of illustration of the best mode contemplated of carrying out the invention. As will be realized the invention is capable of other and different embodiments, and its several details are capable of modifications in various obvious respects, without departing from the invention. Accordingly, the description is to be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 .—The oral administration of PARP-1 inhibitor Compound 13+TMZ demonstrating the enhance survival of mice bearing the B16 melanoma model.
[0037] FIG. 2 .—The oral administration of PARP-1 inhibitor Compound 13+TMZ demonstrating the enhanced survival in the intracranial SJGBM glioma model.
[0038] FIG. 3 .—The oral administration of PARP-1 inhibitor Compound 37+TMZ demonstrating the enhance survival of mice bearing the B16 melanoma model.
[0039] FIG. 4 .—The oral administration of PARP-1 inhibitor Compound 37+TMZ demonstrating the enhanced survival in the intracranial SJGBM glioma model.
[0040] FIG. 5 .—The oral administration of PARP-1 inhibitor Compound 37+radiation demonstrating inhibition of tumor growth in the model of head and neck cancer.
[0041] FIG. 6 .—The oral administration of PARP-1 inhibitor Compound 37 demonstrating inhibition of growth of BRCA1 mutant tumors
DETAILED DESCRIPTION OF THE INVENTION
[0042] The present invention provides compounds described herein, derivatives thereof and their uses to inhibit poly(ADP-ribose) polymerase (“PARP”), compositions containing these compounds and methods for making and using these compounds to treat, prevent and/or ameliorate the effects of cancers by potentiating the cytotoxic effects of ionizing radiation on tumor cells.
[0043] The present invention provides compounds described herein, derivatives thereof and their uses to inhibit poly(ADP-ribose) polymerase (“PARP”), compositions containing these compounds and methods for making and using these compounds to treat the effects of cancers by potentiating the cytotoxic effects of chemotherapeutic agents on tumor cells.
[0044] The present invention provides a chemosensitization method for treating tumor and/or cancer cells comprising contacting said cancer cells with a compound of Formula (I) and further contacting said cancer cells with an anticancer agent.
[0045] The present invention provides compounds described herein, derivatives thereof and their uses to inhibit poly(ADP-ribose) polymerase (“PARP”), compositions containing these compounds and methods for making and using these compounds to inhibit the growth of cells having defects in the homologous recombination (HR) pathway of double-stranded DNA repair.
[0046] The compounds and compositions of the present invention can be used in the presence or absence of radio- or chemo-sensitizers for the treatment of cancer. The compounds and compositions are preferably used in the absence of radio- or chemo-sensitizers where the cancer has a defect in the homologous recombination (HR) pathway of double-stranded DNA repair. Such defects are associated with, and have the phenotypes of, BRCA-1 defects, BRCA-2 defects, dual BRCA-1/BRCA-2 defects, and Fanconi anemia.
[0047] Fanconi anemia is a genetically heterogeneous disease and patients with Fanconi anemia have a greatly increased risk of cancer. Eleven proteins have been associated with Fanconi anemia. FANCA, FANCB, FANCC, FANCE, FANCF, FANCG, and FANCM form a nuclear core complex. The complex interacts with FANCL to incorporate ubiquinone of FANCD2. Modified FANCD2 is need for repair of DNA cross-links. FANCd2 accumulates at sites of DNA damage and associates with BRCA-1 and BRCA-2.
[0048] Exemplary cancers that can be associated with HR defects include breast cancer and ovarian cancer. Breast cancer for treatment by the methods of the invention can include all types of breast cancer and preferably includes invasive ductal carcinoma and invasive lobular carcinoma. Ovarian cancer for treatment by the methods of the invention include all types of ovarian cancer, preferably epithelial ovarian tumors, germ cell ovarian tumors, and sex cord stromal tumors.
[0049] The compounds of the present invention can be synthesized using the starting materials and methods disclosed in U.S. application Ser. No. 10/853,714, which is incorporated herein by reference in its entirety.
[0050] Typically, the compounds, such as those of Formula (I), used in the compositions of the invention will have an IC 50 for inhibiting poly(ADP-ribose) polymerase in vitro of about 20 μM or less, preferably less than about 10 μM, more preferably less than about 1 μM, or preferably less than about 0.1 μM, most preferably less than about 0.01 μM.
[0051] A convenient method to determine IC 50 of a PARP inhibitor compound is a PARP assay using purified recombinant human PARP from Trevigan (Gaithersburg, Md.), as follows: The PARP enzyme assay is set up on ice in a volume of 100 microliters consisting of 100 mM Tris-HCl (pH 8.0), 1 mM MgCl 2 , 28 mM KCl, 28 mM NaCl, 3.0 μg/ml of DNase I-activated herring sperm DNA (Sigma, Mo.), 30 micromolar [ 3 H]nicotinamide adenine dinucleotide (62.5 mCi/mmole), 15 micrograms/ml PARP enzyme, and various concentrations of the compounds to be tested. The reaction is initiated by adding enzyme and incubating the mixture at 25° C. After 2 minutes of incubation, the reaction is terminated by adding 500 microliters of ice cold 30% (w/v) trichloroacetic acid. The precipitate formed is transferred onto a glass fiber filter (Packard Unifilter-GF/C) and washed three times with 70% ethanol. After the filter is dried, the radioactivity is determined by scintillation counting. The compounds of this invention were found to have potent enzymatic activity in the range of a few nanomolar to 20 micromolar in IC 50 in this inhibition assay.
[0052] As used herein, “alkyl” means a branched or unbranched saturated hydrocarbon chain comprising a designated number of carbon atoms. For example, C 1 -C 6 straight or branched alkyl hydrocarbon chain contains 1 to 6 carbon atoms, and includes but is not limited to substituents such as methyl, ethyl, propyl, iso-propyl, butyl, iso-butyl, tert-butyl, n-pentyl, n-hexyl, and the like, unless otherwise indicated. In some embodiments, the alkyl chain is a C 1 to C 6 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 2 to C 5 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 1 to C 4 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 2 to C 4 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 3 to C 5 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 1 to C 2 branched or unbranched carbon chain. In some embodiments, the alkyl chain is a C 2 to C 3 branched or unbranched carbon chain.
[0053] “Alkenyl” means a branched or unbranched unsaturated hydrocarbon chain comprising a designated number of carbon atoms. For example, C 2 -C 6 straight or branched alkenyl hydrocarbon chain contains 2 to 6 carbon atoms having at least one double bond, and includes but is not limited to substituents such as ethenyl, propenyl, isopropenyl, butenyl, iso-butenyl, tert-butenyl, n-pentenyl, n-hexenyl, and the like, unless otherwise indicated. In some embodiments, the alkenyl chain is a C 2 to C 6 branched or unbranched carbon chain. In some embodiments, the alkenyl chain is a C 2 to C 5 branched or unbranched carbon chain. In some embodiments, the alkenyl chain is a C 2 to C 4 branched or unbranched carbon chain. In some embodiments, the alkenyl chain is a C 3 to C 5 branched or unbranched carbon chain.
[0054] “Alkoxy”, means the group —OZ wherein Z is alkyl as herein defined. Z can also be a branched or unbranched saturated hydrocarbon chain containing 1 to 6 carbon atoms.
[0055] “Cyclo”, used herein as a prefix, refers to a structure characterized by a closed ring.
[0056] “Halo” means at least one fluoro, chloro, bromo, or iodo moiety, unless otherwise indicated.
[0057] Each of “NR A R B ”, “NR X R Y ”, “NR C R D ”, and “NR E R F ” as described herein independently encompass amino (NH 2 ) as well as substituted amino. For example, NR A R B may be —NH(CH 3 ), —NH(cyclohexyl), and N(CH 2 CH 3 )(CH 3 ). When more than one substituent is of the form “NR A R B ”, “NR X R Y ”, “NR C R D ”, or “NR E R F ”, each occurrence of R A , R B , R C , R D , R X , or R Y is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl. Such examples are for illustrative purposes only and are not intended to be limiting in any way.
[0058] “Arylcarbonyl” refers to a carbonyl radical substituted with aryl as described herein. Non-limiting examples include phenylcarbonyl and naphthylcarbonyl.
[0059] “Alkylcarbonyl” refers to a carbonyl radical substituted with alkyl as described herein. Non-limiting examples include acyl and propylcarbonyl.
[0060] “Alkoxycarbonyl” refers to a carbonyl radical substituted with alkoxy as described herein. Non-limiting examples include methoxycarbonyl and tert-butyloxycarbonyl.
[0061] “Ar” or “aryl” refer to an aromatic carbocyclic moiety having one or more closed rings. Examples include, without limitation, phenyl, naphthyl, anthracenyl, phenanthracenyl, biphenyl, and pyrenyl.
[0062] “Heterocyclyl” refers to a cyclic moiety having one or more closed rings, with one or more heteroatoms (for example, oxygen, nitrogen or sulfur) in at least one of the rings, and wherein the ring or rings may independently be aromatic, nonaromatic, fused, and/or bridged, Examples include without limitation piperidinyl, piperazinyl, pyridazinyl, dihydropyridyl, tetrahydropyridyl, pyridinyl, pyrimidinyl, dihydropyrimidinyl, tetrahydrophyrimidinyl, hexahydropyrimidinyl, dihydropyrazinyl, tetrahydropyrazinyl, pyrrolidinyl, imidazolidinyl, pyrazolidinyl, pyrrolyl, dihydropyrolyl, imidazolyl, dihydroimidazoyl, pyrazolyl, dihydropyrazolyl, azepanyl, [1,2]diazepanyl, [1,3]diazepanyl, [1,4]diazepanyl, indolyl, dihydroindolyl, isoindolyl, dihydroisoindolyl, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, and tetrahydroisoquinolyl.
[0063] “Arylalkyl” refers to an alkyl radical substituted with aryl. Non-limiting examples include benzyl, phenylethyl, and phenylpropyl.
[0064] “Alkylaryl” refers to an aryl radical substituted with alkyl. Non-limiting examples include tolyl and dimethylphenyl.
[0065] “Cycloalkyl” refers to a hydrocarbon cyclic moiety that is nonaromatic. Examples include without limitation cyclopropane, cyclobutane, cyclopentane, cyclohexane, cyclopheptane, cyclooctane, cyclopentene, cyclohexene, cycloheptene, and cyclooctene.
[0066] The term “nervous insult” refers to any damage to nervous tissue and any disability or death resulting therefrom. The cause of nervous insult may be metabolic, toxic, neurotoxic, iatrogenic, thermal or chemical, and includes without limitation, ischemia, hypoxia, cerebrovascular accident, trauma, surgery, pressure, mass effect, hemorrhage, radiation, vasospasm, neurodegenerative disease, infection, Parkinson's disease, amyotrophic lateral sclerosis (ALS), myelination/demyelination process, epilepsy, cognitive disorder, glutamate abnormality and secondary effects thereof.
[0067] The term “neuroprotective” refers to the effect of reducing, arresting or ameliorating nervous insult, and protecting, resuscitating, or reviving nervous tissue that has suffered nervous insult.
[0068] The term “preventing neurodegeneration” includes the ability to prevent a neurodegenerative disease or preventing further neurodegeneration in patients who are already suffering from or have symptoms of a neurodegenerative disease.
[0069] The term “treating” refers to:
[0070] (i) preventing a disease, disorder or condition from occurring in an animal that may be predisposed to the disease, disorder and/or condition, but has not yet been diagnosed as having it; and/or
[0071] (ii) inhibiting the disease, disorder or condition, i.e., arresting its development; and/or
[0072] (iii) relieving the disease, disorder or condition, i.e., causing regression of the disease, disorder and/or condition.
[0073] The term “chemosensitizer”, as used herein, is defined as a molecule, such as a low molecular weight molecule, administered to animals in therapeutically effective amounts to potentiate the antitumoral activity of chemotherapeutic agents. Such chemosensitizers are useful, for example, to increase the tumor growth-retarding or -arresting effect of a given dose of a chemotherapeutic agent, or to improve the side-effect profile of a chemotherapeutic agent by allowing for reductions in its dose while maintaining its antitumoral efficacy.
[0074] The term “radiosensitizer”, as used herein is defined as a molecule, such as a low molecular weight molecule, administered to animals in therapeutically effective amounts to increase the sensitivity of the cells to be radiosensitized to electromagnetic radiation and/or to promote the treatment of diseases which are treatable with electromagnetic radiation. Diseases which are treatable with electromagnetic radiation include neoplastic diseases, benign and malignant tumors, and cancerous cells. Electromagnetic radiation treatment of other diseases not listed herein is also contemplated.
[0075] “Effective amount” refers to the amount required to produce the desired effect.
[0076] “Substituted” means that at least one hydrogen on a designated group is replaced with another radical, provided that the designated group's normal valence is not exceeded. With respect to any group containing one or more substituents, such groups are not intended to introduce any substitution that is sterically impractical, synthetically non-feasible and/or inherently unstable. In some embodiments of the invention as described herein, a substituent may substitute a radical, which said radical is itself a substituent. For example, in the compound shown below for illustrative purposes only, the piperazinyl ring is a heterocyclyl, which may be substituted with 0-4 substituents as described herein. In the example compound, the piperazinyl ring is substituted with arylsulfonyl wherein aryl is phenyl, and wherein the arylsulfonyl may be further substituted 0-4 times as described herein. In the example compound, the phenylsulfonyl moiety is further substituted with tert-butyl. Such example is given for illustrative purposes only and is not intended to be limiting in any way.
[0000]
[0077] “Subject” refers to a cell or tissue, in vitro or in vivo, an animal or a human. An animal or human subject may also be referred to as a “patient.”
[0078] “Animal” refers to a living organism having sensation and the power of voluntary movement, and which requires for its existence oxygen and organic food. Examples include, without limitation, members of the human, mammalian and primate species.
[0079] Broadly, the compounds and compositions of the present invention can be used to treat or prevent cell damage or death due to necrosis or apoptosis, cerebral ischemia and reperfusion injury or neurodegenerative diseases in an animal, such as a human. The compounds and compositions of the present invention can be used to extend the lifespan and proliferative capacity of cells and thus can be used to treat or prevent diseases associated therewith; they alter gene expression of senescent cells; and they radio sensitize hypoxic tumor cells. Preferably, the compounds and compositions of the invention can be used to treat or prevent tissue damage resulting from cell damage or death due to necrosis or apoptosis, and/or effect neuronal activity, either mediated or not mediated by NMD A toxicity. The compounds of the present invention are not limited to being useful in treating glutamate mediated neurotoxicity and/or NO-mediated biological pathways. Further, the compounds of the invention can be used to treat or prevent other tissue damage related to PARP activation, as described herein.
[0080] The present invention provides compounds which inhibit the in vitro and/or in vivo polymerase activity of poly(ADP-ribose) polymerase (PARP), and compositions containing the disclosed compounds.
[0081] The present invention provides methods to inhibit, limit and/or control the in vitro and/or in vivo polymerase activity of poly(ADP-ribose) polymerase (PARP) in any of solutions, cells, tissues, organs or organ systems. In one embodiment, the present invention provides methods of limiting or inhibiting PARP activity in a mammal, such as a human, either locally or systemically.
[0082] The compounds of the invention act as PARP inhibitors to treat or prevent cancers by chemopotentiating the cytotoxic effects of the chemotherapeutic agents. The compounds of the invention act as PARP inhibitors to treat or prevent cancers by sensitizing cells to the cytotoxic effects of radiation. The compounds of the invention act as PARP inhibitors to treat or prevent BRCA1/2-associated breast cancer.
[0083] The compounds of the present invention may possess one or more asymmetric center(s) and thus can be produced as mixtures (racemic and non-racemic) of stereoisomers, or as individual enantiomers or diastereomers. The individual stereoisomers may be obtained by using an optically active staring material, by resolving a racemic or non-racemic mixture of an intermediate at some appropriate stage of the synthesis, or by resolution of the compound of Formula (I). It is understood that the individual stereoisomers as well as mixtures (racemic and non-racemic) of stereoisomers are encompassed by the scope of the present invention.
[0084] The compounds of the invention are useful in a free base form, in the form of pharmaceutically acceptable salts, pharmaceutically acceptable hydrates, pharmaceutically acceptable esters, pharmaceutically acceptable solvates, pharmaceutically acceptable prodrugs, pharmaceutically acceptable metabolites, and in the form of pharmaceutically acceptable stereoisomers. These forms are all within the scope of the disclosure.
[0085] “Pharmaceutically acceptable salt”, “hydrate”, “ester” or “solvate” refers to a salt, hydrate, ester, or solvate of the inventive compounds which possesses the desired pharmacological activity and which is neither biologically nor otherwise undesirable. Organic acids can be used to produce salts, hydrates, esters, or solvates such as acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, p-toluene sulfonate, bisulfate, sulfamate, sulfate, naphthylate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentane-propionate, digluconate, dodecylsulfate, ethanesulfonate, fumarate, glucoheptanoate, glycerophosphate, hemisulfate heptanoate, hexanoate, 2-hydroxyethanesulfonate, lactate, maleate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, oxalate, tosylate and undecanoate. Inorganic acids can be used to produce salts, hydrates, esters, or solvates such as hydrochloride, hydrobromide, hydroiodide, and thiocyanate.
[0086] Examples of suitable base salts, hydrates, esters, or solvates include hydroxides, carbonates, and bicarbonates of ammonia, alkali metal salts such as sodium, lithium and potassium salts, alkaline earth metal salts such as calcium and magnesium salts, aluminum salts, and zinc salts.
[0087] Salts, hydrates, esters, or solvates may also be formed with organic bases. Organic bases suitable for the formation of pharmaceutically acceptable base addition salts, hydrates, esters, or solvates of the compounds of the present invention include those that are non-toxic and strong enough to form such salts, hydrates, esters, or solvates. For purposes of illustration, the class of such organic bases may include mono-, di-, and trialkylamines, such as methylamine, dimethylamine, triethylamine and dicyclohexylamine; mono-, di- or trihydroxyalkylamines, such as mono-, di-, and triethanolamine; amino acids, such as arginine and lysine; guanidine; N-methyl-glucosamine; N-methyl-glucamine; L-glutamine; N-methyl-piperazine; morpholine; ethylenediamine; N-benzyl-phenethylamine; (trihydroxy-methyl)aminoethane; and the like. See, for example, “Pharmaceutical Salts,” J. Pharm. Sci., 66:1, 1-19 (1977). Accordingly, basic nitrogen-containing groups can be quaternized with agents including: lower alkyl halides such as methyl, ethyl, propyl, and butyl chlorides, bromides and iodides; dialkyl sulfates such as dimethyl, diethyl, dibutyl and diamyl sulfates; long chain halides such as decyl, lauryl, myristyl and stearyl chlorides, bromides and iodides; and aralkyl halides such as benzyl and phenethyl bromides.
[0088] The acid addition salts, hydrates, esters, or solvates of the basic compounds may be prepared either by dissolving the free base of a compound of the present invention in an aqueous or an aqueous alcohol solution or other suitable solvent containing the appropriate acid or base, and isolating the salt by evaporating the solution. Alternatively, the free base of a compound of the present invention can be reacted with an acid, as well as reacting a compound of the present invention having an acid group thereon with a base, such that the reactions are in an organic solvent, in which case the salt separates directly or can be obtained by concentrating the solution.
[0089] “Pharmaceutically acceptable prodrug” refers to a derivative of the inventive compounds which undergoes biotransformation prior to exhibiting its pharmacological effect(s). The prodrug is formulated with the objective(s) of improved chemical stability, improved patient acceptance and compliance, improved bioavailability, prolonged duration of action, improved organ selectivity, improved formulation (e.g., increased hydrosolubility), and/or decreased side effects (e.g., toxicity). The prodrug can be readily prepared from the inventive compounds using methods known in the art, such as those described by Burgers Medicinal Chemistry and Drug Chemistry, Fifth Ed, Vol. 1, pp. 172-178, 949-982 (1995). For example, the inventive compounds can be transformed into prodrugs by converting one or more of the hydroxy or carboxy groups into esters.
[0090] “Pharmaceutically acceptable metabolite” refers to drugs that have undergone a metabolic transformation. After entry into the body, most drugs are substrates for chemical reactions that may change their physical properties and biologic effects. These metabolic conversions, which usually affect the polarity of the compound, alter the way in which drugs are distributed in and excreted from the body. However, in some cases, metabolism of a drug is required for therapeutic effect. For example, anticancer drugs of the antimetabolite class must be converted to their active forms after they have been transported into a cancer cell. Since most drugs undergo metabolic transformation of some kind, the biochemical reactions that play a role in drug metabolism may be numerous and diverse. The main site of drug metabolism is the liver, although other tissues may also participate.
[0091] Further still, the methods of the invention can be used to treat cancer and to chemosensitize and radio sensitize cancer and/or tumor cells. The term “cancer,” as used herein, is defined broadly. The compounds of the present invention can potentiate the effects of “anti-cancer agents,” which term also encompasses “anti-tumor cell growth agents,” “chemotherapeutic agents,” “cytostatic agents,” “cytotoxic agents,” and “anti-neoplastic agents”. The term “BRCA1/2-associated breast cancer” encompasses breast cancer in which the breast cancer cells are deficient in the breast cancer tumor suppressor genes BRCA1 and/or BRCA2.
[0092] For example, the methods of the invention are useful for treating cancers such as ACTH-producing tumors, acute lymphocytic leukemia, acute nonlymphocytic leukemia, cancer of the adrenal cortex, bladder cancer, brain cancer, breast cancer, cervical cancer, chronic lymphocytic leukemia, chronic myelocytic leukemia, colorectal cancer, cutaneous T-cell lymphoma, endometrial cancer, esophageal cancer, Ewing's sarcoma, gallbladder cancer, hairy cell leukemia, head and neck cancer, Hodgkin's lymphoma, Kaposi's sarcoma, kidney cancer, liver cancer, lung cancer (small and/or non-small cell), malignant peritoneal effusion, malignant pleural effusion, melanoma, mesothelioma, multiple myeloma, neuroblastoma, non-Hodgkin's lymphoma, osteosarcoma, ovarian cancer, ovary (germ cell) cancer, prostate cancer, pancreatic cancer, penile cancer, retinoblastoma, skin cancer, soft-tissue sarcoma, squamous cell carcinomas, stomach cancer, testicular cancer, thyroid cancer, trophoblastic neoplasms, uterine cancer, vaginal cancer, cancer of the vulva and Wilm's tumor.
[0093] In some non-limiting embodiments, the cancer and/or tumor cells are selected from the group consisting of brain cancer, melanoma, head and neck cancer, non small cell lung cancer, testicular cancer, ovarian cancer, colon cancer and rectal cancer.
[0094] The present invention also relates to a pharmaceutical composition comprising (i) a therapeutically effective amount of a compound of a compound of Formula (I) and (ii) a pharmaceutically acceptable carrier.
[0095] The above discussion relating to the preferred embodiments' utility and administration of the compounds of the present invention also applies to the pharmaceutical composition of the present invention.
[0096] The term “pharmaceutically acceptable carrier” as used herein refers to any carrier, diluent, excipient, suspending agent, lubricating agent, adjuvant, vehicle, delivery system, emulsifier, disintegrant, absorbent, preservative, surfactant, colorant, flavorant, or sweetener.
[0097] For these purposes, the composition of the invention may be administered orally, parenterally, by inhalation spray, adsorption, absorption, topically, rectally, nasally, bucally, vaginally, intraventricularly, via an implanted reservoir in dosage formulations containing conventional non-toxic pharmaceutically-acceptable carriers, or by any other convenient dosage form The term parenteral as used herein includes subcutaneous, intravenous, intramuscular, intraperitoneal, intrathecal intraventricular, intrasternal, and intracranial injection or infusion techniques.
[0098] When administered parenterally, the composition will normally be in a unit dosage, sterile injectable form (solution, suspension or emulsion) which is preferably isotonic with the blood of the recipient with a pharmaceutically acceptable carrier. Examples of such sterile injectable forms are sterile injectable aqueous or oleaginous suspensions. These suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents. The sterile injectable forms may also be sterile injectable solutions or suspensions in non-toxic parenterally-acceptable diluents or solvents, for example, as solutions in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, saline, Ringer's solution, dextrose solution, isotonic sodium chloride solution, and Hanks' solution. In addition, sterile, fixed oils are conventionally employed as solvents or suspending mediums. For this purpose, any bland fixed oil may be employed including synthetic mono- or di-glycerides, corn, cottonseed, peanut, and sesame oil. Fatty acids such as ethyl oleate, isopropyl myristate, and oleic acid and its glyceride derivatives, including olive oil and castor oil, especially in their polyoxyethylated versions, are useful in the preparation of injectables. These oil solutions or suspensions may also contain long-chain alcohol diluents or dispersants.
[0099] Sterile saline is a preferred carrier, and the compounds are often sufficiently water soluble to be made up as a solution. The carrier may contain minor amounts of additives, such as substances that enhance solubility, isotonicity, and chemical stability, e.g., anti-oxidants, buffers and preservatives.
[0100] Formulations suitable for nasal or buccal administration (such as self-propelling powder dispensing formulations) may comprise about 0.1% to about 5% w/w, for example 1% w/w of active ingredient. The formulations for human medical use of the present invention comprise an active ingredient in association with a pharmaceutically acceptable carrier therefore and optionally other therapeutic ingredient(s).
[0101] When administered orally, the composition will usually be formulated into unit dosage forms such as tablets, cachets, powder, granules, beads, chewable lozenges, capsules, liquids, aqueous suspensions or solutions, or similar dosage forms, using conventional equipment and techniques known in the art. Such formulations typically include a solid, semisolid, or liquid carrier. Exemplary carriers include lactose, dextrose, sucrose, sorbitol, mannitol, starches, gum acacia, calcium phosphate, mineral oil, cocoa butter, oil of theobroma, alginates, tragacanth, gelatin, syrup, methyl cellulose, polyoxyethylene sorbitan monolaurate, methyl hydroxybenzoate, propyl hydroxybenzoate, talc, magnesium stearate, and the like.
[0102] The composition of the invention is preferably administered as a capsule or tablet containing a single or divided dose of the compound of Formula (I) or pharmaceutically acceptable salt thereof. Tthe composition may be administered as a sterile solution, suspension, or emulsion, in a single or divided dose. Tablets may contain carriers such as lactose and corn starch, and/or lubricating agents such as magnesium stearate. Capsules may contain diluents including lactose and dried corn starch.
[0103] A tablet may be made by compressing or molding the active ingredient optionally with one or more accessory ingredients. Compressed tablets may be prepared by compressing, in a suitable machine, the active ingredient in a free-flowing form such as a powder or granules, optionally mixed with a binder, lubricant, inert diluent, surface active, or dispersing agent Molded tablets may be made by molding in a suitable machine, a mixture of the powdered active ingredient and a suitable carrier moistened with an inert liquid diluent.
[0104] The compounds of this invention may also be administered rectally in the form of suppositories. These compositions can be prepared by mixing the drug with a suitable non-irritating excipient which is solid at room temperature, but liquid at rectal temperature, and, therefore, will melt in the rectum to release the drug. Such materials include cocoa butter, beeswax, and polyethylene glycols.
[0105] Compositions and methods of the invention also may utilize controlled release technology. Thus, for example, the disclosed compounds may be incorporated into a hydrophobic polymer matrix for controlled release over a period of days. The composition of the invention may then be molded into a solid implant, or externally applied patch, suitable for providing efficacious concentrations of the PARP inhibitors over a prolonged period of time without the need for frequent re-dosing. Such controlled release films are well known to the art. Particularly preferred are transdermal delivery systems. Other examples of polymers commonly employed for this purpose that may be used in the present invention include nondegradable ethylene-vinyl acetate copolymer a degradable lactic acid-glycolic acid copolymers which may be used externally or internally. Certain hydrogels such as poly(hydroxyethylmethacrylate) or poly(vinylalcohol) also may be useful, but for shorter release cycles than the other polymer release systems, such as those mentioned above.
[0106] In an embodiment, the carrier is a solid biodegradable polymer or mixture of biodegradable polymers with appropriate time release characteristics and release kinetics. The composition of the invention may then be molded into a solid implant suitable for providing efficacious concentrations of the compounds of the invention over a prolonged period of time without the need for frequent re-dosing. The composition of the present invention can be incorporated into the biodegradable polymer or polymer mixture in any suitable manner known to one of ordinary skill in the art and may form a homogeneous matrix with the biodegradable polymer, or may be encapsulated in some way within the polymer, or may be molded into a solid implant.
[0107] In one embodiment, the biodegradable polymer or polymer mixture is used to form a soft “depot” containing the pharmaceutical composition of the present invention that can be administered as a flowable liquid, for example, by injection, but which remains sufficiently viscous to maintain the pharmaceutical composition within the localized area around the injection site. The degradation time of the depot so formed can be varied from several days to a few years, depending upon the polymer selected and its molecular weight. By using a polymer composition in injectable form, even the need to make an incision may be eliminated. In any event, a flexible or flowable delivery “depot” will adjust to the shape of the space it occupies with the body with a minimum of trauma to surrounding tissues. The pharmaceutical composition of the present invention is used in amounts that are therapeutically effective, and may depend upon the desired release profile, the concentration of the pharmaceutical composition required for the sensitizing effect, and the length of time that the pharmaceutical composition has to be released for treatment.
[0108] The compounds of the invention are used in the composition in amounts that are therapeutically effective. The compositions may be sterilized and/or contain adjuvants, such as preserving, stabilizing, welling, or emulsifying agents, solution promoters, salts for regulating the osmotic pressure, and/or buffers. In addition, they may also contain other therapeutically valuable substances, such as, without limitation, the specific chemotherapeutic agents recited herein. The compositions are prepared according to conventional mixing, granulating, or coating methods, and contain about 0.1 to 75% by weight, preferably about 1 to 50% by weight, of the compound of the invention.
[0109] To be effective therapeutically as central nervous system targets, the compounds of the present invention should readily penetrate the blood-brain barrier when peripherally administered. Compounds which cannot penetrate the blood-brain barrier can be effectively administered by an intraventricular route or other appropriate delivery system suitable for administration to the brain.
[0110] For medical use, the amount required of the active ingredient to achieve a therapeutic effect will vary with the particular compound, the route of administration, the mammal under treatment, and the particular disorder or disease being treated. A suitable systematic dose of a compound of the present invention or a pharmacologically acceptable salt thereof for a mammal suffering from, or likely to suffer from, any of condition as described hereinbefore is in the range of about 0.1 mg/kg to about 100 mg/kg of the active ingredient compound, the typical dosage being about 1 to about 10 mg/kg.
[0111] It is understood, however, that a specific dose level for any particular patient will depend upon a variety of factors including the activity of the specific compound employed, the age, body weight, general health, sex, diet, time of administration, rate of excretion, drug combination, and the severity of the particular disease being treated and form of administration.
[0112] It is understood that the ordinarily skilled physician or veterinarian will readily determine and prescribe the effective amount of the compound for prophylactic or therapeutic treatment of the condition for which treatment is administered. In so proceeding, the physician or veterinarian can, for example, employ an intravenous bolus followed by an intravenous infusion and repeated administrations, parenterally or orally, as considered appropriate. While it is possible for an active ingredient to be administered alone, it is preferable to present it as a formulation.
[0113] When preparing dosage form incorporating the compositions of the invention, the compounds may also be blended with conventional excipients such as binders, including gelatin, pregelatinized starch, and the like; lubricants, such as hydrogenated vegetable oil, stearic acid, and the like; diluents, such as lactose, mannose, and sucrose; disintegrants, such as carboxymethylcellulose and sodium starch glycolate; suspending agents, such as povidone, polyvinyl alcohol, and the like; absorbants, such as silicon dioxide; preservatives, such as methylparaben, propylparaben, and sodium benzoate; surfactants, such as sodium lauryl sulfate, polysorbate 80, and the like; colorants; flavorants; and sweeteners. Pharmaceutically acceptable excipients are well known in the pharmaceutical arts and are described, for example, in Remington's Pharmaceutical Sciences, Mack Publishing Co., Easton, Pa. (e.g., 20 th Ed., 2000), and Handbook of Pharmaceutical Excipients, American Pharmaceutical Association, Washington, D.C., (e.g., 1 st , 2 nd and 3 rd Eds., 1986, 1994, and 2000, respectively).
[0114] The present invention relates to the use of a compound of Formula (I) in the preparation of a medicament for the treatment of any disease or disorder in an animal described herein. In an embodiment, the compounds of the present invention are used to treat cancer. In a preferred embodiment, the compounds of the present invention are used to potentiate the cytotoxic effects of ionizing radiation. In such an embodiment, the compounds of the present invention act as a radiosensitizer. In an alternative preferred embodiment, the compounds of the present invention are used to potentiate the cytotoxic effects of chemotherapeutic agents. In such an embodiment, the compounds of the present invention act as a chemosensitizer. In another preferred embodiment, the compounds of the present invention are used to inhibit the growth of cells having defects in the homologous recombination (HR) pathway of double-stranded DNA repair.
[0115] Any pharmacologically-acceptable chemotherapeutic agent that acts by damaging DNA is suitable as the chemotherapeutic agent of the present invention. In particular, the present invention contemplates the use of a chemotherapeutically effective amount of at least one chemotherapeutic agent including, but not limited to: temozolomide, adriamycin, camptothecin, carboplatin, cisplatin, daunorubicin, docetaxel, doxorubicin, interferon-alpha, interferon-beta, interferon-gamma, interleukin 2, irinotecan, paclitaxel, topotecan, ataxoid, dactinomycin, danorubicin, 4′-deoxydoxorubicin, bleomycin, pilcamycin, mitomycin, neomycin, gentamycin, etoposide 4-OH cyclophosphamide, a platinum coordination complex, topotecan, and mixtures thereof. According to a preferred aspect, the chemotherapeutic agent is temozolomide.
[0116] The invention contained herein demonstrates the usefulness of the compounds and compositions of the present invention in treating and/or preventing cancer, such as by radio sensitizing and/or chemosensitizing tumor and/or cancer cells to chemotherapeutic agents, and to inhibit the growth of cells having defects in the homologous recombination (HR) pathway of double-stranded DNA repair.
[0117] The following examples are for illustrative purposes only and are not intended to limit the scope of the application.
[0118] In one embodiment, the present invention provides a tetraaza phenalen-3-one compound of Formula (I), or a pharmaceutically acceptable salt thereof:
[0000]
[0000] wherein R is
(a) NR 1 R 2 , wherein R 1 is selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy,
NR A R B (C 1 -C 6 straight or branched chain alkyl), NR A R B (C 2 -C 6 straight or branched chain alkenyl), (C 1 -C 6 straight or branched chain alkyl)carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 3 -C 8 cycloalkyl)carbonyl,
(C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl, (C 3 -C 8 cycloalkyl)oxycarbonyl,
arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl), aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl),
(C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl,
heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl); wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, and wherein each of R A and R B are independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl;
and R 2 is selected from the group consisting of C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy, NR X R Y (C 1 -C 6 straight or branched chain alkyl), NR X R Y (C 2 -C 6 straight or branched chain alkenyl), (C 1 -C 6 straight or branched chain alkyl)carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 3 -C 8 cycloalkyl)carbonyl, (C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl,
(C 3 -C 8 cycloalkyl)oxycarbonyl, arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl), aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl), (C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl,
heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl); wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, and wherein each of R X and R Y are independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl;
wherein R 1 and R 2 are independently substituted with between 0 and 4 substituents, each independently selected from halo, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, and amino; and provided that R 1 and R 2 may not both be methyl, and R 2 may not be (phenyl)prop-1-yl when R 1 is hydrogen; or
(b) aryloxy, substituted with between 0 and 4 substituents, each independently selected from the group consisting of halo, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, Q-Ce straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, NR C R D , NR C R D (C 1 -C 6 straight or branched chain alkyl), and NR C R D (C 2 -C 6 straight or branched chain alkenyl), wherein each of R C and R D is independently selected from the group consisting of hydrogen, C 1 -C 5 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; and when more than one substituent is of the form NR C R D , each occurrence of R C and R D is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; or
(c) a heterocyclyl having between 1 and 7 heteroatoms independently selected from O, N, or S; and having between 0 and 4 substituents independently selected from the group consisting of halo, haloalkyl, hydroxyl, nitro, trifluoromethyl, trifluoroethyl, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 1 -C 6 alkoxy, C 2 -C 6 alkenyloxy, phenyl, phenoxy, benzyloxy, amino, thiocarbonyl, cyano, imino, NR E R F (C 1 -C 6 straight or branched chain alkyl), NR E R F (C 2 -C 6 straight or branched chain alkenyl) sulfhydryl, thioalkyl, dioxa-spiroethyl, (C 1 -C 6 straight or branched chain alkyl) carbonyl, (C 2 -C 6 straight or branched chain alkenyl)carbonyl, (C 1 -C 6 straight or branched chain alkyl)oxycarbonyl, (C 2 -C 6 straight or branched chain alkenyl)oxycarbonyl, arylcarbonyl, sulfonyl, arylsulfonyl, aryl(C 1 -C 6 straight or branched chain alkyl), aryl(C 2 -C 6 straight or branched chain alkenyl), aryl(C 3 -C 8 cycloalkyl), (C 1 -C 6 straight or branched chain alkyl)aryl, (C 2 -C 6 straight or branched chain alkenyl)aryl, (C 3 -C 8 cycloalkyl)aryl, aryl, heterocyclyl, heterocyclyl(C 1 -C 6 straight or branched chain alkyl), and heterocyclyl(C 2 -C 6 straight or branched chain alkenyl), wherein each heterocyclyl has between 1 and 7 heteroatoms independently selected from O, N, or S, wherein each of R E and R F is independently selected from the group consisting of hydrogen, C 3 -C 8 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; and when more than one substituent is of the form NR E R F each occurrence of R E and R F is independently selected from the group consisting of hydrogen, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, and C 3 -C 8 cycloalkyl; wherein each of said 0-4 substituents is independently substituted with between 0 and 4 further substituents, and each said further substituent is independently selected from halo, C 1 -C 6 straight or branched chain alkyl, C 2 -C 6 straight or branched chain alkenyl, C 3 -C 8 cycloalkyl, C 1 -C 6 alkoxy, trifluoromethyl, trifluoroethyl, and amino; provided that R has at least one substituent when R is an N-piperidinyl, N-pyrrolidinyl or an N-morpholinyl group.
[0119] In some embodiments each ring of each heterocycle of Formula (I) is independently 5-7 atoms in size.
[0120] Some embodiments include one, two or three nitrogen atoms in at least one ring of the heterocycle of Formula (I).
[0121] In some embodiments, the heterocyclyl of Formula (I) comprises 1-3 rings. In some embodiments, the heterocyclyl has 1-7 heteroatoms independently selected from O, N, and S.
[0122] In some embodiments, the heterocyclyl of Formula (I) is selected from the group consisting of piperidinyl, piperazinyl, pyridazinyl, dihydropyridyl, tetrahydropyridyl, pyridinyl, pyrimidinyl, dihydropyrimidinyl, tetrahydrophyrimidinyl, hexahydropyrimidinyl, dihydropyrazinyl, tetrahydropyrazinyl, pyrrolidinyl, imidazolidinyl, pyrazolidinyl, pyrrolyl, dihydropyrolyl, imidazolyl, dihydroimidazoyl, pyrazolyl, dihydropyrazolyl, azepanyl, [1,2]diazepanyl, [1,3]diazepanyl, [1,4]diazepanyl, indolyl, dihydroindolyl, isoindolyl, dihydroisoindolyl, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, and tetrahydroisoquinolyl.
[0123] In another embodiment, the present invention provides a compound selected from the group consisting of
[0000]
[0000] and pharmaceutically acceptable salts thereof.
[0124] In some embodiments the invention provides the compound which is
[0000]
[0000] or a pharmaceutically acceptable salt thereof.
[0125] In some embodiments the invention provides the compound which is
[0000]
[0000] or a pharmaceutically acceptable salt thereof.
[0126] In some embodiments the present invention provides a method of chemo sensitizing cancer cells in a mammal in need of chemotherapy, comprising administering to said mammal a compound of Formula (I) as described herein, or a pharmaceutically acceptable salt thereof. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier. In some embodiments, the chemosensitization method further comprises administering to said mammal a chemotherapeutic agent. In some embodiments, said chemosensitizing compound and said chemotherapeutic agent are administered essentially simultaneously.
[0127] In some embodiments the present invention provides a method of chemo sensitizing cancer cells in a mammal in need of chemotherapy, comprising administering to said mammal a compound selected from the group consisting of compounds 7-28, 30-46, 50-66, 69, 72, 74-76, and pharmaceutically acceptable salts thereof, as described herein. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier. In some embodiments, the chemosensitization method further comprises administering to said mammal a chemotherapeutic agent. In some embodiments, said chemosensitizing compound and said chemotherapeutic agent are administered essentially simultaneously.
[0128] In some embodiments, the chemotherapeutic agent of the invention is selected is selected from the group consisting of temozolomide, adriamycin, camptothecin, carboplatin, cisplatin, daunorubicin, docetaxel, doxorubicin, interferon-alpha, interferon-beta, interferon-gamma, interleukin 2, irinotecan, paclitaxel, topotecan, a taxoid, dactinomycin, danorubicin, 4′-deoxydoxorubicindeoxydoxorubicin, bleomycin, pilcamycin, mitomycin, neomycin, gentamycin, etoposide, 4-OH cyclophosphamide, a platinum coordination complex, and mixtures thereof. In some embodiments, the chemotherapeutic agent is temozolomide or a salt thereof.
[0129] In some embodiments, the present invention provides a method of radiosensitizing cancer cells in a mammal in need of radiation therapy comprising administering to said mammal a compound of Formula (I) as described herein, or a pharmaceutically acceptable salt thereof. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier.
[0130] In some embodiments, the present invention provides a method of radiosensitizing cancer cells in a mammal in need of radiation therapy comprising administering to said mammal a compound selected from the group consisting of compounds 7-28, 30-46, 50-66, 69, 72, 74-76, and pharmaceutically acceptable salts thereof, as described herein. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier.
[0131] In some embodiments, the invention provides a pharmaceutical composition comprising a compound of Formula (I) as described herein, or a pharmaceutically acceptable salt thereof, and a pharmaceutically acceptable carrier. In some embodiments, the pharmaceutical composition further comprises a chemotherapeutic agent as described herein.
[0132] In some embodiments, the invention provides a pharmaceutical composition comprising a compound selected from the group consisting of compounds 7-28, 30-46, 50-66, 69, 72, 74-76, and pharmaceutically acceptable salts thereof, as described herein. In some embodiments, the pharmaceutical composition further comprises a chemotherapeutic agent as described herein.
[0133] In some embodiments, the cancer cells treated by the chemo sensitizing and/or radiosensitizing methods of the invention are selected from the group consisting of ACTH-producing tumors, acute lymphocytic leukemia, acute nonlymphocytic leukemia, cancer of the adrenal cortex, bladder cancer, brain cancer, breast cancer, cervical cancer, chronic lymphocytic leukemia, chronic myelocytic leukemia, colorectal cancer, cutaneous T-cell lymphoma, endometrial cancer, esophageal cancer, Ewing's sarcoma, gallbladder cancer, hairy cell leukemia, head and neck cancer, Hodgkin's lymphoma, Kaposi's sarcoma, kidney cancer, liver cancer, lung cancer (small and/or non-small cell), malignant peritoneal effusion, malignant pleural effusion, melanoma, mesothelioma, multiple myeloma, neuroblastoma, non-Hodgkin's lymphoma, osteosarcoma, ovarian cancer, ovary (germ cell) cancer, prostate cancer, pancreatic cancer, penile cancer, retinoblastoma, skin cancer, soft-tissue sarcoma, squamous cell carcinomas, stomach cancer, testicular cancer, thyroid cancer, trophoblastic neoplasms, uterine cancer, vaginal cancer, cancer of the vulva and Wilm's tumor. In some embodiments, the cancer cells treated by the chemo sensitizing and/or radiosensitizing methods of the invention are selected from the group consisting of brain cancer, melanoma, head and neck cancer, testicular cancer, ovarian cancer, breast cancer, non small cell lung cancer, and rectal cancer.
[0134] In some embodiments, the invention provides a method of treating a mammal having a cancer characterized by having a defect in the homologous recombination (HR) pathway of double-stranded DNA repair, comprising administering to said mammal a compound of Formula (I) as described herein, or a pharmaceutically acceptable salt thereof. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier. In some embodiments, the cancer cells have a phenotype selected from the group consisting of i) a BRCA-1 defect, ii) a BRCA-2 defect, iii) a BRCA-1 and BRCA-2 defect, and iv) Fanconi anemia. In some embodiments, the cancer cells are selected from breast cancer or ovarian cancer.
[0135] In some embodiments, the invention provides a method of treating a mammal having a cancer characterized by having a defect in the homologous recombination (HR) pathway of double-stranded DNA repair, comprising administering to said mammal a compound selected from the group consisting of compounds 7-28, 30-46, 50-66, 69, 72, 74-76, and pharmaceutically acceptable salts thereof, as described herein. In some embodiments, said mammal is a human. In some embodiments, said administration is administration of a pharmaceutical composition comprising said compound and a pharmaceutically acceptable carrier. In some embodiments, the cancer cells have a phenotype selected from the group consisting of i) a BRCA-1 defect, ii) a BRCA-2 defect, iii) a BRCA-1 and BRCA-2 defect, and iv) Fanconi anemia. In some embodiments, the cancer cells are selected from breast cancer or ovarian cancer.
Synthetic Procedures for the Disclosed Compounds
[0136]
Procedure A: Preparation of 3-nitro-phthalic acid dimethyl ester, 2
[0137] To a stirred solution of 4-nitro-isobenzofuran-1,3-dione (150 g, 0.78 mol), 1, in 2 L of MeOH was added 50 mL of concentrated sulfuric acid. The reaction was heated to reflux for 16 hours. The mixture solution was cooled to room temperature and then poured into 3 L of ice water and resulted in a heavy white precipitate. This was triturated for 15 minutes and the precipitated was filtered off and the solid was washed with water thoroughly and dried to afford 120 g of 3-nitro-phthalic acid dimethyl ester, 2, as a white solid (65%). 1 H NMR (300 MHz, DMSO-d 6 ): 8.54 (d, J=7.25 Hz, 1H), 8.42 (d, J=7.82 Hz, 1H), 7.98 (t, J=8.20 Hz, 1H), 3.99 (s, 3H), 3.98 (s, 3H). 13 C NMR: 52.03, 52.29, 111.02, 115.67, 119.08, 131.80, 133.68, 148.80, 167.64, 168.63.
Procedure B: Preparation of 3-amino-phthalic acid dimethyl ester, 3
[0138] The compound 2 (205 g, 1.0 mol) was dissolved in 2 L of MeOH. Catalytic 10% Pd/C was added and the solution was hydrogenated under H 2 (45 psi) on a Parr hydrogenation apparatus at room temperature overnight. Filtered through celite and evaporated to give a quantitative yield of 3-amino-phthalic acid dimethyl ester, 3. 1 H NMR (300 MHz, DMSO-d 6 ): 7.26 (t, J=7.33 Hz, 1H), 6.94 (d, J=8.34 Hz, 1H), 6.77 (d, J=8.33 Hz, 1H), 6.12 (s, 2H), 3.77 (s, 3H), 3.76 (s, 3H). 13 C NMR: 51.51, 51.77, 110.50, 115.16, 118.56, 131.26, 133.16, 148.28, 167.12, 168.11.
Procedure C: Preparation of 2-chloromethyl-4-oxo-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 4
[0139] 100 mL of chloroacetonitrile was set stirring in 130 mL of 1,4 dioxane at room temperature. Dry HCl gas was bubbled through the solution for thirty minutes followed by the addition of 30 g of 3-amino-1,2-phthalic acid dimethyl ester, 3. The reaction was refluxed for approximately three hours, resulting in a heavy white precipitate. The suspension was cooled with an ice bath, filtered and washed with pentane to remove any residual solvents. 30 g (83%) of an analytically pure white solid, 4, was isolated. H NMR (300 MHz, DMSO-d 6 ): 7.88 (t, J=8.33 Hz, 1H), 7.79 (d, J=7.08 Hz, 1H), 7.52 (d, J=7.33 Hz, 1H), 4.60 (s, 2H), 3.84 (s, 3H); 13 C NMR: 42.21, 54.86, 119.95, 127.77, 130.86, 135.71, 136.78, 150.59, 155.70, 162.49, 171.24.
General Procedure D: Preparation of Compounds, 5
[0140] Displacement of the chloro group of compound 4 with nucleophiles such as amine using General procedure D provides the compounds 5. To a solution of the chloro compound 4 in dry DMF or MeCN is added potassium carbonate and a nucleophile such as an amine. The reaction mixture is heated to 70° C. for 12 hours and cooled to room temperature. Water is added to the reaction mixture, followed by ethyl acetate. The organic layer is collected, washed with water, brine and dried over sodium sulfate. The solvents are removed in vacuum. The residue is purified by column chromatography on silica gel using ethyl acetate/hexanes as eluent to give the products 5 in 50-95% yield. An example was given in the preparation of compound 7.
General Procedure E: Preparation of Compounds, 6
[0141] A 2,9-Dihydro-1,2,7,9-tetraaza-phenalen-3-one ring can be formed by condensation of the compounds 6 with hydrazine. To a solution of the compounds 6 in absolute ethanol is added excess anhydrous hydrazine at room temperature. The solution is refluxed for overnight and cooled to room temperature. Ice-cold water is added and white solid is separated. The solid is collected by vacuum filtration and washed with water and small amount of methanol to give white solid products 6 in 40-90% yield. An example was given in the preparation of compound 7.
Example 1
Preparation of 8-(4-hydroxy-piperidin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 7
[0142] Following the General Procedure D: A solution of MeCN (25 ml), 4-hydroxypiperidine (0.46 mg, 4.5 mmol), 4 (1.0 g, 3.9 mmol), and potassium carbonate (1 g, 7 mmol) was set refluxing under nitrogen and stirred overnight. Reaction mixture was evaporated to dryness and extracted with dichloromethane. Purified with a silica column using 9:1 dichloromethane/MeOH to afford 1.05 g (84%) of an off-white solid, 2-(4-Hydroxy-piperidin-1-ylmethyl)-4-oxo-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 7a.
[0143] Following the General Procedure E: To a solution of compound 7a (1.0 g, 3.1 mmol) in EtOH (20 mL) when refluxing was added hydrazine monohydrate (7 mL, large excess) and heated overnight. Reaction was cooled to RT and H 2 O (15 mL) was added resulting in a heavy white precipitate. Filtered and washed with 1:1 EtOH/H 2 O to afford 0.6 g (64%) of an analytically pure white solid, 7. MP: 168-171° C.; MS (ES+): 300; 1 H NMR (300 MHz, CD 3 OD): 1.46-1.55 (m, 2H), 1.71-1.75 (m, 2H) 2.15-2.23 (m, 2H) 2.70-2.75 (m, 2H) 3.16-3.18 (m, 1H) 3.25 (s, 2H) 3.47-3.55 (m, 1H) 7.30-7.33 (m, 1H) 7.60-7.64 (m, 2H). Anal. Calcd. for C 15 H 17 N 5 O 2 .1.7H 2 O: C, 56.45; H, 6.06; N, 21.94. Found: C, 56.10; H, 6.00; N, 22.25.
[0144] The compound 7 can be formulated with an acid. For example: to a solution of 7 (0.6 g, 2.0 mmol) in 10 mL of 1,4 dioxane/DMF (9:1) at 90° C. was added MsOH (0.14 mL, 2.1 mmol) resulting in a heavy white precipitate. Filtered and triturated in diethyl ether to afford 0.5 g (63%) of an off-white solid, mesylate salt of 7. H NMR (300 MHz, DMSO-d 6 ): 1.55-1.58 (m, 2H), 1.78-1.82 (m, 2H), 2.15 (s, 3H), 3.15-3.50 (m, 4H), 3.63-3.65 (m, 1H), 4.04 (s, 2H), 7.24 (d, J=8.5 Hz, 1H), 7.51-7.66 (m, 2H), 11.73 (s, 1H)
[0145] Anal. Calcd. for C 15 H 17 N 5 O 2 . 1CH 3 SO 3 H. 2H 2 O: C, 44.54; H, 5.84; N, 16.23, S, 7.43. Found: C, 44.48; H, 5.76; N, 16.27, S, 7.60.
[0146] The following compounds were synthesized from the similar procedures of preparation of compound 7, using the appropriate corresponding amines.
Preparation of 8-(4-phenyl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 8
[0147] Synthesized using 1-phenylpiperazine for General Procedure D. 52% overall yield for last two steps. MS (ES+): 361; H NMR (300 MHz, DMSO-d 6 ): 2.65-2.68 (m, 4H), 3.19-3.22 (m, 4H) 3.39 (s, 2H); 6.78 (t, J=7.2 Hz, 1H); 6.95 (d, J=8.0 Hz, 2H), 7.19 (t, J=7.2 Hz, 2H), 7.48-7.51 (m, 1H), 7.62-7.64 (d, J=7.2 Hz, 1H), 7.75 (t, J=8.0 Hz, 1H), 11.23 (s, br, 1H), 11.78 (s, 1H); Anal. Calcd. for C 20 H 20 N 6 O 1 .2.0H 2 O: C, 60.59; H, 6.10; N, 21.20. Found: C, 60.48; H, 6.05; N, 21.35.
Preparation of 8-(4-benzyl-piperidin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 9
[0148] Synthesized using 1-benzylpiperazine for General Procedure D. 20% overall yield for last two steps. MS (ES−): 372; 1 H NMR (300 MHz, DMSO-d 6 ): 1.22-1.50 (m, 5H), 2.45-2.55 (m, 4H), 2.85 (d, 2H), 3.28 (s, 2H), 7.14-7.19 (m, 3H), 7.25-7.30 (m, 2H), 7.50 (d, J=7.0 Hz, 1H), 7.62 (d, J=7.7 Hz, 1H), 7.75 (t, J=7.7 Hz, 1H), 11.25 (s, br, 1H), 11.76 (s, 1H); Anal. Calcd. for C 22 H 23 N 5 O 1 : C, 70.76; H, 6.21; N, 18.75. Found: C, 70.36; H, 6.18; N, 18.63.
Preparation of 8-phenoxymethyl-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 10
[0149] Synthesized using phenol for General Procedure D. 60% overall yield for last two steps. MS (ES+): 293; H NMR (300 MHz, DMSO-d 6 ): 4.90 (s, br, 3H), 7.00 (t, J=6.6 Hz, 1H), 7.08 (d, J=8.2 Hz, 2H), 7.34 (t, J=7.7 Hz, 2H), 7.45 (d, J=7.7 Hz, 1H), 7.65 (d, J=7.7 Hz, 1H), 7.76 (t, J=7.2 Hz, 1H), 11.20 (s, br, 1H), 11.80 (s, 1H). Anal. Calcd. for C 16 H 12 N 4 O 2 .0.75H 2 O.0.25N 2 H 4 : C, 61.24; H, 4.66; N, 20.08. Found: C, 61.06; H, 4.27; N, 20.13;
Preparation of 8-[4-(4-fluoro-phenyl)-3,6-dihydro-2H-pyridin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 11
[0150] Synthesized using 4-(4-fluorophenyl)-1,2,3,6-tetrahydropyridine hydrochloride for General Procedure D. 24% overall yield for last two steps. MS (ES+): 376; H NMR (400 MHz, DMSO-d 6 ): 2.51-2.53 (s, br, 2H), 2.77 (t, J=5.4 Hz, 2H), 3.24 (s, br, 2H), 3.46 (s, 2H), 6.16 (m, 1H), 7.16 (t, J=8.8 Hz, 2H), 7.46-7.52 (m, 3H), 7.63 (d, J=7.8 Hz, 1H), 7.44 (t, J=7.8 Hz, 1H), 11.18 (s, br, 1H), 11.79 (s, 1H). A mesylate salt of 11 was prepared. 1 H NMR (400 MHz, DMSO-d 6 ): 2.34 (s, 3H), 2.84 (bs, 2H), 3.66 (m, 2H), 4.11 (m, 2H), 4.36 (s, 2H), 6.21 (m, 1H), 7.25 (t, J=8.8 Hz, 2H), 7.43 (d, J=7.4 Hz, 1H), 7.56-7.59 (m, 2H), 7.72 (d, J=7.4 Hz, 1H), 7.82 (t, J=7.5 Hz, 1H), 11.25 (s, br, 1H), 11.76 (s, 1H). Anal. Calcd. for C 21 H 18 FN 5 O 1 .1.0 CH 3 SOH. 0.2H 2 O: C, 55.62; H, 4.75; N, 14.74; S, 6.75. Found: C, 55.65; H, 4.71; N, 14.73; S, 6.74.
Preparation of 8-[4-(4-chloro-phenyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 12
[0151] Synthesized using 1-(4-chlorophenyl)-piperazine for General Procedure D. 23% overall yield for last two steps. A mesylate salt of 12 was prepared. MS (ES+): 396; 1 H NMR (400 MHz, DMSO-d 6 ): 2.33 (s, 3H), 4.31 (s, 2H), 7.03 (d, J=9.3 Hz, 2H), 7.31 (d, J=9.3 Hz, 2H), 7.43 (d, J=8.5 Hz, 1H), 7.72 (d, J=8.5 Hz, 1H), 7.82 (t, J=7.9 Hz, 1H), 11.23 (s, br, 1H), 11.90 (s, 1H). Anal. Calcd. for C 20 H 19 ClN 6 O 1 .1.0 CH 3 SOH: C, 51.37; H, 4.72; N, 17.12; S, 6.53. Found: C, 51.27; H, 4.91; N, 17.03; S, 6.48.
Preparation of 8-(4-phenyl-3,6-dihydro-2H-pyridin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 13
[0152] Synthesized using 4-phenyl-1,2,3,6-tetrahydro-pyridine for General Procedure D. 80% overall yield for last two steps. MS (ES+): 358; 1 H NMR (400 MHz, DMSO-d 6 ): 2.56 (m, 2H), 2.78 (t, J=5.5 Hz, 2H), 3.25 (d, J=2.6 Hz, 2H), 3.47 (s, 2H), 6.19 (s, 1H), 7.23-7.27 (m, 1H), 7.24 (t, J=7.6 Hz, 2H), 7.45 (d, J=7.1 Hz, 2H), 7.51 (d, J=8.9 Hz, 1H), 7.62 (d, J=7.1 Hz, 1H), 7.75 (t, J=8.0 Hz, 1H), 11.27 (s, br, 1H), 11.78 (s, 1H). A mesylate salt of 13 was prepared. 1 H NMR (400 MHz, DMSO-d 6 ): 2.34 (s, 3H), 2.84-2.88 (m, 2H), 3.65-3.69 (m, 2H), 4.13 (s, 2H), 4.37 (s, 2H), 6.21-6.25 (m, 1H), 7.32-7.44 (m, 4H), 7.53 (d, J=8.6 Hz, 2H), 7.72 (d, J=7.3 Hz, 1H), 7.82 (t, J=8.1 Hz, 1H), 11.30 (s, br, 1H), 11.93 (s, 1H). Anal. Calcd. for C 21 H 19 N 5 O.1.0 CH 3 SOH. 0.4H 2 O: C, 57.35; H, 5.21; N, 15.20; S, 6.96. Found: C, 57.30; H, 5.16; N, 15.29; S, 7.10;
Preparation of 8-[(3,4-dichloro-benzylamino)-methyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 14
[0153] Synthesized using 3,4-dichlorobenzylamine for General Procedure D. 10% overall yield for last two steps. A mesylate salt of 14 was prepared. MS (ES+): 375; 1 H NMR (300 MHz, DMSO-d 6 ): 2.33 (s, 3H), 4.06 (s, 2H), 4.33 (s, 2H), 7.39 (d, J=8.0 Hz, 1H), 7.53-7.57 (m, 1H), 7.69-7.88 (m, 4H), 11.31 (s, br, 1H), 11.91 (s, 1H).
Preparation of 8-{[2-(3-Fluoro-phenyl)-ethylamino]-methyl}-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 15
[0154] Synthesized using 3-fluorophenethylamine for General Procedure D. 12% overall yield for last two steps. A mesylate salt of 15 was prepared. MS (ES+): 338; 1 H NMR (300 MHz, DMSO-d 6 ): 2.34 (s, 3H), 3.02-3.08 (m, 2H), 3.34-3.38 (m, 2H), 4.14 (s, 2H), 7.08-7.18 (m, 3H), 7.37-7.44 (m, 2H), 7.71 (d, J=7.8 Hz, 1H), 7.82 (t, J=7.8 Hz, 1H), 11.92 11.35 (s, br, 1H), (s, 1H).
Preparation of 8-[(3-trifluoromethyl-benzylamino)-methyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 16
[0155] Synthesized using 3-(trifluoromethyl)benzylamine for General Procedure D. 14% overall yield for last two steps. A mesylate salt of 16 was prepared. MS (ES+): 374; 1 H NMR (300 MHz, DMSO-d 6 ): 2.33 (s, 3H), 4.10 (s, 2H), 4.43 (s, 2H), 7.39 (d, J=7.6 Hz, 1H), 7.69-7.86 (m, 5H), 7.99 (s, 1H), 11.25 (s, br, 1H), 11.91 (s, 1H). Anal. Calcd. for C 19 H 18 F 3 N 5 O.1.0 CH 3 SOH.1.0H 2 O: C, 46.82; H, 4.14; N, 14.37; S, 6.58. Found: C, 46.81; H, 4.17; N, 14.64; S, 6.35.
Preparation of 8-(1,4-dioxa-8-aza-spiro[4.5]dec-8-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 17
[0156] Synthesized using 4-piperidone ethylene ketal for General Procedure D. 10% overall yield for last two steps. MS (ES−): 370; 1 H NMR (300 MHz, DMSO-d 6 ): 169-1.71 (m, 4H), 2.57 (s, br, 4H), 3.35 (s, 2H), 3.87 (s, 4H), 7.51 (d, J=7.8 Hz, 1H), 7.62 (d, J=7.7 Hz, 1H), 7.74 (t, J=7.8 Hz, 1H), 11.23 (s, br, 1H), 11.76 (s, 1H). Anal. Calcd. for C 17 H 19 N 5 O 3 0.2H 2 O: C, 59.19; H, 5.67; N, 20.30. Found: C, 59.03; H, 5.60; N, 20.63.
Preparation of 8-{[2-(3,4-dichloro-phenyl)-ethylamino]-methyl}-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 18
[0157] Synthesized using 3,4-dichlorophenethylamine for General Procedure D. 17% overall yield for last two steps. A mesylate salt of 18 was prepared. MS (ES−): 387; 1 H NMR (300 MHz, DMSO-d 6 ): 2.36 (s, 3H), 3.04 (t, J=8.2 Hz, 2H), 3.37 (t, J=8.1 Hz, 2H), 4.14 (s, 2H), 7.30-7.43 (m, 2H), 7.61-7.75 (m, 3H), 7.79-7.84 (m, 1H), 11.31 (s, br, 1H), 11.91 (s, 1H).
Preparation of 8-{[2-(3-trifluoromethyl-phenyl)-ethylamino]-methyl}-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 19
[0158] Synthesized using 2-(3-Trifluoromethyl-phenyl)-ethylamine for General Procedure D. 39% overall yield for last two steps. A mesylate salt of 19 was prepared. MS (ES−): 387; 1 H NMR (300 MHz, DMSO-d 6 ): 3.74 (s, 3H), 3.13 (t, J=8.1 Hz, 2H), 3.30 (t, J=8.2 Hz, 2H), 4.15 (s, 2H), 7.40-7.43 (m, 1H), 7.62-7.72 (m, 4H), 7.79-7.85 (m, 1H), 11.35 (s, br, 1H), 11.92 (s, 1H).
Preparation of 8-[(1-Aza-bicyclo[2.2.2]oct-3-ylamino)-methyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 20
[0159] Synthesized using (S)-(−)-3-aminoquinuclidine for General Procedure D. 23% overall yield for last two steps. A mesylate salt of 20 was prepared. MS (ES+): 325; 1 H NMR (300 MHz, DMSO-d 6 ): 1.97-2.03 (m, 3H), 2.20-2.35 (m, 1H), 2.35-2.44 (m, 2H), 2.42 (s, 3H), 3.72-3.80 (m, 6H), 4.15-4.21 (m, 1H), 4.38 (s, 2H), 7.46 (d, J=7.6, 1H) 7.69-7.72 (m, 1H), 7.78-7.84 (m, 1H), 8.63 (s, br, 3H).
Preparation of 8-(4-ethyl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 21
[0160] Synthesized using ethylpiperazine for General Procedure D. 35% overall yield for last two steps. A mesylate salt of 21 was prepared. MS (ES+): 313; H NMR (300 MHz, DMSO-d 6 ): 1.25, (t, J=7.4 Hz, 3H), 2.41 (s, 6H), 2.51-3.87 (m, 10H), 3.87 (s, 2H), 7.70 (d, J=8.0 Hz, 1H), 7.81 (d, J=7.9 Hz, 1H), 7.91 (t, J=8.1 Hz, 1H), 9.82 (s, 1H), 11.96 (s, 1H). 13 C NMR (DMSO-d 6 ): 157.40, 155.99, 140.65, 135.96, 133.84, 126.72, 119.71, 118.65, 115.85, 56.09, 50.30, 49.05, 48.66, 8.51. Anal. Calcd. for C 16 H 20 N 6 O. 2.0 CH 3 SO 3 H. 1.2H 2 O: C, 40.84; H, 5.43; N, 15.79. Found: C, 41.09; H, 5.82; N, 15.97.
Preparation of 8-(4-methyl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 22
[0161] Synthesized using methylpiperazine for General Procedure D. 29% overall yield for last two steps. A mesylate salt of 22 was prepared. MS (ES+): 299; 1 H NMR (400 MHz, DMSO-d 6 ): 2.38 (s, 3H), 2.58-2.63 (m, 2H), 3.09-3.18 (m, 4H), 3.40-3.45 (m, 2H), 3.51 (s, 2H), 7.50 (d, J=7.8 Hz, 1H), 7.67 (d, J=7.8 Hz, 1H), 7.79 (t, J=7.8 Hz, 1H), 9.53 (s, br, 1H), 11.85 (s, 1H). Anal. Calcd. for C 15 H 18 N 6 O. 1.15 CH 3 SO 3 H. 1.0H 2 O.: C, 45.44; H, 5.81; N, 19.69; S, 8.64. Found: C, 45.18; H, 5.88; N, 19.83; S, 8.68;
Preparation of 8-(4-benzyl-[1,4]diazepan-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 23
[0162] Synthesized using 1-benzyl-[1,4]diazepane for General Procedure D. 24% overall yield for last two steps. MP: 140-142° C.; MS (ES−): 387; 1 H NMR (400 MHz, CDCl 3 ): 1.88 (m, 2H), 2.77 (m, 4H), 2.89 (m, 4H), 3.62 (s, 2H), 3.69 (s, 2H), 7.20-7.42 (m, 6H), 7.45 (s, br, 1H), 7.74 (t, J=7.8 Hz, 1H), 7.87 (d, J=7.6 Hz, 1H), 11.50 (s, br, 1H); Anal. Calcd. for C 22 H 24 N 6 O. 1.35H 2 O.: C, 64.01; H, 6.52; N, 20.36. Found: C, 64.18; H, 6.59; N, 20.46.
[0163] An HCl salt of 23 was prepared: to a solution of 23 (0.5 g) in 20 mL of dioxane was bubbled HCl gas for 30 min. The solution was stirred at room temperature overnight. After filtration, the precipitate was washed with dioxane to afford 0.25 g (48%) of analytically pure off white solid, an HCl salt of 23. 1 H NMR (400 MHz, D 2 O): 2.08 (m, 2H), 3.36 (m, 4H), 3.56 (m, 4H), 4.04 (s, 2H), 4.24 (s, 2H), 7.02 (d, 1H), 7.20-7.35 (m, 5H); 7.36 (d, 1H), 7.45 (t, 1H); Anal. Calcd. for C 22 H 24 N 6 O.2.0 HCl. 1.15H 2 O: C, 54.81; H, 5.92; N, 17.43. Found: C, 54.81; H, 5.92; N, 17.36.
Preparation of 4-(3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-[1,4]diazepane-1-carboxylic acid tert-butyl ester, 24
[0164] Synthesized using [1,4]diazepane-1-carboxylic acid t-butyl ester for General Procedure D. 30% overall yield for last two steps. MP: 219-221° C.; MS (ES−): 397; 1 H NMR (400 MHz, CDCl 3 ): 1.46 (s, 9H); 1.88 (m, 2H); 2.83 (m, 4H); 3.50 (m, 4H); 3.59 (s, 2H); 7.63 (m, 1H), 7.72-7.86 (m, 3H), 11.90 (s, br, 1H). Anal. Calcd. for C 20 H 26 N 6 O 3 . 0.5H 2 O: C, 58.95; H, 6.68; N, 20.62. Found: C, 58.83; H, 6.69; N, 20.60.
Preparation of 8-[4-(4-fluoro-benzyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 25
[0165] Synthesized using 1-(4-fluoro-benzyl)-[1,4]diazepane for General Procedure D. 35% overall yield for last two steps. MP: 163-165° C.; MS (ES−): 405; 1 H NMR (400 MHz, CDCl 3 ): 1.87 (m, 2H), 2.72 (m, 4H), 2.88 (m, 4H), 3.63 (s, 2H), 3.65 (s, 2H), 6.99 (t, J=8.4 Hz, 2H), 7.30 (m, 3H) 7.61 (s, br, 1H), 7.78 (m, 1H); 7.93 (d, J=7.3 Hz 1H), 10.82 (s, br, 1H). Anal. Calcd. for C 22 H 23 N 6 O. 1.5H 2 O: C, 60.96; H, 6.05; N, 19.39. Found: C, 61.07; H, 5.97; N, 19.59.
[0166] A mesylate salt of 25 was prepared. 1 H NMR (400 MHz, D 2 O): 2.06 (m, 2H), 2.70 (s, 3H), 3.06 (m, 2H), 3.24 (m, 2H), 3.46 (m, 4H), 3.65 (s, 4H), 3.74 (s, 2H), 4.33 (s, 2H), 7.25 (m, 3H), 7.46 (m, 3H), 7.62 (t, J=8.4 Hz, 1H). Anal. Calcd. for C 22 H 23 FN 6 O. 1.3 CH 3 SO 3 H. 0.5C 4 H 2 O 2 . 2.0H 2 O: C, 49.70; H, 5.97; N, 13.74; S, 6.82. Found: C, 49.40; H, 5.97; N, 13.37; S, 6.65.
Preparation of 8-[1,4]diazepan-1-ylmethyl-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 26
[0167] Synthesized from compound 24. To a solution of 24 (1.5 g, 3.7 mmol) in 30 mL of CH 2 Cl 2 was added 6 mL of TFA while stirring at room temperature. After 30 minutes, the solvents were evaporated and the residue was washed with acetonitrile to afford 1.0 g (90%) of analytically pure white solid. MP: 147-149° C.; MS (ES−): 297; 1 H NMR (400 MHz, D 2 O): 1.96 (m, 2H), 2.82 (t, 2H), 3.01 (t, 2H), 3.28 (t, 4H), 3.53 (s, 2H), 7.22 (d, 1H), 7.47 (d, 1H), 7.61 (t, 1H). Anal. Calcd. for C 15 H 18 N 6 O. 1.1 CF 3 CO 2 H. 1.0H 2 O: C, 46.76; H, 4.81; N, 19.02. Found: C, 46.64; H, 4.98; N, 19.02.
Preparation of 8-[4-(2-trifluoromethyl-benzoyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 27
[0168] Synthesized from compound 26. To a solution of compound 26 (0.2 g, 0.6 mmol) in 5 mL of CH 2 Cl 2 was added 1 mmol of TEA and 0.8 mmol of 2-trifluoromethyl-benzoyl chloride. The reaction was stirred overnight at room temperature. After the solvents were evaporated, the residue was purified with semi-preparative HPLC to afford a solid (15% yield). MP: 140-142° C.; MS (ES−): 469; H NMR (400 MHz, CDCh): 1.92-2.10 (m, 2H), 2.91-3.10 (m, 4H), 3.36-3.44 (m, 2H), 3.64-3.74 (m, 2H), 3.93 (m, 2H), 7.38 (m, 1H), 7.57 (m, 3H), 7.79 (m, 2H), 7.93 (m, 1H). Anal. Calcd. for C 23 H 21 F 3 N 6 O 2 -0.9 HCl: C, 54.89; H, 4.39; N, 16.70. Found: C, 54.93; H, 4.43; N, 16.34.
Preparation of 8-[4-(3-chloro-benzoyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 28
[0169] Synthesized from compound 26. To a solution of compound 26 (0.2 g, 0.6 mmol) in 5 mL of CH 2 Cl 2 was added 1 mmol of TEA and 0.8 mmol of 3-chloro-benzoyl chloride. The reaction was stirred overnight at room temperature. After the solvents were evaporated, the residue was purified with semi-preparative HPLC to afford a solid (16% yield). MP: 147-149° C.; MS (ES−): 436; 1 H NMR (400 MHz, CDCl 3 ): 1.88-2.08 (m, 2H), 2.86-3.07 (m, 4H), 3.52-3.71 (m, 4H), 3.81-3.89 (m, 2H), 7.33-7.43 (m, 4H), 7.62 (d, 1H), 7.81 (t, 1H), 7.90 (t, 1H). Anal. Calcd. for C 22 H 21 ClN 6 O 2 .0.7H 2 O: C, 54.89; H, 4.39; N, 16.70. Found: C, 54.93; H, 4.43; N, 16.34.
Preparation of 8-(4-pyridin-2-yl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 30
[0170] Synthesized using l-pyridin-2-yl-piperazine for General Procedure D. 20% overall yield for last two steps. A mesylate salt of 30 was prepared. MS (ES−): 360; 1 H NMR (400 MHz, DMSO-d 6 ): 2.37 (s, 6H), 3.52 (s, br, 4H), 3.93 (s, br, 4H), 4.30 (s, 2H), 6.93 (t, J=6.6 Hz, 1H), 7.25 (d, J=8.6 Hz, 1H), 7.47 (d, J=7.8 Hz, 1H), 7.73 (d, J=7.8 Hz, 1H), 7.82-7.91 (m, 2H), 8.16-8.18 (m, 1H), 11.96 (s, 1H). Anal. Calcd. for C 19 H 19 N 7 O. 1.9 CH 3 SO 3 H. 1.2H 2 O: C, 44.38; H, 5.17; N, 17.33; S, 10.77. Found: C, 44.21; H, 5.19; N, 17.28; S, 10.68.
Preparation of 8-{[2-(2-fluoro-phenyl)-ethylamino]-methyl}-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 31
[0171] Synthesized using 2-(2-fluoro-phenyl)-ethylamine for General Procedure D. 20% overall yield for last two steps. A mesylate salt of 31 was prepared. MS (ES−): 336; 1 H NMR (400 MHz, DMSO-d 6 ): 2.41 (s, 5H), 3.02 (t, J=7.6 Hz, 2H), 3.32 (t, J=8.3 Hz, 2H), 4.16 (s, 2H), 7.19 (t, J=8.8 Hz, 2H), 7.32-7.35 (m, 2H), 7.42 (d, J=7.8 Hz, 1H), 7.71 (d, J=7.8 Hz, 1H), 7.82 (t, J=8.1 Hz, 1H), 9.10 (s, br, 1H), 11.92 (s, 1H). Anal. Calcd. for C 18 H 16 FN 5 O. 1.75 CH 3 SO 3 H. 0.75H 2 O: C, 45.70; H, 4.76; N, 13.49; S, 10.81. Found: C, 45.45; H, 4.69; N, 13.42; S, 11.10.
Preparation of 8-[4-(4-fluoro-phenyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 32
[0172] Synthesized using 4-(4-fluoro-phenyl)-piperazine for General Procedure D. 57% overall yield for last two steps. A mesylate salt of 32 was prepared. MS (ES−): 377; 1 H NMR (400 MHz, DMSO-d 6 ): 2.40 (s, 5H), 3.45 (s, br, 4H), 3.59 (s, br, 4H), 4.37 (s, 2H), 7.03-7.15 (m, 4H), 7.44 (d, J=7.8 Hz, 1H), 7.72 (d, J=7.8 Hz, 1H), 7.83 (t, J=7.8 Hz, 1H), 9.8 (s, br, 1H), 11.94 (s, 1H). Anal. Calcd. for C 20 H 19 FN 6 O. 1.65 CH 3 SO 3 H: C, 46.85; H, 5.01; N, 15.14; S, 9.53. Found: C, 46.74; H, 5.15; N, 15.14; S, 9.53.
Preparation of 8-{[2-(4-Fluoro-phenyl)-ethylamino]-methyl}-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 33
[0173] Synthesized using 2-(4-fluoro-phenyl)-ethylamine for General Procedure D. 19% overall yield for last two steps. A mesylate salt of 33 was prepared. MS (ES−): 336; 1 H NMR (400 MHz, DMSO-d 6 ): 2.38 (s, 6H), 3.06-3.10 (m, 2H), 3.30-3.34 (m, 2H), 4.18 (s, 2H), 7.19-7.22 (m, 2H), 7.34-7.42 (m, 3H), 7.71 (d, J=8.6 Hz, 1H), 7.82 (t, J=7.8 Hz, 1H), 9.6 (s, br, 1H), 11.92 (s, 1H). Anal. Calcd. for CigHieFNsO. 2.0 CH 3 SO 3 H: C, 45.36; H, 4.57; N, 13.22; S, 12.11. Found: C, 45.34; H, 4.58; N, 13.16; S, 11.88.
Preparation of 8-(4-acetyl-[1,4]diazepan-1-ylmethy one, 34
[0174] Synthesized using [1,4]diazepane-1-yl-ethanone for General Procedure D. 16% overall yield for last two steps. MP: 191-193° C.; MS (ES−): 339; 1 H NMR (400 MHz, CDCl 3 ): 2.11 (s, 3H), 2.84-2.93 (m, 4H), 3.56-3.76 (m, 6H), 7.66 (m, 1H), 7.83-7.92 (m, 2H), 9.3 (s, br, 1H), 11.3 (s, br, 1H). Anal. Calcd. for C 17 H 20 N 6 O 2 . 0.6H 2 O: C, 58.14; H, 6.08; N, 23.93. Found: C, 58.09; H, 6.18; N, 24.08.
Preparation of 8-(phenethylamino-methyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 35
[0175] Synthesized using phenetyhlamine for General Procedure D. 29% overall yield for last two steps. A mesylate salt of 35 was prepared. MS (ES−): 358; H NMR (400 MHz, DMSO-Je): 2.32 (s, 3H), 3.00-3.04 (m, 2H), 3.31-3.36 (m, 2H), 4.15 (s, 1H), 7.27-7.42 (m, 6H), 7.71 (d, J=7.8 Hz, 1H), 7.82 (t, J=7.8 Hz, 1H), 9.70 (s, br, 1H), 11.92 (s, 1H). Anal. Calcd. for C 18 H 17 N 5 O. 1.0 CH 3 SO 3 H. 1.8H 2 O: C, 50.95; H, 5.54; N, 15.64; S, 7.16. Found: C, 50.95; H, 5.54; N, 15.64; S, 7.16;
Preparation of 8-(4-phenyl-piperidin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 36
[0176] Synthesized using 4-phenyl-piperidine for General Procedure D. 33% overall yield for last two steps. MS (ES−): 318; 1 HNMR (400 MHz, DMSO-d 6 ): 1.87-1.93 (m, 4H), 2.37-2.46 (m, 2H), 2.56 (m, 1H), 3.10-3.14 (m, 2H), 3.54 (s, 2H), 7.17-7.34 (m, 5H), 7.56 (bs, 1H), 7.76 (t, J=7.8 Hz, 1H), 7.93 (d, J=7.8 Hz, 1H), 11.10 (s, br, 1H), 11.76 (s, 1H). A mesylate salt of 36 was prepared. H NMR (400 MHz, D 2 O): 2.08 (m, 4H), 2.95 (m, 1H), 3.34 (m, 2H), 3.84 (m, 2H), 4.23 (s, 2H), 7.21-7.39 (m, 6H), 7.59 (m, 1H), 7.70 (m, 1H). Anal. Calcd. for C 21 H 21 N 50 . 1.3 CH 3 SO 3 H. 0.5H 2 O: C, 54.29; H, 5.56; N, 14.19; S, 8.45. Found: C, 54.03; H, 5.65; N, 13.98; S, 8.64.
Preparation of 8-(1,3-dihydro-isoindol-2-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 37
[0177] Synthesized using isoindoline for General Procedure D. 40% overall yield for last two steps. MS (ES−): 316; H NMR (400 MHz, DMSO-d 6 ): 3.77 (s, 2H), 4.04 (s, 4H), 7.20-7.30 (m, 4H), 7.49 (d, J=7.8 Hz, 1H), 7.6 (d, J=7.8 Hz, 1H), 7.74 (t, J=7.8 Hz, 1H), 11.34 (s, br, 1H), 11.78 (s, 1H). A mesylate salt of 37 was prepared. 1 H NMR (400 MHz, DMSO-d 6 ): 2.34 (s, 3H), 4.64 (s, 2H), 4.87 (s, 4H), 7.39-7.46 (m, 5H), 7.72 (d, J=7.8 Hz, 1H), 7.83 (t, J=8.1 Hz, 1H), 11.30 (s, br, 1H), 11.95 (s, 1H). Anal. Calcd. for C 18 H 15 N 5 O. 1.25 CH 3 SO 3 H. 2.0H 2 O: C, 48.83; H, 5.11; N, 14.79; S, 8.46. Found: C, 48.80; H, 5.11; N, 14.97; S, 8.71.
Preparation of 8-(4-benzenesulfonyl-[1,4]diazepan-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 38
[0178] Synthesized from compound 26. To a solution of 26 (0.2 g, 0.67 mmol) in 5 mL of CH 2 Cl 2 was added TEA (2 mmol) and benzensulfonyl chloride (1 mmol). The mixture was stirred at room temperature over night. After the solvents were evaporated, the residue was poured into 10 mL of H 2 O and the product was purified by preparative HPLC to afford analytically pure white solid (5% yield). MP: 265-268° C.; MS (ES−): 437; 1 H NMR (400 MHz, DMSO-d 6 ): 1.79 (m, 2H), 2.50 (m, 4H), 2.79 (m, 4H), 3.51 (s, 2H), 7.44 (d, 1H), 7.62-7.79 (m, 7H), 11.1 (s, br, 1H), 11.75 (s, 1H). Anal. Calcd. for C 21 H 22 N 6 O 3 S. 0.5H 2 O: C, 56.36; H, 5.18; N, 18.78; S, 7.17. Found: C, 56.44; H, 5.12; N, 19.00; S, 7.19.
[0179] A mesylate salt of 38 was prepared. MS (ES+): 439; 1 H NMR (400 MHz, D 2 O): 2.18 (m, 2H), 2.35 (s, 6H), 3.36 (m, 2H), 3.65 (m, 6H), 4.3 (s, 2H), 7.24 (d, 1H), 7.51-7.71 (m, 7H). Anal. Calcd. for C 21 H 22 N 6 O 3 S. 1.8 CH 3 SO 3 H. 1.0H 2 O: C, 43.50; H, 5.00; N, 13.35; S, 14.26. Found: C, 43.61; H, 5.00; N, 13.15; S, 14.59.
Preparation of 8-(4-pyridin-4-yl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 39
[0180] Synthesized using 1-(4-pyridyl)piperazine for General Procedure D. 10% overall yield for last two steps. MS (ES−): 360; 1 HNMR (400 MHz, DMSO-d 6 ): 2.80 (t, J=5.0 Hz, 4H), 3.61 (t, J=5.0 Hz, 4H), 3.99 (s, 2H), 6.83 (d, J=7.1 Hz, 2H), 7.42-7.45 (m, 1H), 7.73-7.81 (m, 2H), 8.26 (d, J=7.1 Hz, 2H), 11.20 (s, br, 1H), 11.90 (s, 1H). An HCl salt of 39 was prepared. 1 H NMR (400 MHz, D 2 O): 2.74-2.77 (m, 4H), 3.43 (s, 2H), 3.35-3.69 (m, 4H), 6.93 (d, J=7.1 Hz, 2H), 7.13 (d, J=8.0 Hz, 1H), 7.37 (d, J=7.8 Hz, 1H), 7.58 (t, J=7.8 Hz, 1H), 7.92 (d, J=7.1 Hz, 2H). Anal. Calcd. for C 19 H 19 N 7 O. 1.0 HCl. 2.5H 2 O: C, 51.53; H, 5.69; N, 22.14; Cl, 8.00. Found: C, 51.46; H, 5.69; N, 21.90; Cl, 8.27.
Preparation of 8-(4-benzyl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 40
[0181] Synthesized using 4-benzyl-piperazine for General Procedure D. 12% overall yield for last two steps. MS (ES−): 373; 1 H NMR (400 MHz, DMSO-d 6 ): 2.44 (s, br, 4H), 3.35 (s, br, 4H), 3.48 (s, 2H), 7.23-7.34 (m, 5H), 7.49 (d, J=8.8 Hz, 1H), 7.62 (d, J=7.8 Hz, 1H), 7.74 (t, J=7.8 Hz, 1H), 11.10 (s, br, 1H), 11.77 (s, 1H). An HCl salt of 40 was prepared. 1 H NMR (400 MHz, D 2 O): 2.54-2.70 (m, 2H), 3.10-3.50 (m, 6H), 3.48 (s, 2H), 4.35 (s, 2H), 7.20 (d, J=8.1 Hz, 1H), 7.45 (t, J=7.8 Hz, 1H), 7.47-7.51 (m, 5H), 7.62 (t, J=8.1 Hz, 1H). Anal. Calcd. for C 21 H 22 N 6 O.1.0 HCl. 2.5H 2 O: C, 55.32; H, 6.19; N, 18.43. Found: C, 55.54; H, 6.08; N, 18.32.
Preparation of 8-(4-methyl-[1,4]diazepan-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 41
[0182] Synthesized using 1-methyl-[1,4]diazepane for General Procedure D. 24% overall yield for last two steps. MS (ES−): 311; 1 H NMR (400 MHz, DMSO-d 6 ): 1-75 (m, 2H), 2.26 (s, 3H), 2.55 (m, 4H), 2.79 (m, 4H), 3.48 (s, 2H), 7.52 (d, J=8.2 Hz, 1H), 7.64 (d, J=7.2 Hz, 1H), 7.75 (t, J=8.1 Hz, 1H), 11.55 (s, 1H). Anal. Calcd. for C 16 H 20 N 6 O. 0.95H 2 O: C, 58.33; H, 6.70; N, 25.51. Found: C, 58.32; H, 6.65; N, 25.53.
Preparation of 8-[4-(1H-indol-3-yl)-piperidin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 42
[0183] Synthesized using 3-piperidin-4-yl-1H-indole for General Procedure D. 19% overall yield for last two steps. MS (ES−): 397; 1 H NMR (400 MHz, DMSCw/6): 1.83-1.94 (m, 4H), 2.31 (m, 2H), 2.50 (s, 2H), 2.79-2.99 (m, 3H), 6.96-7.09 (m, 3H), 7.32 (d, J=8.1 Hz, 1H), 7.54-7.63 (m, 3H), 7.75 (t, J=7.3 Hz, 1H), 10.79 (s, 1H), 11.80 (s, 1H). A mesylate salt of 42 was prepared. 1 H NMR (400 MHz, DMSO-d 6 ): 2.15 (m, 4H), 2.32 (s, 3H), 3.11 (m, 1H), 3.52 (m, 2H), 3.73 (m, 2H), 4.29 (s, 2H), 7.10-7.18 (m, 3H), 7.36 (d, 1H); 7.46 (d, J=8.2 Hz, 1H), 7.69-7.83 (m, 3H), 10.91 (s, 1H), 11.93 (s, 1H). Anal. Calcd. for C 23 H 22 N 60 . 1.0 CH 3 SO 3 H. 1.25H 2 O: C, 55.23; H, 5.62; N, 16.91; S, 6.14. Found: C, 55.27; H, 5.53; N, 16.95; S, 6.00.
Preparation of 8-[(2-pyridin-4-yl-ethylamino)-methyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 43
[0184] Synthesized using 4-ethylamino-pyridine for General Procedure D. 10% overall yield for last two steps. An HCl salt of 43 was prepared. MS (ES−): 319; HNMR (400 MHz, D 2 O): 3.28 (t, J=7.8 Hz, 2H), 3.53 (t, J=7.8 Hz, 2H), 4.09 (s, 2H), 7.02 (d, J=8.0 Hz, 1H), 7.35 (d, J=8.0 Hz, 1H), 7.52 (t, J=8.0 Hz, 1H), 7.70 (d, J=5.3 Hz, 2H), 8.52 (d, J=5.3 Hz, 2H). Anal. Calcd. for C 17 H 16 N 6 O.1.3HCl. 2.6H 2 O. 0.1N 2 H 4 : C, 47.52; H, 5.38; N, 20.27. Found: C, 47.12; H, 5.26; N, 20.67.
Preparation of 8-(3,4-dihydro-1H-isoquinolin-2-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 44
[0185] Synthesized using 1,2,3,4-tetrahydro-isoquinoline for General Procedure D. 30% overall yield for last two steps. MS (ES−): 330; 1 H NMR (400 MHz, DMSO-d 6 ): 2.81-2.90 (m, 4H); 3.52 (s, 2H), 3.72 (s, 2H), 7.05-7.25 (m, 4H), 7.51 (d, J=7.8 Hz, 1H), 7.63 (d, J=8.0 Hz, 1H), 7.74 (t, J=8.0 Hz, 1H), 11.30 (s, br, 1H), 11.91 (s, 1H). Anal. Calcd. for C 19 H 17 N 5 O: C, 68.87; H, 5.17; N, 21.13. Found: C, 68.34; H, 5.19; N, 21.30.
[0186] A mesylate salt of 44 was prepared. MS (ES−): 330; 1 H NMR (400 MHz, D 2 O): 2.80 (s, 3H), 3.31 (t, 2H), 3.85 (m, 2H), 4.47 (s, 2H), 4.68 (s, 2H), 7.23 (d, J=7.8 Hz, 1H), 7.28-7.42 (m, 4H), 7.67 (d, J=8.0 Hz, 1H); 7.80 (t, J=7.9 Hz, 1H). Anal. Calcd. for C 19 H 17 N 5 O. 1.12 CH 3 SO 3 H. 2.0H 2 O: C, 50.87; H, 5.41; N, 14.74; S, 7.56. Found: C, 50.89; H, 5.47; N, 14.84; S, 7.63.
Preparation of 8-(5,6-Dimethoxy-3,4-dihydro-1H-isoquinolin-2-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 45
[0187] Synthesized using 5,6-dimethoxy-1,2,3,4-tetrahydro-isoquinoline for General Procedure D. 29% overall yield for last two steps. MS (ES−): 311; 1 H NMR (400 MHz, DMSO-d 6 ): 2.79 (s, 4H), 3.49 (s, 2H), 3.61 (s, 2H), 3.67 (s, 3H), 3.70 (s, 3H), 6.69 (d, J=8.8 Hz, 2H), 7.48 (d, J=7.6 Hz, 1H), 7.63 (d, J=7.8 Hz, 1H), 7.74 (t, J=7.6 Hz, 1H), 11.55 (s, 1H). Anal. Calcd. for C 21 H 21 N 5 O 3 : C, 64.44; H, 5.41; N, 17.89. Found: C, 64.24; H, 5.43; N, 17.98.
[0188] A mesylate salt of 45 was prepared. MS (ES−): 330; 1 H NMR (400 MHz, D 2 O): 2.82 (s, 3H), 3.21 (t, 2H), 3.65-3.85 (m, 8H), 4.48 (s, 2H), 4.60 (s, 2H), 6.75 (s, 1H), 6.83 (s, 1H), 7.38 (d, 1H), 7.71 (d, 1H), 7.82 (t, 1H). Anal. Calcd. for C 21 H 21 N 5 O 3 . 1.18 CH 3 SO 3 H. 1.75H 2 O: C, 49.70; H, 5.49; N, 13.07; S, 7.03. Found: C, 49.77; H, 5.49; N, 13.17; S, 7.03.
Preparation of 8-[4-(3-Trifluoromethyl-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 46
[0189] Synthesized from compound 26. To a solution of 26 (0.2 g, 0.67 mmol) in 5 mL of CH 2 Cl 2 was added TEA (2 mmol) and 3-trifluoromethyl-benzenesulfony chloride (1 mmol). The mixture was stirred at room temperature over night. After the solvents were evaporated, the residue was poured into 10 mL of H 2 O and the product was purified by preparative HPLC to afford analytically pure white solid (15% yield). MS (ES+): 507; 1 H NMR (400 MHz, DMSO-d 6 ): 1.82 (m, 2H), 2.73-2.81 (m, 4H), 3.25-3.42 (m, 6H), 7.44 (d, J=7.8 Hz, 1H), 7.63 (d, J=7.2 Hz, 1H), 7.74 (t, J=7.8 Hz, 1H), 7.89 (t, J=8.2 Hz, 1H), 8.04-8.13 (m, 3H), 11.10 (s, br, 1H), 11.75 (s, 1H). Anal. Calcd. for C 22 H 21 F 3 N 6 O 3 S. 1.1H 2 O: C, 50.21; H, 4.44; N, 15.97; S, 6.09. Found: C, 50.19; H, 4.54; N, 15.50; S, 5.97.
[0000]
General Procedure F: Preparation of compounds 47A and 47B
[0190] Displacement of the chloro group of compound 4 with piperazine or [1,4]diazepane using General procedure F provides the compound 47A or 47B. To a stirring solution of 4 (1 eq) in acetonitrile was added piperazine or [1,4]diazepane (large excess) under a blanket of nitrogen. The solution was allowed to stir overnight and then evaporated to dryness. The crude material was purified via silica plug with 9:1 dichloromethane:methanol to afford a white solid, 4-Oxo-2-piperazin-1-ylmethy 1-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 47A or 2-[1,4]diazepan-1-ylmethyl-4-oxo-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 47B.
General Procedure G: Preparation of Compounds 48A and 48B
[0191] A reaction of amine 47A or 47B with various sulfonyl chloride yields sulfonyl amide 48A or 48B. To a stirring solution of 47A or 47B (1.0 eq) in pyridine was added various sulfonyl chloride (1.1 eq). The reaction was allowed to stir overnight and then was evaporated to dryness. The residue was then extracted with dichloromethane and washed with brine. The product was evaporated to dryness and used without further purification.
General Procedure E: Preparation of compounds 49A and 49B
[0192] A 2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one ring can be formed by condensation of the compound 48A or 48B with hydrazine. To a solution of the compounds 6 in absolute ethanol is added excess anhydrous hydrazine at room temperature. The solution is refluxed for overnight and cooled to room temperature. Ice-cold water is added and white solid is separated. The solid is collected by vacuum filtration and washed with water and small amount of methanol to give white solid products 6 in 40-90% of yield. An example was given in the preparation of compounds 49A and 49B.
Example 2
Preparation of 8-[4-(4-methoxy-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 50
[0193] To a stirring solution of 4 (2.2 g, 8.73 mmol, 1 eq) in 200 mL of acetonitrile was added piperazine (14 g, 0.162 mol, large excess) under a blanket of nitrogen. The solution was allowed to stir overnight and then evaporated to dryness. The crude material was purified via silica plug with 9:1 dichloromethane:methanol to afford 2.0 g of a fluffy white solid, 4-Oxo-2-piperazin-1-ylmethyl-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 47A. MS (ES−): 301; 1 H NMR (400 MHz, DMSO-t/6): 2.40-2.43 (m, 4H), 2.69-2.72 (m, 4H), 3.41 (s, 2H), 3.83 (s, 3H), 7.44 (d, J=7.2 Hz, 1H), 7.74 (d, J=8.2 Hz, 1H), 7.82 (t, J=7.8 Hz, 1H).
[0194] To a stirring solution of 47A (170 mg, 0.56 mmol, 1 eq) in 5 mL of pyridine was added 4-methoxybenzene sulfonyl chloride (130 mg, 0.62 mmol, 1.1 eq) resulting in a bright yellow solution. The reaction was allowed to stir overnight and then was evaporated to dryness. The waxy residue was then extracted with dichloromethane and washed with brine. The crude material was dissolved in 10 mL of EtOH and 5 mL of hydrazine monohydrate (large excess). This solution was refluxed overnight resulting in a heavy white precipitate which was filtered, washed with ethyl ether and dried to give an off white solid. This solid was then purified via chromatography to afford 112 mg of analytically pure compound 50. A mesylate salt of 50 was prepared. 8% overall yield for last three steps. MS (ES+): 455; H NMR (400 MHz, DMSO-d 6 ): 2.34 (s, 3H), 3.19 (bs, 4H), 3.44 (bs, 4H), 3.89 (s, 3H), 4.20 (s, 2H), 7.25 (d, J=9.0 Hz, 2H), 7.72 (d, J=7.8 Hz, 1H), 7.70-7.83 (m, 4H), 11.20 (s, br, 1H), 11.93 (s, 1H). Anal. Calcd. for C 21 H 22 N 6 O 4 S. 1.5 CH 3 SO 3 H. 3.0H 2 O.0.1N 2 H 4 : C, 41.20; H, 5.29; N, 13.24; S, 12.22. Found: C, 41.07; H, 5.09; N, 13.53; S, 12.62.
[0195] The following compounds were synthesized from the similar procedures of preparation of compound 50, using the appropriate corresponding sulfonyl chloride.
Preparation of 8-[4-(3-fluoro-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 51
[0196] Synthesized using 3-fluoro-benzenesulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 51 was prepared. 35% overall yield for last three steps. MS (ES−): 441; 1 H NMR (400 MHz, DMSO-d 6 ): 2.31 (s, 3H), 3.25 (bs, 4H), 3.39 (bs, 4H), 4.15 (s, 2H), 7.42 (d, J=7.8 Hz, 1H), 7.65-7.71 (m, 4H), 7.78-7.82 (m, 2H), 11.78 (s, 1H). Anal. Calcd. for C 20 H 19 N 6 O 3 S. 1.25 CH 3 SO 3 H. 2.4H 2 O: C, 42.43; H, 4.87; N, 13.87; S, 11.91. Found: C, 42.13; H, 4.79; N, 13.48; S, 11.89.
Preparation of 8-[4-(toluene-4-sulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 52
[0197] Synthesized using toluene-4-sulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 52 was prepared. 38% overall yield for last three steps. MS (ES−): 438; 1 H NMR (400 MHz, DMSO-d 6 ): 2.36 (s, 3H), 2.45 (s, 3H), 3.20 (bs, 4H), 3.46 (bs, 4H), 4.22 (s, 2H), 7.43 (d, J=7.8 Hz, 1H), 7.54 (d, J=7.8 Hz, 2H), 7.68-7.81 (m, 4H), 11.90 (s, 1H). Anal. Calcd. for C 21 H 22 N 6 O 3 S. 1.3 CH 3 SO 3 H. 4.0H 2 O: C, 42.25; H, 5.58; N, 13.22; S, 11.61. Found: C, 42.63; H, 5.53; N, 13.40; S, 11.90.
Preparation of 8-(4-benzenesulfonyl-piperazin-1-ylmethyl)-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 53
[0198] Synthesized using benzensulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 53 was prepared. 30% overall yield for last three steps. MS (ES−): 438; 1 H NMR (400 MHz, DMSO-d 6 ): 2.70 (s, 3H), 3.36 (bs, 4H), 3.51 (bs, 4H), 4.14 (s, 2H), 7.11 (d, J=8.0 Hz, 1H), 7.40-7.70 (m, 7H), 11.90 (s, 1H). Anal. Calcd. for C 20 H 20 N 6 O 3 S. 1.2 CH 3 SO 3 H. 2.5H 2 O. 0.08N 2 H 4 : C, 43.36; H, 5.17; N, 14.67; S, 12.01. Found: C, 43.00; H, 5.17; N, 15.05; S, 12.40.
Preparation of 8-[4-(3-trifluoromethyl-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 54
[0199] Synthesized using 3-trifluoro-benzensulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 54 was prepared. 15% overall yield for last three steps. MS (ES−): 438; H NMR (400 MHz, DMSO-d 6 ): 2.32 (s, 3H), 3.26-3.35 (m, 8H), 4.10 (s, 2H), 7.43 (d, J=8.0 Hz, 1H), 7.69-7.80 (m, 2H), 7.98-8.26 (m, 4H), 11.92 (s, 1H)
[0200] Anal. Calcd. for C 21 H 19 F 3 N 6 O 3 S. 1.3 CH 3 SO 3 H. 2.0H 2 O: C, 40.99; H, 4.35; N, 12.86; S, 11.29. Found: C, 40.71; H, 4.60; N, 12.68; S, 11.50.
Preparation of 8-[4-(4-chloro-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 55
[0201] Synthesized using 4-chlorobenzensulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 55 was prepared. 15% overall yield for last three steps. MS (ES−): 458; H NMR (400 MHz, DMSO-d 6 ): 2.31 (s, 3H), 3.18 (bs, 4H), 3.40 (bs, 4H), 3.98 (s, 2H), 7.43 (d, J=7.7 Hz, 1H), 7.68-7.84 (m, 5H), 11.90 (s, 1H). Anal. Calcd. for C 20 H 19 ClN 6 O 3 S. 1.3 CH 3 SO 3 H. 2.0H 2 O: C, 41.27; H, 4.59; N, 13.56; S, 11.90. Found: C, 41.07; H, 4.66; N, 13.30; S, 11.89.
Preparation of 8-[4-(4-fluoro-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 56
[0202] Synthesized using 4-fluorobenzensulfonyl chloride and compound 47A for General Procedure G. An HCl salt of 56 was prepared. 42% overall yield for last three steps. MS (ES−): 441; 1 H NMR (400 MHz, DMSO-d 6 ): 2.31 (s, 3H), 3.18 (bs, 4H), 3.40 (bs, 4H), 3.98 (s, 2H), 7.43 (d, J=7.8 Hz, 1H), 7.68-7.84 (m, 5H), 11.90 (s, 1H).
Preparation of 8-[4-(4-isopropyl-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 57
[0203] Synthesized using 4-isopropylbenzensulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 57 was prepared. 22% overall yield for last three steps. MS (ES−): 465; H NMR (400 MHz, DMSO-d 6 ): 1.26 (d, J=6.8 Hz, 6H), 2.33 (s, 3H), 3.01-3.05 (m, 1H), 3.16-3.32 (m, 10H), 7.41 (d, J=8.1 Hz, 1H), 7.59 (d, J=8.6 Hz, 2H), 7.68-7.80 (m, 4H), 11.89 (s, 1H). Anal. Calcd. for C 23 H 26 N 6 O 3 S. 1.35 CH 3 SO 3 H. 1.75H 2 O. 0.1N 2 H 4 : C, 46.35; H, 5.64; N, 13.76; S, 11.94. Found: C, 46.01; H, 5.62; N, 13.80; S, 12.33.
Preparation of 8-[4-(4-tert-butyl-benzenesulfonyD-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 58
[0204] Synthesized using 4-tertbutylbenzensulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 58 was prepared. 23% overall yield for last three steps. MS (ES−): 480; 1 H NMR (400 MHz, DMSO-d 6 ): 1.25 (s, 9H), 2.21 (s, 3H), 3.05-3.15 (m, 8H), 3.99 (bs, 2H), 7.32 (d, J=8.1 Hz, 1H), 7.59-7.72 (m, 6H), 11.81 (s, 1H). Anal. Calcd. for C 24 H 28 N 6 O 3 S. 1.5 CH 3 SO 3 H. 2.75H 2 O: C, 45.42; H, 5.90; N, 12.46; S, 11.89. Found: C, 45.23; H, 5.76; N, 12.84; S, 12.17.
Preparation of 8-[4-(4-isopropyl-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 59
[0205] Synthesized using 4-isopropylbenzensulfonyl chloride and compound 47B for General Procedure G. 22% overall yield for last two steps. MS (ES−): 479; 1 H NMR (400 MHz, DMSO-d 6 ): 1.23 (d, 6H), 1.79 (m, 2H), 2.40-2.55 (m, 4H), 2.71-2.90 (m, 4H), 3.00 (m, 1H), 3.48 (s, 2H), 7.48 (m, 3H), 7.73 (m, 4H), 11.80 (s, 1H). Anal. Calcd. for C 24 H 28 N 6 O 3 S: C, 59.98; H, 5.87; N, 17.49; S, 6.67. Found: C, 60.02; H, 5.85; N, 17.55; S, 6.52.
Preparation of 8-[4-(4-chloro-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 60
[0206] Synthesized using 4-chloro-benzenesulfony chloride and compound 47B for General Procedure G. 8% overall yield for last three steps. MS (ES−): 472; 1 H NMR (400 MHz, DMSO-d 6 ): 1.80 (m, 2H), 2.73-2.78 (m, 4H), 3.50 (m, 4H), 3.69 (s, 2H), 7.45 (d, J=8.2 Hz, 1H), 7.71-7.83 (m, 6H), 10.95 (s, br, 1H), 11.76 (s, 1H). A mesylate salt of 60 was prepared. 1 H NMR (400 MHz, D 2 O): 1.92 (m, 2H), 2.73 (s, 5H), 3.50-3.77 (m, 8H), 4.36 (s, 2H), 7.49 (d, J=7.2 Hz, 1H), 7.75 (t, J=8.1 Hz, 2H), 7.78-7.93 (m, 4H). Anal. Calcd. for C 21 H 21 ClN 6 O 3 S. 1.61 CH 3 SO 3 H: C, 39.57; H, 4.99; N, 12.25; S, 12.20. Found: C, 39.50; H, 5.29; N, 12.57; S, 12.47.
Preparation of 8-[4-(3-fluoro-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 61
[0207] Synthesized using 3-fluoro-benzenesulfony chloride and compound 47B for General Procedure G. 16% overall yield for last two steps. MS (ES+): 457; 1 H NMR (400 MHz, DMSO-d 6 ): 1.79 (m, 2H), 2.70-2.81 (m, 4H), 3.26-3.40 (m, 4H), 3.48 (s, 2H), 7.45 (d, J=7.3 Hz, 1H); 7.55-7.74 (m, 6H), 11.10 (s, br, 1H), 11.75 (s, 1H). Anal. Calcd. for C 21 H 21 FN 6 O 3 S. 1.15H 2 O: C, 52.85; H, 4.92; N, 17.61; S, 6.72. Found: C, 52.88; H, 4.93; N, 17.43; S, 6.48.
Preparation of 8-[4-(4-methoxy-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 62
[0208] Synthesized using 4-methoxy-benzensulfonyl chloride and compound 47B for General Procedure G. 21% overall yield for last two steps. MS (ES+): 469; 1 H NMR (400 MHz, DMSO-d 6 ): 1-78 (m, 2H), 2.72-2.79 (m, 4H), 3.30-3.39 (m, 4H), 3.48 (s, 2H), 3.84 (s, 3H), 7.14 (d, J=8.2 Hz, 2H), 7.48 (d, J=8.1 Hz, 1H), 7.63 (d, J=7.2 Hz, 1H); 7.09-7.22 (m, 3H), 11.10 (s, br, 1H), 11.80 (s, 1H). Anal. Calcd. for C 22 H 24 N 6 O 4 S. 1.0H 2 O: C, 54.31; H, 5.39; N, 17.27; S, 6.59. Found: C, 54.38; H, 5.34; N, 17.28; S, 6.19.
Preparation of 8-[4-(4-tert-butyl-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 63
[0209] Synthesized using 4-t-butyl-benzenesulfony chloride and compound 47B for General Procedure G. 14% overall yield for last two steps. MS (ES−): 493; 1 H NMR (400 MHz, DMSO-d 6 ): 1.31 (s, 9H), 1.79 (m, 2H), 2.73-2.86 (m, 4H), 3.26-3.41 (m, 4H), 3.48 (s, 2H), 7.45 (d, J=8.6 Hz, 1H), 7.62-7.76 (m, 6H), 11.20 (s, br, 1H), 11.80 (s, 1H). Anal. Calcd. for C 25 H 30 N 6 O 3 S: C, 60.71; H, 6.11; N, 16.99; S, 6.48. Found: C, 60.78; H, 6.10; N, 17.08; S, 6.36.
Preparation of 8-[4-(4-amino-benzenesulfonyl)-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 64
[0210] Synthesized using 4-nitro-benzenesulfony chloride and compound 47B for General Procedure G. 14% overall yield for last two steps. MS (ES−): 452; 1 H NMR (400 MHz, DMSO-d 6 ): 1.76 (m, 2H), 2.71-2.79 (m, 4H), 3.21-3.31 (m, 4H), 3.46 (s, 2H), 6.01 (s, 2H), 6.64 (d, J=8.6 Hz, 2H), 7.39 (d, J=8.6 Hz, 2H), 7.48 (d, J=8.0 Hz, 1H), 7.63 (d, J=7.9 Hz, 1H), 7.74 (t, J=7.8 Hz, 1H), 11.10 (s, br, 1H), 11.75 (s, 1H). Anal. Calcd. for C 21 H 23 N 7 O 3 S. 0.5H 2 O: C, 54.53; H, 5.23; N, 21.20; S, 6.93. Found: C, 54.50; H, 5.24; N, 20.84; S, 6.74.
Preparation of 8-[4-(biphenyl-4-sulfonyD-[1,4]diazepan-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 65
[0211] Synthesized using biphenyl-4-sulfony chloride and compound 47B for General Procedure G. 10% overall yield for last two steps. MS (ES−): 513; 1 H NMR (400 MHz, DMSO-d 6 ): 1.82 (m, 2H), 2.73-2.83 (m, 4H), 3.29-3.41 (m, 4H), 3.48 (s, 2H), 7.47-7.53 (m, 4H), 7.62 (d, J=8.1 Hz, 1H), 7.68-7.78 (m, 3H), 7.82-7.93 (m, 4H), 11.00 (s, br, 1H), 11.75 (s, 1H). Anal. Calcd. for C 27 H 26 N 6 O 3 S. 2.3H 2 O: C, 58.32; H, 5.55; N, 15.11; S, 5.77. Found: C, 58.24; H, 4.89; N, 15.10; S, 5.79.
Preparation of 8-[4-(4-amino-benzenesulfonyl)-piperazin-1-ylmethyl]-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 66
[0212] Synthesized using 4-nitrobenzene sulfonyl chloride and compound 47A for General Procedure G. A mesylate salt of 66 was prepared. 35% overall yield for last three steps. MS (ES−): 438; H NMR (400 MHz, DMSO-d 6 ): 2.32 (s, 3H), 3.13 (bs, 4H), 3.42 (bs, 4H), 4.18 (s, 2H), 6.71 (d, J=8.8 Hz, 2H), 7.40-7.43 (m, 3H), 7.70-7.80 (m, 2H), 11.20 (s, br, 1H), 11.92 (s, 1H). Anal. Calcd. for C 20 H 21 N 7 O 3 S. 1.3 CH 3 SO 3 H. 2.75H 2 O: C, 41.67; H, 5.20; N, 15.97; S, 12.01. Found: C, 41.76; H, 5.25; N, 15.92; S, 12.22.
[0000]
[0213] General Procedure L to prepare compounds 71. To a stirring solution of 70 (1.0 eq) in THF under nitrogen was added TEA (1 mL, excess) and either sulfonyl chloride or acid chloride (1.2 eq). The reaction was allowed to stir for four hours after which time it was evaporated and extracted with CH 2 Cl 2 /H 2 O, dried and condensed. Crude material was further purified via column chromatography using 9:1 CEbCk/MeOH to afford analytically pure products 71.
Example 3
Preparation of (3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-carbamic acid tert-butyl ester, 69
[0214] Procedure H to prepare 2-aminomethyl-4-oxo-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 67. To a solution of 25 mL of 7N NH 3 (large excess) in MeOH at 0° C. was added compound 4 (1.0 g, 4.0 mmol) in a sealed tube. The mixture was then heated to 60° C. for 4 hours. The mixture was evaporated to dryness, dissolved and re-evaporated in 2×50 mL of CH 2 Cl 2 . Product was used as is without further purification.
[0215] Procedure I to prepare 2-(tert-butoxycarbonylamino-methyl)-4-oxo-3,4-dihydro-quinazoline-5-carboxylic acid methyl ester, 68. To a solution of 50 mL CH 2 Cl 2 of with 2 mL of TEA (excess), catalytic DMAP and compound 67 (from Procedure H) was added boc anhydride (2.6 g, 3 eq) at room temperature. Reaction was allowed to stir for 60 minutes, during which time all solids went into solution. The solution was evaporated to dryness and purified via column chromatography using CH 2 Cl 2 and 5% MeOH to afford 0.5 g of analytically pure compound, 68.
[0216] Procedure J to prepare 69.5 g of compound 68 was dissolved in 10 mL of hydrazine monohydrate and 25 mL of ethanol. The mixture was refluxed for four hours until no starting material was detected by TLC. Reaction was cooled, poured over 100 mL of cold water and extracted with 2×25 mL of EtOAc. Organic layers were dried with brine and then magnesium sulfate. Purified via column chromatography using 9:1 CH 2 Cl 2 /MeOH to afford 2.7 g of analytically pure compound 69. MS (ES−): 314; 1 H NMR (400 MHz, CDCl 3 ): 1.45 (s, 9H), 3.90 (s, 2H), 6.15 (bs, 1H), 6.94-7.30 (m, 3H), 12.38-12.43 (m, br, 2H). Anal. Calcd. for C 15 H 17 N 5 O 3 . 0.2H 2 O: C, 56.49; H, 5.50; N, 21.96;
[0217] Found: C, 56.61; H, 5.60; N, 21.85.
Preparation of 8-aminomethyl-2,9-dihydro-1,2,7,9-tetraaza-phenalen-3-one, 70
[0218] Procedure K to prepare 70. 250 mg of compound 69 was dissolved in 10 mL of CH 2 Cl 2 along with 4 mL of TFA. The reaction was allowed to stir at room temperature overnight resulting in a heavy white precipitate, which was filtered off and washed with CH 2 Cl 2 and dried under vacuum to afford a quantitative yield of analytically pure material, a TFA salt of compound 70. MS (ES+): 216; H NMR (400 MHz, D 2 O): 3.97 (s, 2H), 6.91 (d, J=8.2 Hz, 1H), 7.23 (d, J=7.8 Hz, 1H), 7.43 (t, J=8.0 Hz, 1H). Anal. Calcd. for C 10 H 9 N 5 O. 1.3 CF 3 COOH. 0.2H 2 O: C, 41.27; H, 2.86; N, 19.10. Found: C, 41.00; H, 3.04; N, 19.25.
Preparation of 4-methyl-N-(3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-benzenesulfonamide, 72
[0219] Synthesized using 4-methylbenzene sulfonyl chloride and compound 70 for General Procedure L. 20% yield for compound 72. MS (ES−): 368; 1 H NMR (400 MHz, CDCl 3 ): 2.27 (s, 3H), 3.93 (s, 2H), 7.28-7.43 (m, 3H), 7.67-7.78 (m, 4H), 11.43 (s, 1H), 11.83 (s, 1H). Anal. Calcd. for C 17 H 15 N 5 O 3 S: C, 55.27; H, 4.09; N, 18.96; S, 8.68. Found: C, 54.93; H, 4.09; N, 18.63; S, 8.33.
Preparation of N-(3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-benzenesulfonamide, 74
[0220] Synthesized using benzene sulfonyl chloride and compound 70 for General Procedure L. 25% yield for compound 74. MS (ES−): 354; 1 H NMR (400 MHz, CDCl 3 ): 3.95 (d, J=5.0 Hz, 2H), 7.44 (d, J=7.8 Hz, 1H), 7.45-7.60 (m, 3H), 7.67-7.77 (m, 2H), 7.91-7.93 (m, 2H), 8.24 (t, J=8.8 Hz, 1H), 11.24 (s, 1H), 11.83 (s, 1H). Anal. Calcd. for C 16 H 13 N 5 O 3 S. 1.0H 2 O: C, 51.47; H, 4.05; N, 18.76; S, 8.59. Found: C, 51.17; H, 4.20; N, 18.73; S, 8.31.
Preparation of N-(3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-acetamide, 75
[0221] Synthesized using acetic anhydride and compound 70 for General Procedure L. 22% yield for compound 75. MS (ES−): 256; 1 H NMR (400 MHz, DMSO-d 6 ): 1.91 (s, 3H), 4.05 (s, 2H), 7.32 (d, J=8.1 Hz, 1H), 7.49-7.81 (m, 2H), 8.40 (t, J=8.3 Hz, 1H). 11.25 (s, 1H), 11.75 (s, 1H). Anal. Calcd. for C 12 H 11 N 5 O 2 . 0.5H 2 O: C, 54.13; H, 4.54; N, 26.30. Found: C, 54.14; H, 4.52; N, 26.00.
Preparation of 4-nitro-N-(3-oxo-2,9-dihydro-3H-1,2,7,9-tetraaza-phenalen-8-ylmethyl)-benzamide, 76
[0222] Synthesized using 4-nitro-benzoyl chloride and compound 70 for General Procedure L. 25% yield for compound 76. MS (ES−): 363; 1 H NMR (400 MHz, CDCl 3 ): 3.99 (s, 2H), 7.18-7.20 (m, 1H), 7.34-7.38 (m, 1H), 7.75-7.90 (m, 2H), 8.20-8.32 (m, 2H), 8.40-8.48 (m, 3H).
In Vitro PARP Inhibitory Potency—IC 50
[0223] A convenient method to determine IC 50 of a PARP inhibitor compound is a PARP assay using purified recombinant human PARP from Trevigan (Gaithersburg, Md.), as follows: The PARP enzyme assay is set up on ice in a volume of 100 microliters consisting of 100 mM Tris-HCl (pH 8.0), 1 mM MgCl 2 , 28 mM KCl, 28 mM NaCl, 3.0 μg/ml of DNase I-activated herring sperm DNA (Sigma, Mo.), 30 micromolar [ 3 H]nicotinamide adenine dinucleotide (62.5 mci/mmole), 15 micrograms/ml PARP enzyme, and various concentrations of the compounds to be tested. The reaction is initiated by adding enzyme and incubating the mixture at 25° C. After 2 minutes of incubation, the reaction is terminated by adding 500 microliters of ice cold 30% (w/v) trichloroacetic acid. The precipitate formed is transferred onto a glass fiber filter (Packard Unifilter-GF/C) and washed three times with 70% ethanol. After the filter is dried, the radioactivity is determined by scintillation counting. The compounds of this invention were found to have potent enzymatic activity in the range of a few nanomolar to 20 micromolar in IC 50 in this inhibition assay.
[0224] Using the PARP assay described above, approximate IC 50 values were obtained for the following compounds:
[0000]
TABLE I
Compound
Structure
IC50 nM
7
35
8
23
9
35
10
19
11
6
12
9
13
12
14
18
15
32
16
21
17
20
18
17
19
18
20
35
21
n/a
22
35
23
39
24
51
25
26
26
41
27
43
28
29
30
13
31
28
32
31
33
n/a
34
49
35
44
36
19
37
12
38
20
39
15
40
39
41
42
42
13
43
38
44
21
45
49
46
11
50
52
51
15
52
21
53
23
54
14
55
18
56
27
57
17
58
13
59
23
60
24
61
27
62
22
63
19
64
15
65
22
66
45
69
47
72
171
74
23
75
30
76
10
[0225] Efficacy In Vivo for Compound 13
1) Mouse Intracranial Model of B16 Melanoma:
[0226] The murine melanoma cell line B16 of C57BL/6J (H-2 b /H-2 b ) origin was cultured in RPMI-1640 containing 10% fetal calf serum (Invitrogen, Milan, Italy), 2 mM L-glutamine, 100 units/ml penicillin and 100 μg/ml streptomycin (Flow Laboratories, Mc Lean, Va.), at 37° C. in a 5% CO 2 humidified atmosphere. TMZ was provided by Schering-Plough Research Institute (Kenilworth, N.J.). Compound 13 was dissolved in 70 mM PBS without potassium.
[0227] For intracranial transplantation, cells (10 4 in 0.03 ml of RPMI-1640) were injected intracranially (ic) through the center-middle area of the frontal bone to a 2 mm depth, using a 0.1 ml glass microsyringe and a 27-gauge disposable needle. Murine melanoma B16 cells (10 4 ) were injected ic into male B6D2F1 (C57BL/6 XDBA/2) mice. Before tumor challenge, animals were anesthetized with ketamine (100 mg/kg) and xylazine (5 mg/kg) in 0.9% NaCl solution (10 ml/kg/ip). Histological evaluation of tumor growth in the brain was performed 1-5 days after tumor challenge, in order to determine the timing of treatment.
[0228] The compound 13 was administered per os 15 min before TMZ. Control mice were always injected with drug vehicles. In tumor-bearing mice treatment started 48 h after challenge, when tumor infiltration in the surrounding brain tissue was histologically evident. Mice were treated with compound 13 by oral gavage once a day for five days, at the doses of 10 mg/kg.
[0229] In tumor-bearing mice, treatment started on day 2 after challenge, when tumor infiltration in the surrounding brain tissue was histologically evident. Mice were treated daily with compound 13 plus TMZ for 5 days and monitored for mortality for 90 days. Median survival times (MST) were determined and the percentage of increase in lifespan (ILS) was calculated as: {[MST (days) of treated mice/MST (days) of control mice]−1}×100. Efficacy of treatments was evaluated by comparing survival curves between treated and control groups. [00222]All procedures involving mice and care were performed in compliance with national and international guidelines (European Economy Community Council Directive 86/109, OLJ318, Dec. 1, 1987 and NIH Guide for care and use of laboratory animals, 1985).
[0230] Survival curves were generated by Kaplan-Meier product-limit estimate and statistical differences between the various groups (8 animals/group) were evaluated by log-rank analysis with Yates correction (software Primer of Biostatistics, McGraw-Hill, New York, N.Y.). Statistical significance was determined at a p=0.05 level. Differences were considered statistically significant when P<0.05.
[0231] The results indicate oral administration of 10 mg/kg compound 13 significantly increased the survival time of mice treated with compound 13+TMZ combination and was significantly higher than that observed in animals receiving TMZ as single agent (P<0.0001). No significant differences in survival times were observed between control and TMZ treated groups ( FIG. 1 ).
2) Intracranial Xenograft Model of SJGBM2 Glioma in Mice:
[0232] The compound 13 was tested in the intracranial xenograft model of SJGBM2 glioma in mice (Tentori, et al. Clin. Cancer Reser. 2003, 9, 5370). For this purpose compound 13 was given once at 15 min pre-TMZ at 10 mg/kg, po.
[0233] A dose of 10 mg/kg compound 13 was found to be efficacious ( FIG. 2 ). Its combination with TMZ increased MTS from 22.5 d (TMZ alone) to 25 d (P=0.002).
Efficacy In Vivo for Compound 37
1) Mouse Intracranial Model of B16 Melanoma:
[0234] The experiment was performed as described above for Compound 13. It was investigated whether oral administration of Compound 37 (5 mg/kg or 12.5 mg/kg), might increase the efficacy of TMZ against B16 melanoma growing at the CNS site. In mice bearing B16 melanoma, the results indicated that the mean survival time of the groups treated with Compound 3712.5 mg/kg+TMZ combination was significantly higher than that observed in animals receiving TMZ as single agent ( FIG. 3 ).
2) Intracranial Xenograft Model of SJGBM2 Glioma in Mice:
[0235] The efficacy of Compound 37 was then investigated using an orthotopic model of a human glioblastoma multiforme xenograft (SJGBM2) in nude mice. The response of SJGBM2 to TMZ, used as single agent or in combination with Compound 37 (10 mg/kg or 20 mg/kg) for five days or in combination with Compound 37 (MGI25036) 10 mg/kg for five days followed by a 14-day treatment with Compound 37100 mg/kg as single agent, is shown in FIG. 4 . The results indicate that oral administration of Compound 37 (10 mg/kg or 20 mg/kg)+TMZ significantly prolonged survival of tumor bearing mice with respect to controls or to animals treated with TMZ. It should be noted that in this tumor model TMZ was ineffective. Treatment with 10 mg/kg Compound 37+TMZ for five days followed by a high dose of Compound 37 (100 mg/kg) for 14 days significantly increased animal survival with respect to 10 mg/kg Compound 37+TMZ for five days.
3) Enhancement of Radiation Treatment of Head and Neck Squamous Cell Carcinoma
[0236] Human HNSCC cell line JHU012 was used, having been previously genetically characterized and originally derived at the Johns Hopkins University Head and Neck Laboratories from human tumor explants. The cell line was maintained in RPMI 1640 medium with 10% fetal bovine serum and 1% penicillin/streptomycin at 5% CO 2 in 37° C. humidified incubators. Experiments were performed on 6-week-old male BALB/c nude mice nu/nu. The animals were randomly divided into the following treatment groups: Group 1—controls, Group 2—Radiation alone (2 Gray (gy)/day for 2 days), Group 3—100 mg/kg Compound 37 alone orally (PO) qdx17, Group 4-30 mg/kg Compound 37 PO+Radiation, Group 5-100 mg/kg Compound 37 PO+Radiation, with each group consisting of 8 mice. Mice were anesthetized by intraperitoneal injection of 3-5 mL tribromoethanol. Tumors were established at the right flank by subcutaneous injection of 1×10 7 cells. Fourteen days post cell injection tumors were surgically exposed and measured in 3 dimensions using calipers. Compound 37 was then dosed orally in treatment Groups 3-5. In Groups 4 and 5, animals received Compound 37 15 minutes prior to radiation (2 gy/day for 2 days). At day 31 post tumor cell inoculation, tumors were again surgically exposed and measured in 3 dimensions using calipers A significant inhibition of tumor growth was observed in Group 5 treated with 100 mg/kg orally administered Compound 37+Radiation (tumor volume at end of experiment=209.04 mm 3 ) compared to the control Group 1 (tumor volume at end of experiment=585.9 mm 3 p<0.01). ( FIG. 5 ) Compound 37 at 30 mg/kg in combination with radiation had no significant effect on tumor growth inhibition compared to radiation alone ( FIG. 5 ). In addition, 100 mg/kg Compound 37 PO qdx17 alone had no significant effect on tumor growth inhibition compared to vehicle controls ( FIG. 5 ). This indicates an enhanced effect when the higher dose of Compound 37 was combined with radiation as opposed to either treatment modality alone.
4) Effect of Compound 37 on Tumor Growth in Mice Bearing BRCA-1 Deficient Tumors
[0237] 1×10 6 BRCA-1 null cells were injected subcutaneously on the right flank of female nu/nu mice (6-7 weeks old; Harlan Sprague Dawley, Indianapolis Ind.). After approximately 10-14 days, the tumors were approximately 100 mm 3 . Mice were sorted into groups so that mean tumor size was similar among groups with minimum standard deviations. Dosing started the day after sorting and tumor volume was monitored three times per week. Tumors were measured in two diameters and volume calculated by (lxw) 2 /2. Mice were removed from the study when tumors reached 1500 mm 3 . “Time to Endpoint” or TTE (the number of days it takes for the tumor to reach 1500 mm 3 or greater) is the endpoint of the study. Compound 37 was weighed out every 2-3 days and solubilized in sterile bottled water (J. T. Baker, Ultrapure Bioreagent 4221-02) to 10 mg/ml. The compound was dosed orally, daily for 28 days from start of the study—day 1. A positive control was utilized, using a well known PARP inhibitor shown to be effective as a stand alone agent in the BRCA models (Bryant et al). The positive control agent was dosed at 25 mg/kg IP qdx5 from start of experiment. 100 mg/kg Compound 37 was effective in significantly retarding tumor growth in the BRCA-1 null model both times tested. When the dosing of Compound 37 was stopped at day 28, the tumors start to grow approximately 10-14 days later. Compound 37 not only significantly delayed tumor growth compared to vehicle controls but also delayed tumor growth compared to the positive control (p<0.05) in both experiments.
[0238] A study was conducted to compare the bioavailablity and brain plasma levels of various mammals administered with the disclosed compounds and a similar prior art compound. The prior art compound has the following formula:
[0000]
[0000] The comparative study was conducted as follows:
[0239] PARP inhibitors in water solutions were dosed either by bolus (<1 min) intravenous injection, or by oral gavage. For dogs, intravenous and oral dosing was performed in a crossover design with a one-week washout period between dose routes. The screening dose was 30 mg/kg for each compound. For mice, three animals per time point were sacrificed by CO 2 asphyxia and blood collected by cardiac puncture. For rats and dogs, serial blood samples were taken at various time points from the indicated number of animals. For rats, the volume of blood sampled was immediately replaced with 2× volume of 1:1 donor rat blood:heparinized saline. The blood samples were transferred to heparinized containers, briefly mixed, and stored on ice until centrifugation to prepare plasma. The plasma was transferred to fresh containers and stored at ≦−70° C. until bioanalysis. In some cases brains or tumor tissue were collected after sacrifice and stored at ≦−70° C. until bioanalysis.
[0240] Plasma samples were processed by precipitation with acetonitrile, evaporation and reconstitution. Brain and tumor tissue samples were homogenized with phosphate buffered saline, pH 7.4, precipitated with acetonitrile, followed by evaporation and reconstitution. The reconstituted samples were analyzed vs. matrix calibration standards by LC-MS/MS. The bioanalytical method performance was verified by the performance of quality control samples. Generally, the plasma lower limit of quantitation was 5 ng/mL. Tissue lower limits of quantitation depended on the degree of dilution during homogenization, but usually were 15 to 20 ng/g.
[0241] Plasma, brain, and tumor concentration data were processed by noncompartmental pharmacokinetic analysis using WinNonlin Professional Version 4.1. AUC was calculated using the Linear/Log rule. Time points for the Lambda Z phase were selected by visual inspection. The slopes of terminal phases were calculated by unweighted linear regression.
[0242] Selective PARP inhibitors were tested for basic plasma and tissue pharmacokinetic properties in mice, rats, and dogs. After assessment, this family compounds appear to be orally bioavailable in all species and to penetrate brain and tumor tissue. Table 1 summarizes the oral bioavailability (PO) for compounds 8, 13, 36 and 37 and the comparative compound in mice and rats and brain/plasma ratio (B/P) for these five compounds in mice and rats.
[0243] The results of the comparative study are summarized in Table II. The results show that while the prior art compound has good bioavailability the prior art compound has a ratio of brain to plasma levels that is very low. Unexpectedly, the disclosed compounds of Formula (I) have a good ratio of brain to plasma level compared to the prior art compound. These results show the disclosed compounds are unexpectedly available to the central nervous system where needed for therapeutic benefit as compared to the prior art compound.
[0000]
TABLE II
Comparison of Bioavailabity (PO) and Ratio of Brain to Plasma levels (B/P) for
selected compounds of Formula (I) relative to a related prior art compound.
Compound
PO in mice
B/P in mice
PO in rats
B/P in rats
77%
<5%
77%
<5%
49%
49%
58%
40%
61%
46%
51%
42%
75%
30-64%
50%
71-117%
81%
26%
45%
36%
[0244] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications are intended to be included within the scope of the following claims.
INCORPORATION BY REFERENCE
[0245] All publications, patents, and pre-grant patent application publications cited in this specification are herein incorporated by reference, and for any and all purposes, as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. In the case of inconsistencies the present invention will prevail. | The present invention relates to tetraaza phenalen-3-one compounds which inhibit poly (ADP-ribose) polymerase (PARP) and are useful in the chemosensitization of cancer therapeutics. The induction of peripheral neuropathy is a common side-effect of many of the conventional and newer chemotherapies. The present invention further provides means to reliably prevent or cure chemotherapy-induced neuropathy. The invention also relates to the use of the disclosed PARP inhibitor compounds in enhancing the efficacy of chemotherapeutic agents such as temozolomide. The invention also relates to the use of the disclosed PARP inhibitor compounds to radio sensitize tumor cells to ionizing radiation. The invention also relates to the use of the disclosed PARP inhibitor compounds for treatment of cancers with DNA repair defects. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation-in-Part of PCT Application No. PCT/EP2006/006218 filed 27 Jun. 2006, which claims priority from DE 10 2005 030 516.4 filed 28 Jun. 2005.
FIELD OF THE INVENTION
[0002] The invention pertains to a turbine rotor and to a method for producing a rotor of the type having a row of turbine blades associated with each groove in a rotor disk, wherein each turbine blade has a blade foot received in the groove, a blade profile above the foot, and a shroud plate above the profile, each blade foot and each shroud plate having end surfaces and side surfaces which form a rhomboid, the end surfaces of each shroud plate tapering toward each other along respective radii and abutting the end surfaces of adjacent shroud plates so that the shroud plates form a closed ring.
DESCRIPTION OF THE RELATED ART
[0003] Vibrations in the blades of steam or gas turbines lead to the formation of cracks in the blades, and after enough time a blade can break off, causing severe damage to the turbine. So that problem-free operation of the turbine can be guaranteed, blade vibrations must be reduced by suitable design measures. To damp the vibrations of rotor blades in the medium-pressure and low-pressure ranges of steam turbines, the following solutions, among others, are used:
[0004] In the case of relatively large final-stage blades in the low-pressure range of the turbine, a retaining wire passing circumferentially through bores in the profile area damps the vibrations. This type of vibration damping is usually used for blades without shroud plates.
[0005] In the case of rotor blades which are subjected to only low circumferential velocities, a shroud band is riveted segment-by-segment to the ends of the profiles of the blades installed in the rotor. This design was frequently used in older turbines. In the case of turbines with high circumferential velocities, the strength of these riveted joints is insufficient. The riveted design cannot be used here.
[0006] In the medium-pressure and also increasingly in the low-pressure ranges of turbines, shroud-plate rotor blades, which combine good strength with high efficiency, are used almost exclusively today. The blades and the cover band (shroud plate) belonging to them in this design form a one-piece unit. The disadvantage of the low strength of the riveted Joint is avoided here, because the blade and the shroud plate are an integral part of each other. After the rotor blades have been installed in the turbine rotor, the shroud plates of the individual blades form a ring. The vibration damping occurs in the ring at the contact surfaces between the shroud plates of the individual blades.
[0007] The known design suffers from the following weaknesses, however. Because of the manufacturing tolerances to which each blade is subject and which are different in each case, it is impossible in practice—in the case of a stage with 70 rotor blades, for example—to install the blades in such a way that there is no play between them. Other reasons for this difficulty include the powerful centrifugal forces which act on the blades and the thermal expansion which acts on each individual section of the rotor blade during operation of the turbine. The centrifugal forces and the thermal expansion have the effect of causing the feet of the blades in the rotor to shift outward slightly. The shroud plates of the blades, furthermore, move outward in the longitudinal direction as a result of the elongation of the blade profile. Because the base surface and the shroud plate surface of each blade form a wedge, the outward-shifting movements of the blades just described leads to the formation of a gap between the shroud plate surfaces of the individual blades. As a result of this gap, the vibrations are no longer damped as desired. To avoid the disadvantages caused by the formation of gaps as described above, the following known solutions are available:
[0008] In U.S. Pat. No. 7,104,758, a turbine rotor is described, in which vibration dampers are installed at the contact surfaces between the shroud plates. While the turbine is operating, the vibration dampers are pushed outward by centrifugal force and thus create a connection between the shroud plates. Any gap which may be present is bridged by the vibration damper, as a result of which the vibrations are damped.
[0009] JP 2003097216 A1 describes an application in which the blade profile is bent slightly in the longitudinal direction by centrifugal force. As a result of this bending, an opposing movement is generated in the shroud plate. This movement compensates for any gap which may be present and thus guarantees the damping of the vibrations.
[0010] According to U.S. Pat. No. 4,840,539 B2, the shroud plates of the turbine blades are designed in the form of a “V”. After the blades are installed in the rotor, the shroud plates touch each other on only one side in the radial direction. To damp vibrations, torsional stress is produced by twisting the blade profile. On the free side of the shroud plate, there is an additional axial contact surface for vibration damping.
[0011] U.S. Pat. No. 6,568,908 B2 describes an application in which centrifugal force generates an opposing twisting movement at the contact surfaces of the shroud plate as a result of the elongation of the blade profile; this twisting movement is used to damp vibrations. The contact surfaces on the shroud plates are profiled with radii. A similar application is also used in practice by several turbine manufacturers. Here, too, the twisting of the blade profile caused by centrifugal force is used to damp the vibrations. The shroud plates are designed here in the form of a “Z”, with only their middle sections contacting each other during operation of the turbine. The two applications can be used only in the case of blades with a conical and simultaneously twisted blade profile, because only here will the shroud plates twist as desired as a result of centrifugal force.
[0012] The present invention is based on a known application which several turbine manufacturers have used for many years for rhomboidal rotor blades with shroud plates; it is also described in JP 5098906 A1. Here the outer surface of the blade foot and the outer surface of the shroud plate are at the same angle to the center of the rotor. A spacing surface on the shroud plate is made oversized with respect to the theoretically correct spacing. The idea is that, when the blades are installed in the rotor, the shroud plates will twist with respect to the blade feet as a result of the spacing oversize until the theoretically correct spacing is restored. The shroud plates are twisted when they are installed in the rotor under the effect of the radial force used to drive the blades in. The blade feet must be mounted without any gaps between them. As a result of the friction at the contact surfaces between the blade base and the rotor, the blades are supposed to assume their intended radial position and simultaneously absorb the opposing forces of the twisting of the shroud plates. In addition, a device is used to spread the last gap between the blades radially during installation of the locking blade. The twisting of the shroud plate generates torsional stress in the blade profile, which, through its spring-like action, prevents the formation of gaps between the shroud plates during operation of the turbine, and this in turn guarantees that the task of vibration damping will be fulfilled.
[0013] The process known from JP 5098906 A1 suffers from the following disadvantages. The friction between the blade foot and the rotor cannot reliably generate and maintain the necessary radial force to withstand the twisting of the shroud plates upon installation of the blades—this depends on the ratio between the width of the profile to its length or thickness. Because all of the installed blade shroud plates must be twisted in the same direction, the forces necessary for twisting are additive. The first blade to be installed occupies the desired radial position in the rotor. The following blades, however, because of the spacing oversize of the shroud plates and the insufficient degree of twisting, deviate increasingly from the required radial positioning. As a result of the deviation from the required radial positioning, only one side of the blade support shoulders rests on the rotor groove, and increasingly wider, wedge-shaped gaps form between the blade feet.
[0014] The force required to twist the shroud plates is introduced from the blade foot and proceeds via the blade profile into the shroud plate. Because of the length of the path along which this force is transmitted and because of the uncertain amount of friction actually present, the known process cannot be implemented reliably. In addition, when the force is being transmitted from the foot to the shroud, the blade profiles are bent in the longitudinal direction. The spacing surfaces at the blade foot and at the shroud plate must be free to permit the installation of the next blade. A device for holding and absorbing the opposing forces generated by the twisting cannot be used on these surfaces.
[0015] The device used to produce the necessary shroud plate gap above the locking opening for installation of the last blade must accordingly fulfill the following requirements: The last installed blade must be pushed by its shroud plate into the required radial position without causing a change in the position of the first blade. Decreasing from the last blade to the second installed blade, the force generated by the known device must flow seamlessly in the radial direction through the entire stage and twist all of the shroud plates to generate the torsional stress. Any gaps present between the blade feet must be compensated. The blades may not be damaged by uncontrolled forces. The device may not intrude into the space required to install the locking blade. These requirements on the known device can be fulfilled, if at all, only with great difficulty and at very high cost. It must also be kept in mind that, as a result of the rhomboidal angle of the shroud plate, forces introduced in the radial direction leave the stage again after only a few blades.
SUMMARY OF THE INVENTION
[0016] The invention is based on the task of designing a rotor of the general type in question in such a way and to provide a process and a device of such a type that, after installation of the blades in the rotor, it is possible to produce the torsional stress required to damp the vibrations of the rhomboidal rotor blades easily, with a high degree of reliability in terms of the process technology involved, and at low cost.
[0017] According to the invention, the blade profiles are torsionally stressed by twisting the cover plates through an angle alpha so that the side surfaces of adjacent cover plates are circumferentially aligned in a plane perpendicular to the longitudinal axis.
[0018] During assembly, each blade foot is inserted into one of the grooves so that the end surfaces of each blade foot abut the end surfaces of adjacent blade feet and the end surfaces of each shroud plate abut the end surfaces of adjacent shroud plates, the side surfaces of each shroud plate forming an angle alpha with the radial plane. A force acting in the direction of the longitudinal axis is then applied to each shroud plate to twist the shroud plate through the angle alpha so that the blades are torsionally stressed and the side surfaces of adjacent cover plates are circumferentially aligned in a plane perpendicular to the longitudinal axis. This force is maintained on the blades until a complete circumferential row of blades has been inserted into the groove and the cover plates form a closed ring.
[0019] The force is preferably maintained by clamping devices which each have a longitudinal channel bounded by two sides, one of the sides having a pair of threaded bores oriented transversely to the longitudinal channel, each of the bores receiving a clamping screw. The channel is placed over the combs of two adjacent shroud plates and the device is centered between the two shroud plates, followed by tightening the clamping screws against respective shroud plates to twist at least one of the shroud plates through the angle alpha.
[0020] The invention can be applied easily and with great technical reliability as a result of the following points. When the rotor is being designed, the calculation or design department will determine the torsion angle of the blades and enter it on the drawing of the shroud plate of the blade. The side surfaces or plan surfaces of the shroud plates are fabricated with this angle on all of the blades.
[0021] The shroud plates of all the blades are fabricated with the angle indicated in the drawing. After installation in the rotor, each blade is then twisted by means of a clamping device by application of a predetermined, minimally calculated axial force and held reliably in this position throughout the installation process.
[0022] The blades can be twisted easily and reliably upon assembly. The force needed to twist the shroud plates is generated positively and directly on the shroud plates and also positively maintained on the shroud plates during installation. The application of the invention is thus independent of the friction generated between the contact surfaces of the blades in the rotor.
[0023] After the installation of each blade, its radial position in the rotor can be checked. The gap for installing the locking blade is present immediately. The installation of the locking blade is not impeded by the presence of the clamping devices. Because the clamping devices are simple to use and inexpensive, the invention can be implemented at low cost. All of the previously described disadvantages of the process known from JP 5098906 A1, especially the danger that the blades could be damaged when they are twisted as a result of the uncontrolled introduction of radial force, are avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIG. 1 shows a front view of a rotor blade;
[0025] FIG. 2 shows a side view of FIG. 1 , looking in the direction A of FIG. 3 ;
[0026] FIG. 3 shows a plan view of FIG. 1 ;
[0027] FIG. 4 shows an axial cross section of a rotor blade after installation in the rotor;
[0028] FIG. 5 shows a plan view of the shroud plates of three rotor blades installed in the rotor before they are twisted;
[0029] FIG. 6 shows a plan view of the shroud plates of three rotor blades installed in the rotor after they are twisted;
[0030] FIG. 7 shows a front view of the clamping device as it is being used;
[0031] FIG. 8 shows a side view of the clamping device as it is being used;
[0032] FIG. 9 shows a plan view of the clamping device as it is being used;
[0033] FIG. 10 shows an example of an alternative use of a retaining wire instead of a clamping device;
[0034] FIG. 11 shows an example of a clamping device extending over the entire width of the shroud plate;
[0035] FIG. 12 shows an example with a retaining groove next to the width of the shroud plate;
[0036] FIG. 13 shows a plan view of the contours of a shroud plate before and after twisting;
[0037] FIG. 14 shows the way in which the decrease in spacing functions on an enlarged scale;
[0038] FIG. 15 shows a concrete example of the triangles and formulas used to calculate the torsion angle Alpha; FIG. 16A is an end view of the locking blade foot and the blade lock in the area of the loading channel; and FIG. 16B is a plan view of the arrangement of FIG. 16A .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0039] The blade of a turbine consists of a blade foot 1 , which has a tapered shape and, in the case shown here, is designed as a double hammer head with support shoulders 1 . 4 and 1 . 5 , lateral surfaces 1 . 2 and 1 . 3 , and a base surface 1 . 1 . From the foot plate of the blade, a blade profile 2 proceeds upward with a taper and also with a twist. A shroud plate 3 with an expansion bevel, which forms an angle Gamma with the horizontal ( FIG. 1 ), is provided at the top end of the blade profile 2 . The blade foot 1 and the shroud plate 3 have the geometric form of a rhomboid or parallelogram. The shroud plate 3 has two side or plan surfaces 3 . 2 , 3 . 3 and two end or spacing surfaces 3 . 4 and 3 . 5 . The plate is also provided with a sealing comb 3 . 6 . In the installed state, the side or plan surfaces 3 . 2 , 3 . 3 are aligned with each other in the circumferential direction of the rotor 4 , whereas the end or spacing surfaces 3 . 4 , 3 . 5 are at an angle to the longitudinal axis of the rotor 4 (rotor center RM).
[0040] The shroud plate 3 and the blade foot 1 in FIG. 2 are designed with the same taper on both sides, which is characterized by the angle Delta. The one spacing surface 3 . 4 of the shroud plate 3 lies on the same plane as the slanted foot surface of the blade foot 1 . The other spacing surface 3 . 5 is provided with a parallel spacing oversize 3 . 1 with the dimension “tz”. As can be seen in FIG. 3 , the two spacing surfaces 3 . 4 and 3 . 5 of the shroud plate 3 and the associated spacing surfaces on the blade foot 1 are at a rhomboidal angle Beta 1 to the longitudinal axis RM of the rotor 4 . The shroud plate 3 has a length with the dimension “ts”. The dimension “ts”, which is defined by the two spacing surfaces 3 . 4 and 3 . 5 , is based on the maximum diameter of the shroud plate 3 and is shown in simplified form in FIG. 3 without consideration of the expansion bevel.
[0041] The invention is also applicable to blades with other foot shapes such as those with a single hammer head and those with a one-sided or asymmetric taper as well as to shroud plates 3 of different designs such as those without an expansion bevel and those with spacing oversizes 3 . 1 on both sides.
[0042] In the case illustrated in FIG. 4 , the blade feet 1 are inserted into a radial groove extending around the circumference of the rotor 4 of the turbine, the groove being designed to conform to the shape of the blade foot 1 . The tapered spacing surfaces of the blade feet 1 rest against each other and thus fill up the groove. The two lateral surfaces 1 . 2 and 1 . 3 define the width of the foot by which the blade is guided in the rotor 4 . The bottom surface 1 . 1 of the blade foot 1 is installed on the base of the groove 4 . 1 in the rotor 4 without play by the use of shim strips 7 . The support shoulders 1 . 4 and 1 . 5 of the blade foot 1 rest with slight pretension against the rotor 4 . The support shoulders 1 . 4 and 1 . 5 absorb the centrifugal forces and transmit them to the rotor.
[0043] According to a feature of the invention, the blade is fabricated so that it can be inserted into the groove in the rotor 4 in such a way that the plan surfaces 3 . 2 and 3 . 3 of the shroud plate 3 and the plan surfaces of the sealing comb 3 . 6 do not lie in the radial plane RE but rather deviate by a twist angle Alpha from the radial plane RE to form an angle of 90° minus Alpha to the longitudinal axis RM of the rotor 4 , as shown in FIG. 3 . To make it easier to understand this aspect, the twist angle Alpha is shown enlarged in all the figures.
[0044] After a blade has been inserted into the groove of the rotor 4 , each individual blade is twisted. According to a feature of the invention, the force F 1 , F 2 required to twist the blade is applied positively in the axial direction directly to the shroud plate 3 . The introduced force F 1 , F 2 is also maintained positively, directly on the shroud plates 3 .
[0045] The way in which the invention works can be derived from FIGS. 5 and 6 . FIG. 5 shows a plan view of three shroud plates 3 before they are twisted. The spacing surfaces 3 . 4 and 3 . 5 rest against each other, and, because of the angle Alpha, the sides with the oblique angles project beyond the plan surfaces 3 . 2 and 3 . 3 of the shroud plates 3 of the adjacent blades. The same also applies to the middle sealing comb 3 . 6 . For an angle of 90° to the longitudinal axis RM of the rotor 4 , the total spacing T1 is obtained for the shroud plates 3 in the radial plane RE.
[0046] FIG. 6 shows a plan view of the three shroud plates 3 after they have been twisted. By means of the clamping devices consisting of U-shaped blocks 5 and clamping screws 6 , to be described later, the sealing comb 3 . 6 and simultaneously the plan surfaces 3 . 2 and 3 . 3 are brought into alignment. The clamping devices generate an opposite twist on all three shroud plates 3 . As a result of the twisting produced by the clamping devices, the original rhomboid angle Beta 1 of the shroud plate 3 changes ( FIG. 5 ) to a new rhomboid angle Beta 2 . As a result of the change in the angle, the total spacing T1 of FIG. 5 is reduced to T2 in FIG. 6 :
[0047] The invention cannot be applied to rotor blades with an angle Beta 1 equal to 0°. In this case, the shroud plate has the form of a rectangle. The spacing reaches the minimum value for “ts” in FIG. 3 . When the shroud plate is twisted, “ts” increases. The decrease—as desired in accordance with the invention—which occurs in the effective shroud plate spacing in the radial plane RE when the plates are twisted does not occur in the case of rectangles.
[0048] As can be seen in FIG. 4 , the twisting of the shroud plates 3 is blocked by the blade feet 1 held in the groove in the rotor 4 , specifically by the foot width between the lateral surfaces 1 . 2 and 1 . 3 , which fits widthwise precisely in the groove. The blade profile 2 itself, however, does twist, the degree of twist decreasing from the shroud plate 3 to the blade foot 1 . The twisting of the blade profile 2 generates torsional stress in the elastic range, which remains stored as if in a spring. After the locking blade has been installed and the entire row of blades is complete and all of the clamping devices have been removed, the shroud plates 3 of the ring of blades form a closed ring, in which the shroud plates 3 block each other. Because of the spacing oversize 3 . 1 on all the shroud plates 3 , these plates 3 can no longer twist back into their original positions (see FIG. 5 ). The torsional stress remains stored in the blade profiles 2 and can thus fulfill the task imposed on them, namely, to compensate for any gaps which may occur between the shroud plates 3 during operation of the turbine.
[0049] Before the shroud plates 3 are twisted, the twist angle Alpha with which the shroud plates are already fabricated has the effect of producing an offset at the end or spacing surfaces 3 . 4 , 3 . 5 of the shroud plates 3 with respect to the adjacent shroud plates 3 when the blades are installed without force in the rotor 4 ( FIG. 5 ). The size of the offset determines the degree to which the clamping devices, to be described later, will twist the shroud plates 3 .
[0050] The twist angle Alpha is composed of the theoretical twist angle required for the increased spacing plus a loss allowance. The loss allowance is intended to compensate for losses which result from changes in position at the blade foot 1 on installation in the rotor 4 as a result of play which may exist in the guide width, from the efficiency of the clamping device, from the spring-back of the blades, and from the formation of gaps at the spacing surfaces of the shroud plates during installation of the blades. In addition, it is necessary to produce a gap of least 1 mm in the last shroud plate spacing to ensure that the locking blade can be installed without force. The size of the loss allowance added to the theoretical twist angle required for the increased spacing is determined by the actual design of the rotor blade and of the rotor 4 . It is an empirical value and can only be estimated during the first application. To ensure unobstructed installation of the blades, it is advisable to make the allowance greater than necessary.
[0051] FIGS. 7-9 show a simple clamping device for twisting the shroud plates 3 . This clamping device consists of a U-shaped block 5 with a longitudinal groove 5 . 1 . One of the sides of the block 5 is provided with two threaded bores, each of which holds a clamping screw 6 . The longitudinal groove 5 . 1 of the block 5 is placed with play on the sealing combs 3 . 6 of two adjacent shroud plates 3 and centered with respect to the two spacing surfaces 3 . 4 and 3 . 5 of the two plates. The two clamping screws 6 are then tightened against the two adjacent blades, namely, the blade just inserted into the groove in the rotor 4 and the blade inserted just before that. The clamping screws 6 twist the two shroud plates by the angle Alpha and thus bring the sealing combs 3 . 6 and the plan surfaces 3 . 2 and 3 . 3 into alignment. After the last blade in the row has been inserted and twisted with respect to the adjacent blade, the clamping device blocks 5 are removed. The shroud plate 3 is premachined with a machining allowance to facilitate installation into the rotor 4 . The finished contour 3 . 7 is turned after installation of the blades.
[0052] Depending on the shape and size of the shroud plate 3 , a similar clamping device can also be used alternatively on the web of the plan surface 3 . 3 or placed across the entire width of the shroud plate ( FIG. 11 ).
[0053] As an alternative to the previously described clamping device, it is also possible, as shown in FIG. 10 , to machine an auxiliary groove into the outside diameter of the shroud plate 3 to hold a retaining wire 8 . The shroud plates 3 are twisted by hand into the desired position with a suitable tool such as a pliers or wrench, and the retaining wire 8 is inserted into the groove. The retaining wire 8 then holds the shroud plates 3 in position until all of the blades have been installed in the stage. Then it is removed, and the shroud plate 3 is turned to final shape according to the finished contour 3 . 7 . The retaining wire 8 can be introduced as a continuous length into the auxiliary groove, or it can be divided into sections. As an alternative to the retaining wire 8 , it is also possible to use a strip of sheet metal to perform the same function.
[0054] FIG. 12 shows how, on a simple shroud plate 3 without expansion bevel, the auxiliary groove with the retaining wire 8 can be located outside the width of the blade profile 2 .
[0055] FIGS. 13 and 14 illustrate the theoretical background of the invention. FIG. 13 shows a plan view of the shroud plate 3 before and after it is twisted. Before it is twisted, the shroud plate 3 has the contour shown in broken line with the spacing “t1” from point A to A on the radial plane RE. After the shroud plate 3 is twisted by the angle Alpha, it assumes the contour shown in solid line. The spacing “t2” now lies from point C to C on the radial plane RE. The spacing “t1” has decreased by the value “a” on both sides. The rhomboid angle Beta 1 before twisting has been reduced by minus angle Alpha to Beta 2 after twisting.
[0056] The twisting of the shroud plate 3 occurs around the longitudinal axis of the blade passing through the point DP, which is located at the center of gravity of the blade profile 2 . In FIG. 13 , the point DP lies in the center of the shroud plate, as a result of which a symmetrical picture is obtained. If the point DP were outside the center of the shroud plate, the decreases in the spacing at the two spacing surfaces 3 . 4 and 3 . 5 would be unequal, but the sum would remain equal to that of the symmetrical design. The degree to which the spacing is decreased is independent of the position of the center of rotation DP on the shroud plate 3 ; this value is determined by the twist angle Alpha. When twisted, all of the points on the shroud plate 3 describe circular arcs around the point DP, such as, for example, D 1 , D 2 , and D 3 . Point A moves along the circular arc D 1 to point B and then lies above the radial plane RE by the value “c”. The detail X in FIG. 13 is shown again in FIG. 14 on a larger scale.
[0057] FIG. 15 shows a plan view of the shroud plate 3 and the method used to calculate the twist angle Alpha. Under the condition that the blade spacing Delta as in FIG. 2 is equal on both sides to Delta/ 2 , the vertical spacing [ts] at the shroud plate 3 is calculated according to the following formula from the number [n] of blades installed per stage, the diameter [D max.], the rhomboid angle [Beta 1 ] of the shroud plate 3 , and the selected spacing oversize [tz]:
[0000]
ts
=
sin
360
°
n
×
2
×
D
max
.
×
cos
Beta
1
+
tz
[0058] The parameters used in FIG. 15 have the following meanings:
[0059] t1 is the shroud plate spacing on the radial plane RE before the plates are twisted;
[0060] Beta 1 is the rhomboid angle around the center of the rotor RM before twisting (e.g., 30°);
[0061] t 3 =R is t1 without the spacing oversize tz (e.g., 0.2 mm) or the shroud plate spacing after twisting to tz on the radial plane RE
[0062] Alpha 1 is the theoretical twist angle for the selected spacing oversize tz (e.g., 0.36°);
[0063] Beta 3 is the rhomboid angle around the center of the rotor RM after twisting by Alpha 1 ;
[0064] Z % is the loss allowance added to Alpha 1 ; and
[0065] Alpha is the overall twist angle of the shroud plate 3 , consisting of Alpha 1 and the selected loss allowance Z % (e.g., 0.6°).
[0066] FIGS. 16A shows the foot 1 of the last turbine blade inserted, i.e., the locking blade. Here a loading channel 10 has been milled as an offset in the side of the groove 4 . 1 in the rotor disk 4 . This permits dropping the locking blade into groove 4 . 1 radially, whereupon a first wedge 11 with a complementary one-sided hammer head profile is emplaced, and a second wedge 12 is emplaced against the first wedge as shown. The wedges 11 , 12 are then secured with grub screws 13 as shown in FIG. 16B . The loading channel 10 can also receive the other blades prior to sliding them into place in groove 4 . 1 . After the locking blade is secured by the two-piece blade lock, the blocks 5 can be removed from the sealing combs
[0067] The invention is not limited by the embodiments described above which are presented as examples only but can be modified in various ways within the scope of protection defined by the appended patent claims. | A turbine rotor has a row of turbine blades associated with a circumferential groove in a disk, each turbine blade having foot received in the groove, a blade profile above the foot, and a shroud plate above the profile. Each blade foot and each shroud plate have end surfaces and side surfaces which form a rhomboid, the end surfaces of each shroud plate tapering toward each other along respective radii and abutting the end surfaces of adjacent shroud plates to form a closed ring. The blade profiles are torsionally stressed by applying a force to each plate in a direction parallel to the axis of the disk, thereby twisting the cover plates through an angle alpha so that the side surfaces of adjacent cover plates are circumferentially aligned in a plane perpendicular to the longitudinal axis. This force is maintained by clamping devices applied to the combs of adjacent blades. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates to a printer system and in particular to a removable printer cartridge for an inkjet printer system.
CROSS-REFERENCE TO CO-PENDING APPLICATIONS
[0002] The following applications have been filed by the Applicant simultaneously with the present application:
WAL01US WAL02US WAL03US WAL04US WAL05US WAL06US WAL07US WAL08US WAL09US WAL10US WAL11US WAL12US WAL13US WAL14US WAL15US WAL16US WAL17US WAL18US WAL19US WAL20US MPA01US MPA02US MPA03US MPA04US MPA05US MPA06US MPA07US MPA08US MPA09US MPA10US MPA11US MPA12US MPA13US MPA14US MPA15US MPA16US MPA17US MPA18US MPA19US MPA20US MPA21US MPA22US MPA23US MPA24US MPA25US MPA26US MPA27US MPA28US MFA29US MPA30US MPA31US MPA32US MPA33US RRA01US RRA03US RRA04US RRA05US RRA06US RRA07US RRA08US RRA09US RRA10US RRA11US RRA12US RRA13US RRA14US RRA15US RRA16US RRA17US RRA18US RRA19US RRA20US RRA21US RRA22US RRA23US RRA24US RRA25US RRA26US RRA27US RRA28US RRA29US RRA30US RRA31US RRA32US RRA33US SMA01US SMA02US SMA03US SMA04US SMA05US SMA06US SMA07US SMA08US SMA09US SMA10US
The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
BACKGROUND OF THE INVENTION
[0003] Traditionally, most commercially available inkjet printers employ a printhead that traverse back and forth across the width of the print media as it prints. Such a print head is supplied with ink for printing and typically has a finite life, after which replacement of the printhead is necessary. Due to the size and configuration of the traversing printhead, removal and replacement of this element is relatively easy, and the printer unit is designed to enable easy access to this element. Whilst printer systems employing such traditional traversing printheads have proven capable of performing printing tasks to a sufficient quality, as the printhead must continually traverse the stationary print media, such systems are typically slow, particularly when used to perform print jobs of photo quality.
[0004] Recently, it has been possible to provide printheads that extend the entire width of the print media so that the printhead remains stationary as the print media progresses past. Such printheads are typically referred to as pagewidth printheads, and as the printhead does not move back and forth across the print media, much higher printing speeds are possible with this printhead than with traditionally traversing printheads. However as the printhead is the length of the print media, it must be supported within the structure of the printer unit and requires multiple electrical contacts to deliver power and data to drive the printhead, and as such removal and replacement of the printhead is not as easy as with traditional traversing printheads.
[0005] Accordingly, there is a need to provide a printer system that is capable of providing high quality print jobs at high speeds and which facilitates relatively easy replacement of the printhead when necessary.
SUMMARY OF THE INVENTION
[0006] Accordingly, in one embodiment of the present invention there is provided a method for facilitating maintenance of an inkjet printer of a type having a pagewidth printhead, the method including the steps of:
providing the inkjet printer in at least first and second portions detachable from each other, the first portion requiring replacement more frequently than the second portion in use; wherein the first portion includes the pagewidth printhead.
[0008] The first portion may further include a printing fluid storage for storing printing fluids to be delivered by the pagewidth printhead and be in the form of a printer cartridge that can be removably received within the second portion.
[0009] The second portion may be a printer cradle unit having a cavity adapted to receive the printer cartridge. The printer cradle unit may further include an electrical control unit to control the operation of the printer cartridge via power and data connectors which mate with corresponding power and data connectors provided on said printer cartridge following receival of the printer cartridge within the printer cradle unit. The printer cradle unit may also include a print media handling system for supplying print media to the printhead of the printer cartridge to facilitate printing on the surface of the print media.
[0010] It will be appreciated that the present invention provides a method for facilitating maintenance of a printer system that employs a pagewidth printhead and associated printing fluid storage means in a cartridge form which can be readily removed and replaced from a printer unit. Such an arrangement makes it possible to provide a printer system that is capable of providing high quality print jobs at high speeds and which facilitates easy removal and replacement of the printhead where necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view, showing front, top and right-hand sides of a printer cartridge according to a preferred embodiment of the present invention in combination with a printer cradle.
[0012] FIG. 2 is a block diagram of the printer cartridge.
[0013] FIG. 3 is a perspective view, showing front, top and right-hand sides of the printer cartridge prior to insertion into the printer cradle.
[0014] FIG. 4 is a perspective view, showing rear, bottom and left-hand sides of the printer cartridge.
[0015] FIG. 5 is a perspective view, showing, front, bottom and right-hand, sides of the printer cartridge in a partly dismantled state.
[0016] FIG. 6 is a perspective view, showing front, bottom and right-hand sides of the printer cartridge in an exploded state.
[0017] FIG. 7 is a plan view of the underside of a base molding of the cartridge revealing a number printing fluid conduits.
[0018] FIG. 8 is a right-hand plan view of the printer cartridge.
[0019] FIG. 9 is a cross-sectional view of the printer cartridge.
[0020] FIG. 10 is a cross sectional view through a printhead chip nozzle in a first state of operation.
[0021] FIG. 11 is a cross sectional view through the printhead chip nozzle in a second state of operation.
[0022] FIG. 12 is a cross sectional view through a printhead chip nozzle subsequent to ejection of an ink droplet.
[0023] FIG. 13 is a perspective, and partially cutaway, view of a printhead chip nozzle subsequent to ejection of an ink droplet.
[0024] FIG. 14 is a perspective cross section of a printhead chip nozzle.
[0025] FIG. 15 is a cross section of a printhead chip nozzle.
[0026] FIG. 16 is a perspective and partially cutaway perspective view of a printhead chip nozzle.
[0027] FIG. 17 is a plan view of a printhead chip nozzle.
[0028] FIG. 18 is a plan, and partially cutaway view of a printhead chip nozzle.
[0029] FIG. 19 is a perspective cross-sectioned view of a portion of a printhead chip.
[0030] FIG. 20 is a block diagram of the printer cradle.
[0031] FIG. 21 is a perspective, front, left-hand, upper side view of the printer cradle.
[0032] FIG. 22 is a front plan view of the printer cradle.
[0033] FIG. 23 is a top plan view of the printer cradle.
[0034] FIG. 24 is a bottom plan view of the printer cradle.
[0035] FIG. 25 is a right-hand plan view of the printer cradle.
[0036] FIG. 26 is a perspective view of the left-hand, front and top sides of the printer cradle in an exploded state.
[0037] FIG. 27 is a right-hand, and partially cutaway, plan view of the printer cradle.
[0038] FIG. 28 is a perspective, rear left-hand and upper view of the printer cradle with print cartridge inserted.
[0039] FIG. 29 is a perspective, rear left-hand and upper side view of the printer cradle with RFI shield removed.
[0040] FIG. 30 is a perspective detail view of a portion of the left-hand side of the printer cradle.
[0041] FIG. 31 is a perspective detail view of a portion of the right-hand side of the printer cradle.
[0042] FIG. 32 is a perspective view of a single SoPEC chip controller board.
[0043] FIG. 33 is a perspective view of a twin SoPEC chip controller board.
[0044] FIG. 34 is a block diagram of a SoPEC chip.
[0045] FIG. 35 is a perspective view of an ink refill cartridge in an emptied state.
[0046] FIG. 36 is a perspective view of the ink refill cartridge in a full state.
[0047] FIG. 37 is a perspective view of the ink refill cartridge in an exploded state.
[0048] FIG. 38 is a cross section of the ink refill cartridge in an emptied state.
[0049] FIG. 39 is a cross section of the ink refill cartridge in a full state.
[0050] FIG. 40 depicts a full ink refill cartridge aligned for docking to a printer cartridge.
[0051] FIG. 41 depicts the ink refill cartridge docked to a printer cartridge prior to dispensing ink.
[0052] FIG. 42 depicts the ink refill cartridge docked to a printer cartridge subsequent to dispensing ink.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0053] FIG. 1 depicts an inkjet printer 2 which includes a cradle 4 that receives a replaceable print cartridge 6 into a recess formed in the cradle's body according to a preferred embodiment of the present invention. Cartridge 6 is secured in the cradle recess by a retainer in the form of latch 7 that is connected by a hinge to cradle 4 . Visible on the upper surface of print cartridge 6 is an ink refill port 8 which receives an ink refill cartridge during use.
[0000] Print Cartridge
[0054] Referring now to FIG. 2 , there is depicted a block diagram of removable inkjet printer cartridge 6 . Cartridge 6 includes ink refill port 8 and an ink delivery assembly 10 for storing and delivering ink to a micro-electromechanical pagewidth print head chip 52 . Printhead chip 52 receives power and data signals from cradle 4 via power and data interface 58 . A rotor element 60 , which is mechanically driven by cradle 4 has three faces which respectively serve to: blot printhead chip 52 subsequent to ink ejection; seal the printhead when it is not in use; and act as a platen during printing. Accordingly, rotor element 60 acts as an auxiliary assembly to the printhead in that it assists in maintaining proper printhead functioning. Cartridge 6 also includes an authentication device in the form of quality assurance chip 57 which contains various manufacturer codes that are read by electronic circuitry of controller board 82 of cradle 4 during use. The manufacturer codes are read to verify the authenticity of cartridge 6 .
[0055] With reference to FIGS. 3 to 9 , and initially to FIG. 6 , structurally cartridge 6 has a body including a base molding 20 that houses a polyethylene membrane 26 including ink storage reservoirs in the form of pockets 28 , 30 , 32 , 34 for each of four different printing fluids. Typically the printing fluids will be cyan, magenta, yellow and black inks. Additional storage reservoirs may also be provided within base molding 20 in order to receive and store an ink fixative and/or an infrared ink as various applications may require. In this regard there may be up to six storage reservoirs provided with base molding 20 . As membrane 26 is filled with printing fluids it expands and conversely, as ink is consumed during printing the membrane collapses.
[0056] Cover molding 36 includes a recess 38 that receives an ink inlet molding 24 having a number of passageways. A number of apertures 42 A- 42 E are formed through recess 38 and are arranged to communicate with corresponding passageways of ink inlet molding 24 . The passages of the ink inlet member convey ink from an externally fitted ink refill cartridge to each of the ink storage reservoirs via a series of ink delivery paths formed into ink membrane 26 . The ink delivery paths connect each aperture 42 A- 42 E of the ink inlet member 24 to its dedicated ink storage reservoir 28 - 34 . The ink is typically delivered under pressure thereby causing it to flow into and expand the reservoirs of membrane 26 . An ink inlet seal 40 is located over the outside of recess 38 in order to seal apertures 42 A- 42 E prior to use.
[0057] Pagewidth printhead chip 52 is disposed along the outside of cartridge base molding 20 in the region below the ink storage reservoirs. As shown in FIG. 7 , a number of conduits 43 A- 43 E are formed in the underside of the cartridge base molding and are in direct communication with each of ink storage reservoirs 28 , 30 , 32 , 34 . The conduits provide an ink delivery path from the underside of cartridge base molding 20 to inlet ports provided in ink delivery moldings 48 onto which the printhead chip 52 is attached.
[0058] Referring again to FIG. 6 , ink delivery moldings 48 are preferably made from a plastic, such as LCP (Liquid Crystal Polymer) via an injection molding process and include a plurality of elongate conduits disposed along the length thereof arranged to distribute printing fluids from the reservoirs in membrane 26 to printhead chip 52 . Each of the elongate conduits are dedicated to carry a specific fluid, such as a particular color ink or a fixative and to allow the fluid to be distributed along the length of the printhead. To assist in controlled delivery of the printing fluid an ink sealing strip 45 is placed between cartridge base molding 20 and ink delivery molding 48 . The ink sealing strip is formed with apertures that allow fluid transfer to occur between the two elements, however the strip acts to seal the channels formed in the cartridge base molding to prevent fluid leakage.
[0059] Formed in cartridge base molding 20 adjacent the elongate ink distribution conduits, is an air distribution channel 50 that acts to distribute pressurized air from air inlet port 76 over the nozzles of printhead 52 . The air distribution channel runs along the length of printhead 52 and communicates with air inlet port 76 . A porous air filter 51 extends along the length of air distribution channel 50 and serves to remove dust and particulate matter that may be present in the air and which might otherwise contaminate printhead 52 . Porous air filter 51 has a selected porosity so that only air at a desired threshold pressure is able to pass through it, thereby ensuring that the air is evenly delivered at a constant pressure along the length of the printhead. In use, channel 50 firstly fills with compressed air until it reaches the threshold pressure within the channel. Once the threshold pressure is reached the air is able to pass through porous air filter 51 evenly along the length of the filter. The filtered air is then directed over the printhead.
[0060] The purpose of the pressurized air is to prevent degradation of the printhead by keeping its nozzles free of dust and debris. The pressurized air is provided by an air compressor (item 122 of FIG. 14 ) incorporated into cradle 4 . An air nozzle (item 124 of FIG. 15 ) of the compressor pierces air seal 44 upon insertion of cartridge 6 into cradle 4 and mates with air inlet port 76 . An air coverplate 54 is fixed to the cartridge base molding and evenly distributes air across printhead 52 in the manner described above.
[0061] Power and data signals are provided to printhead 52 by means of busbar 56 which is in turn coupled to external data and power connectors 58 A and 58 B. An authentication device in the form of a quality assurance (QA) chip 57 is mounted to connector 58 A. Upon inserting print cartridge 6 into cradle 4 the data and power connectors 58 A and 58 B, and QA chip 57 , mate with corresponding connectors (items 84 A, 84 B of FIG. 9 ) on cradle 4 , thereby facilitating power and data communication between the cradle and the cartridge. QA chip 57 is tested in use by a portion of controller board 82 configured to act as a suitable verification circuit.
[0062] Rotor element 60 is rotatably mounted adjacent and parallel to printhead 52 . The rotor element has three faces, as briefly explained previously, as follows: a platen face, which during printing acts as a support for print media and assists in bringing the print media close to printhead 52 ; a capping face for capping the printhead when not in use in order to reduce evaporation of printing fluids from the nozzles; and a blotter face, for blotting the printhead subsequent to a printing operation. The three faces of the rotor element are each separated by 120 degrees.
[0063] At opposite ends of rotor element 60 there extend axial pins 64 A and 64 B about which are fixed cogs 62 A and 62 B respectively. The free ends of axial pins 64 A and 64 B are received into slider blocks 66 A and 66 B. Slider blocks 66 A and 66 B include flanges 68 A and 68 B which are located within slots 70 A and 70 B of end plates 22 A and 22 B. The end plates are fixed at either end of cartridge base molding 20 .
[0064] Slider blocks 66 A and 66 B are biased towards the printhead end of slots 70 A and 70 B by springs 72 A and 72 B held at either end by their insertion into blind holes in slider block 66 A and 66 B and by their seating over protrusions into slots 70 A and 70 B as best seen in FIG. 8 . Accordingly, rotor element 60 is normally biased so it is brought closely adjacent to printhead 52 .
[0065] During transport, and whilst printer cartridge 6 is being inserted into cradle 4 , rotor element 60 is arranged so that its capping face caps printhead 52 in order to prevent the surrounding air from drying out the printhead's nozzles.
[0066] Printhead
[0067] A preferred design for pagewidth printhead 52 will now be explained. A printhead of the following type may be fabricated with a width of greater than eight inches if desired and will typically include at least 20,000 nozzles and in some variations more than 30,000. The preferred printhead nozzle arrangement, comprising a nozzle and corresponding actuator, will now be described with reference to FIGS. 10 to 19 . FIG. 19 shows an array of the nozzle arrangements 801 formed on a silicon substrate 8015 . The nozzle arrangements are identical, but in the preferred embodiment, different nozzle arrangements are fed with different colored inks and fixative. It will be noted that rows of the nozzle arrangements 801 are staggered with respect to each other, allowing closer spacing of ink dots during printing than would be possible with a single row of nozzles. The multiple rows also allow for redundancy (if desired), thereby allowing for a predetermined failure rate per nozzle.
[0068] Each nozzle arrangement 801 is the product of an integrated circuit fabrication technique. In particular, the nozzle arrangement 801 defines a micro-electromechanical system (MEMS). For clarity and ease of description, the construction and operation of a single nozzle arrangement 801 will be described with reference to FIGS. 10 to 18 .
[0069] The ink jet printhead chip 12 includes a silicon wafer substrate 801 . 0.35 Micron 1 P4M 12 volt CMOS microprocessing circuitry is positioned on the silicon wafer substrate 8015 .
[0070] A silicon dioxide (or alternatively glass) layer 8017 is positioned on the wafer substrate 8015 . The silicon dioxide layer 8017 defines CMOS dielectric layers. CMOS top-level metal defines a pair of aligned aluminium electrode contact layers 8030 positioned on the silicon dioxide layer 8017 . Both the silicon wafer substrate 8015 and the silicon dioxide layer 8017 are etched to define an ink inlet channel 8014 having a generally circular cross section (in plan). An aluminium diffusion barrier 8028 of CMOS metal 1 , CMOS metal 2 / 3 and CMOS top level metal is positioned in the silicon dioxide layer 8017 about the ink inlet channel 8014 . The diffusion barrier 8028 serves to inhibit the diffusion of hydroxyl ions through CMOS oxide layers of the drive circuitry layer 8017 .
[0071] A passivation layer in the form of a layer of silicon nitride 8031 is positioned over the aluminium contact layers 8030 and the silicon dioxide layer 8017 . Each portion of the passivation layer 8031 positioned over the contact layers 8030 has an opening 8032 defined therein to provide access to the contacts 8030 .
[0072] The nozzle arrangement 801 includes a nozzle chamber 8029 defined by an annular nozzle wall 8033 , which terminates at an upper end in a nozzle roof 8034 and a radially inner nozzle rim 804 that is circular in plan. The ink inlet channel 8014 is in fluid communication with the nozzle chamber 8029 . At a lower end of the nozzle wall, there is disposed a moving rim 8010 , that includes a moving seal lip 8040 . An encircling wall 8038 surrounds the movable nozzle, and includes a stationary seal lip 8039 that, when the nozzle is at rest as shown in FIG. 10 , is adjacent the moving rim 8010 . A fluidic seal 8011 is formed due to the surface tension of ink trapped between the stationary seal lip 8039 and the moving seal lip 8040 . This prevents leakage of ink from the chamber whilst providing a low resistance coupling between the encircling wall 8038 and the nozzle wall 8033 .
[0073] As best shown in FIG. 17 , a plurality of radially extending recesses 8035 is defined in the roof 8034 about the nozzle rim 804 . The recesses 8035 serve to contain radial ink flow as a result of ink escaping past the nozzle rim 804 .
[0074] The nozzle wall 8033 forms part of a lever arrangement that is mounted to a carrier 8036 having a generally U-shaped profile with a base 8037 attached to the layer 8031 of silicon nitride.
[0075] The lever arrangement also includes a lever arm 8018 that extends from the nozzle walls and incorporates a lateral stiffening beam 8022 . The lever arm 8018 is attached to a pair of passive beams 806 , formed from titanium nitride (TiN) and positioned on either side of the nozzle arrangement, as best shown in FIGS. 13 and 18 . The other ends of the passive beams 806 are attached to the carrier 8036 .
[0076] The lever arm 8018 is also attached to an actuator beam 807 , which is formed from TiN. It will be noted that this attachment to the actuator beam is made at a point a small but critical distance higher than the attachments to the passive beam 806 .
[0077] As best shown in FIGS. 13 and 16 , the actuator beam 807 is substantially U-shaped in plan, defining a current path between the electrode 809 and an opposite electrode 8041 . Each of the electrodes 809 and 8041 are electrically connected to respective points in the contact layer 8030 . As well as being electrically coupled via the contacts 809 , the actuator beam is also mechanically anchored to anchor 808 . The anchor 808 is configured to constrain motion of the actuator beam 807 to the left of FIGS. 10 to 12 when the nozzle arrangement is in operation.
[0078] The TiN in the actuator beam 807 is conductive, but has a high enough electrical resistance that it undergoes self-heating when a current is passed between the electrodes 809 and 8041 . No current flows through the passive beams 806 , so they do not expand.
[0079] In use, the device at rest is filled with ink 8013 that defines a meniscus 803 under the influence of surface tension. The ink is retained in the chamber 8029 by the meniscus, and will not generally leak out in the absence of some other physical influence.
[0080] As shown in FIG. 11 , to fire ink from the nozzle, a current is passed between the contacts 809 and 8041 , passing through the actuator beam 807 . The self-heating of the beam 807 due to its resistance causes the beam to expand. The dimensions and design of the actuator beam 807 mean that the majority of the expansion in a horizontal direction with respect to FIGS. 10 to 12 . The expansion is constrained to the left by the anchor 808 , so the end of the actuator beam 807 adjacent the lever arm 8018 is impelled to the right.
[0081] The relative horizontal inflexibility of the passive beams 806 prevents them from allowing much horizontal movement the lever arm 8018 . However, the relative displacement of the attachment points of the passive beams and actuator beam respectively to the lever arm causes a twisting movement that causes the lever arm 8018 to move generally downwards. The movement is effectively a pivoting or hinging motion. However, the absence of a true pivot point means that the rotation is about a pivot region defined by bending of the passive beams 806 . The downward movement (and slight rotation) of the lever arm 8018 is amplified by the distance of the nozzle wall 8033 from the passive beams 806 . The downward movement of the nozzle walls and roof causes a pressure increase within the chamber 29 , causing the meniscus to bulge as shown in FIG. 11 . It will be noted that the surface tension of the ink means the fluid seal 11 is stretched by this motion without allowing ink to leak out.
[0082] As shown in FIG. 12 , at the appropriate time, the drive current is stopped and the actuator beam 807 quickly cools and contracts. The contraction causes the lever arm to commence its return to the quiescent position, which in turn causes a reduction in pressure in the chamber 8029 . The interplay of the momentum of the bulging ink and its inherent surface tension, and the negative pressure caused by the upward movement of the nozzle chamber 8029 causes thining, and ultimately snapping, of the bulging meniscus to define an ink drop 802 that continues upwards until it contacts adjacent print media.
[0083] Immediately after the drop 802 detaches, meniscus 803 forms the concave shape shown in FIG. 12 . Surface tension causes the pressure in the chamber 8029 to remain relatively low until ink has been sucked upwards through the inlet 8014 , which returns the nozzle arrangement and the ink to the quiescent situation shown in FIG. 10 .
[0084] As best shown in FIG. 13 , the nozzle arrangement also incorporates a test mechanism that can be used both post-manufacture and periodically after the printhead is installed. The test mechanism includes a pair of contacts 8020 that are connected to test circuitry (not shown). A bridging contact 8019 is provided on a finger 8043 that extends from the lever arm 8018 . Because the bridging contact 8019 is on the opposite side of the passive beams 806 , actuation of the nozzle causes the priding contact to move upwardly, into contact with the contacts 8020 . Test circuitry can be used to confirm that actuation causes this closing of the circuit formed by the contacts 8019 and 8020 . If the circuit closed appropriately, it can generally be assumed that the nozzle is operative.
[0000] Cradle
[0085] FIG. 20 is a functional block diagram of printer cradle 4 . The printer cradle is built around a controller board 82 that includes one or more custom Small Office Home Office Printer Engine Chips (SOPEC) whose architecture will be described in detail shortly. Controller board 10 is coupled to a USB port 130 for connection to an external computational device such as a personal computer or digital camera containing digital files for printing. Controller board 10 also monitors:
a paper sensor 192 , which detects the presence of print media; a printer cartridge chip interface 84 , which in use couples to printer cartridge QA chip 57 ; an ink refill cartridge QA chip contact 132 , which in use couples to an ink refill cartridge QA chip (visible as item 176 in FIG. 37 ); and rotor element angle sensor 156 , which detects the orientation of rotor element 60 .
[0090] In use the controller board processes the data received from USB port 130 and from the various sensors described above and in response drives a motor 110 , tricolor indicator LED 135 and, via interface 84 , printhead chip 52 . As will be explained in more detail later, motor 110 is mechanically coupled to drive a number of mechanisms that provide auxiliary services to print cartridge 6 . The driven mechanisms include:
a rotor element drive assembly 145 , for operating rotor element 60 ; a print media transport assembly 93 , which passes print media across printhead chip 52 during printing; and an air compressor 122 which provides compressed air to keep printhead chip 52 clear of debris.
[0094] As will be explained in more detail shortly, motor 110 is coupled to each of the above mechanisms by a transmission assembly which includes a direct drive coupling from the motor spindle to an impeller of the air compressor and a worm-gear and cog transmission to the rotor element and print media transport assembly.
[0095] The structure of cradle 4 will now be explained with reference to FIGS. 21 to 31 . As most clearly seen in the exploded view of FIG. 26 , cradle 4 has a body shaped to complement cartridge 6 so that when mated together they form an inkjet printer. The cradle body is formed of base molding 90 and cradle molding 80 . The base molding acts as a support base for the cradle and also locates drive motor 110 , rotor element roller 94 and drive roller 96 . The base molding is snap fastened to cradle molding 80 by means of a number of corresponding flanges 120 and slots 123 . Cradle molding 80 defines an elongate recess 89 dimensioned to locate print cartridge 6 . A number of indentations in the form of slots 86 are formed in an internal wall of the cradle for receiving complementary protrusions in the form of ribs 78 ( FIG. 4 ) of cartridge 6 . Consequently cartridge 6 must be correctly orientated in order for it to be fully received into cradle molding 80 . Furthermore, the slots ensures that only those cartridges that are supported by the electronics of the cradle, and hence have non-interfering ribs, can be inserted into the cradle, thereby overcoming the problem of the drive electronics of the cradle attempting to drive cartridges having unsupported performance characteristics. Controller 82 is arranged to determine the performance characteristics of cartridges inserted into cradle 4 and to operate each cartridge in response to the determined performance characteristics. Consequently, it is possible for an inkjet cradle to be provided with a starter cartridge having relatively basic performance characteristics and then to upgrade as desired by replacing the starter cartridge with an improved performance upgrade cartridge. For example the upgrade cartridge may be capable of a higher print rate or support more inks than the starter cartridge.
[0096] With reference to FIG. 25 , drive shaft 127 of motor 110 terminates in a worm gear 129 that meshes with a cog 125 B that is, in turn, fixed to drive roller 96 . Referring again to FIG. 26 , the drive roller is supported at either end by bearing mount assemblies 100 A and 100 B, which are in turn fixed into slots 101 A and 101 B of cradle mounting 80 . Similarly, rotor element translation roller 94 and pinch roller 98 are also supported by bearing mount assemblies 100 A and 100 B.
[0097] Referring now to FIG. 30 , opposite the motor end of drive roller 96 there is located a flipper gear assembly 140 . The flipper gear assembly consists of a housing 144 which holds an inner gear 142 and an outer gear 143 that mesh with each other. The inner gear is fixed and coaxial with drive roller 96 whereas housing 144 is free to rotate about drive roller 96 . In use the housing rotates with drive roller 96 taking with it outer gear 143 until it either abuts a stopper located on the cradle base molding 90 or outer gear 143 meshes with rotor element drive cog 146 . The direction of rotation of drive roller 96 is dependent on the sense of the driving current applied to motor 110 by control board 82 . The meshing of outer gear 143 with rotor element drive cog 146 forms rotor element drive assembly 145 comprising drive roller 96 , inner gear 142 , outer gear 143 and rotor element drive cog 146 . Consequently, in this configuration power can be transmitted from drive roller 96 to rotor element drive roller 94 .
[0098] With reference to FIG. 31 , the opposite ends of rotor element drive roller 94 terminate in cams 148 A and 148 B which are located in corresponding cam followers 150 A and 150 B. Cam followers 150 A and 150 B are ring shaped and pivotally secured at one side by pivot pins 152 A and 152 B respectively. Hinged jaws 154 A and 154 B are provided for clutching the rotor element slider blocks (items 66 A, 66 B of FIG. 6 ) of the printer cartridge. The jaws are each pivotally connected to cam followers 150 A and 150 B opposite pins 152 A and 152 B respectively. Upon rotor element drive roller 94 being rotated, cams 148 A and 148 B abut the inner wall of cam followers 150 A and 150 B thereby causing the cam followers to rise taking with them jaws 154 A and 154 B respectively.
[0099] In order to ensure that rotor element 60 is rotated through the correct angle, cradle 4 includes a rotor element sensor unit 156 ( FIG. 20 ) to detect the actual orientation of the rotor element. Sensor unit 156 consists of a light source and a detector unit which detects the presence of reflected light. Rotor element 60 has a reflective surface that is arranged to reflect rays from the light source so that the orientation of the rotor element can be detected by sensor 156 . In particular, by monitoring sensor unit 156 , controller board 82 is able to determine which face of rotor element 60 is adjacent printhead 52 .
[0100] Apart from driving drive roller 96 , motor 110 also drives an air compressor 122 that includes a fan housing 112 , air filter 116 and impeller 114 . Fan housing 112 includes an air outlet 124 that is adapted to mate with air inlet port 76 ( FIG. 6 ) of cartridge 6 .
[0101] A metal backplane 92 is secured to the rear of cradle molding 80 as may be best seen in side view in FIG. 25 and in cross section in FIG. 27 . Mounted to backplane 92 is a control board 82 loaded with various electronic circuitry. The control board is covered by a metal radio frequency interference (RFI) shield 102 . Control board 82 is electrically coupled to cradle connectors 84 A and 84 B via a flex PCB connector 106 and also to an external data and power connection point in the form of USB port connector 130 . USB connector 130 enables connection to an external personal computer or other computational device. Cradle connectors 84 A, 84 B are supported in slots formed at either end of cradle molding 80 and are arranged so that upon printer cartridge 6 being fully inserted into recess 89 of the cradle molding, cradle connectors 84 A and 84 B make electrical contact with cartridge connectors 58 A and 58 B.
[0102] Controller board 82 is connected by various cable looms and flexible PCB 106 to QA chip contact 132 . The QA chip contact is located in a recess 134 formed in cradle molding 80 and is situated so that during ink refilling it makes contact with a QA chip 176 located in ink refill cartridge 162 as will be described shortly.
[0103] Controller board 82 also drives a tricolor indicator LED (item 135 of FIG. 20 ) which is optically coupled to a lightpipe 136 . The lightpipe terminates in an indicator port 138 formed in cradle molding 80 so that light from the tricolor indicator LED may be viewed from outside the casing.
[0104] Controller Board
[0105] Printer units according to a preferred embodiment of the invention have a fundamental structure, namely a cradle assembly which contains all of the necessary electronics, power and paper handling requirements, and a cartridge unit that includes the highly specialised printhead and ink handling requirements of the system, such that it may be possible for a cradle unit to support a cartridge unit which enables different capabilities without the need to purchase a new cradle unit.
[0106] In this regard, a range of cartridge units, each having a number of different features may be provided. For example, in a simple form it may be possible to provide a cartridge unit of three distinct types:
Starter Unit—15 ppm cartridge with 150 ml of ink capacity Intermediate Unit—30 ppm cartridge with 300 ml of ink capacity Professional Unit—60 ppm cartridge with +300 ml of ink storage capacity.
Such a system may be supported on one cradle unit with the user able to purchase different cartridge units depending upon their requirements and cost considerations.
[0110] In the case of the professional unit, it may be required that a special cradle unit be provided that supports the more developed and refined functionality of such a cartridge unit. Cartridge units of different functionality may bear indicia such as color coded markings so that their compatibility with the cradle units can be easily identified.
[0111] In this regard, FIG. 32 shows the main PCB unit for a cradle unit operating at 15-30 ppm, whilst FIG. 33 shows a main PCB unit for driving a cartridge unit operating at 60 ppm. As can be seen the PCBs are almost identical with the main difference being the presence of 2 SoPEC chips on the 60 ppm PCB. Hence, even if a user has purchased a cradle unit which may not initially support a more powerful cartridge unit, the present system structure makes it easy for the cradle unit to be easily upgraded to support such systems.
[0112] The printer preferably also includes one or more system on a chip (SoC) components, as well as the print engine pipeline control application specific logic, configured to perform some or all of the functions described above in relation to the printing pipeline.
[0113] Referring now to FIG. 4 , from the highest point of view a SoPEC device consists of 3 distinct subsystems: a Central Processing Unit (CPU) subsystem 301 , a Dynamic Random Access Memory (DRAM) subsystem 302 and a Print Engine Pipeline (PEP) subsystem 303 .
[0114] The CPU subsystem 301 includes a CPU 30 that controls and configures all aspects of the other subsystems. It provides general support for interfacing and synchronizing the external printer with the internal print engine. It also controls the low-speed communication to QA chips (which are described elsewhere in this specification). The CPU subsystem 301 also contains various peripherals to aid the CPU, such as General Purpose Input Output (GPIO, which includes motor control), an Interrupt Controller Unit (ICU), LSS Master and general timers. The Serial Communications Block (SCB) on the CPU subsystem provides a full speed USB 1.1 interface to the host as well as an Inter SoPEC Interface (ISI) to other SoPEC devices (not shown).
[0115] The DRAM subsystem 302 accepts requests from the CPU, Serial Communications Block (SCB) and blocks within the PEP subsystem. The DRAM subsystem 302 , and in particular the DRAM Interface Unit (DIU), arbitrates the various requests and determines which request should win access to the DRAM. The DIU arbitrates based on configured parameters, to allow sufficient access to DRAM for all requesters. The DIU also hides the implementation specifics of the DRAM such as page size, number of banks and refresh rates.
[0116] The Print Engine Pipeline (PEP) subsystem 303 accepts compressed pages from DRAM and renders them to bi-level dots for a given print line destined for a printhead interface that communicates directly with up to 2 segments of a bi-lithic printhead. The first stage of the page expansion pipeline is the Contone Decoder Unit (CDU), Lossless Bi-level Decoder (LBD) and Tag Encoder (TE). The CDU expands the JPEG-compressed contone (typically CMYK) layers, the LBD expands the compressed bi-level layer (typically K), and the TE encodes Netpage tags for later rendering (typically in IR or K ink). The output from the first stage is a set of buffers: the Contone FIFO unit (CFU), the Spot FIFO Unit (SFU), and the Tag FIFO Unit (TFU). The CFU and SFU buffers are implemented in DRAM.
[0117] The second stage is the Halftone Compositor Unit (HCU), which dithers the contone layer and composites position tags and the bi-level spot layer over the resulting bi-level dithered layer.
[0118] A number of compositing options can be implemented, depending upon the printhead with which the SoPEC device is used. Up to 6 channels of bi-level data are produced from this stage, although not all channels may be present on the printhead. For example, the printhead may be CMY only, with K pushed into the CMY channels and IR ignored. Alternatively, the encoded tags may be printed in K if IR ink is not available (or for testing purposes).
[0119] In the third stage, a Dead Nozzle Compensator (DNC) compensates for dead nozzles in the printhead by color redundancy and error diffusing of dead nozzle data into surrounding dots.
[0120] The resultant bi-level 6 channel dot-data (typically CMYK, Infrared, Fixative) is buffered and written to a set of line buffers stored in DRAM via a Dotline Writer Unit (DWU).
[0121] Finally, the dot-data is loaded back from DRAM, and passed to the printhead interface via a dot FIFO. The dot FIFO accepts data from a Line Loader Unit (LLU) at the system clock rate (pclk), while the PrintHead Interface (PHI) removes data from the FIFO and sends it to the printhead at a rate of 2/3 times the system clock rate.
[0122] In the preferred form, the DRAM is 2.5 Mbytes in size, of which about 2 Mbytes are available for compressed page store data. A compressed page is received in two or more bands, with a number of bands stored in memory. As a band of the page is consumed by the PEP subsystem 303 for printing, a new band can be downloaded. The new band may be for the current page or the next page.
[0123] Using banding it is possible to begin printing a page before the complete compressed page is downloaded, but care must be taken to ensure that data is always available for printing or a buffer under-run may occur.
[0124] The embedded USB 1.1 device accepts compressed page data and control commands from the host PC, and facilitates the data transfer to either the DRAM (or to another SoPEC device in multi-SoPEC systems, as described below).
[0125] Multiple SoPEC devices can be used in alternative embodiments, and can perform different functions depending upon the particular implementation. For example, in some cases a SoPEC device can be used simply for its onboard DRAM, while another SoPEC device attends to the various decompression and formatting functions described above. This can reduce the chance of buffer under-run, which can happen in the event that the printer commences printing a page prior to all the data for that page being received and the rest of the data is not received in time. Adding an extra SoPEC device for its memory buffering capabilities doubles the amount of data that can be buffered, even if none of the other capabilities of the additional chip are utilized.
[0126] Each SoPEC system can have several quality assurance (QA) devices designed to cooperate with each other to ensure the quality of the printer mechanics, the quality of the ink supply so the printhead nozzles will not be damaged during prints, and the quality of the software to ensure printheads and mechanics are not damaged.
[0127] Normally, each printing SoPEC will have an associated printer QA, which stores information printer attributes such as maximum print speed. An ink cartridge for use with the system will also contain an ink QA chip, which stores cartridge information such as the amount of ink remaining. The printhead also has a QA chip, configured to act as a ROM (effectively as an EEPROM) that stores printhead-specific information such as dead nozzle mapping and printhead characteristics. The CPU in the SoPEC device can optionally load and run program code from a QA Chip that effectively acts as a serial EEPROM. Finally, the CPU in the SoPEC device runs a logical QA chip (ie, a software QA chip).
[0128] Usually, all QA chips in the system are physically identical, with only the contents of flash memory differentiating one from the other.
[0129] Each SoPEC device has two LSS system buses that can communicate with QA devices for system authentication and ink usage accounting. A large number of QA devices can be used per bus and their position in the system is unrestricted with the exception that printer QA and ink QA devices should be on separate LSS busses.
[0130] In use, the logical QA communicates with the ink QA to determine remaining ink. The reply from the ink QA is authenticated with reference to the printer QA. The verification from the printer QA is itself authenticated by the logical QA, thereby indirectly adding an additional authentication level to the reply from the ink QA.
[0131] Data passed between the QA chips, other than the printhead QA, is authenticated by way of digital signatures. In the preferred embodiment, HMAC-SHAI authentication is used for data, and RSA is used for program code, although other schemes could be used instead.
[0132] A single SoPEC device can control two bi-lithic printheads and up to six color channels. Six channels of colored ink are the expected maximum in a consumer SOHO, or office bi-lithic printing environment, and include:
CMY (cyan, magenta, yellow), for regular color printing. K (black), for black text, line graphics and gray-scale printing. IR (infrared), for Netpage-enabled applications. F (fixative), to prevent smudging of prints thereby enabling printing at high speed.
[0137] Because the bi-lithic printer is capable of printing so fast, a fixative may be required to enable the ink to dry before the page touches the page already printed. Otherwise ink may bleed between pages. In relatively low-speed printing environments the fixative may not be required.
[0138] In the preferred form, the SoPEC device is color space agnostic. Although it can accept contone data as CMYX or RGBX, where X is an optional 4th channel, it also can accept contone data in any print color space. Additionally, SoPEC provides a mechanism for arbitrary mapping of input channels to output channels, including combining dots for ink optimization and generation of channels based on any number of other channels. However, inputs are typically CMYK for contone input, K for the bi-level input, and the optional Netpage tag dots are typically rendered to an infrared layer. A fixative channel is typically generated for fast printing applications.
[0139] In the preferred form, the SoPEC device is also resolution agnostic. It merely provides a mapping between input resolutions and output resolutions by means of scale factors. The expected output resolution for the preferred embodiment is 1600 dpi, but SoPEC actually has no knowledge of the physical resolution of the Bi-lithic printhead.
[0140] In the preferred form, the SoPEC device is page-length agnostic. Successive pages are typically split into bands and downloaded into the page store as each band of information is consumed.
Unit Subsystem Acronym Unit Name Description DRAM DIU DRAM interface unit Provides interface for DRAM read and write access for the various SoPEC units, CPU and the SCB block. The DIU provides arbitration between competing units and controls DRAM access. DRAM Embedded DRAM 20 Mbits of embedded DRAM. CPU CPU Central Processing Unit CPU for system configuration and control. MMU Memory Management Unit Limits access to certain memory address areas in CPU user mode. RDU Real-time Debug Unit Facilitates the observation of the contents of most of the CPU addressable registers in SoPEC, in addition to some pseudo-registers in real time. TIM General Timer Contains watchdog and general system timers. LSS Low Speed Serial Interfaces Low level controller for interfacing with the QA chips GPIO General Purpose IOs General IO controller, with built-in Motor control unit, LED pulse units and de-glitch circuitry ROM Boot ROM 16 KBytes of System Boot ROM code ICU Interrupt Controller Unit General Purpose interrupt controller with configurable priority, and masking. CPR Clock, Power and Reset block Central Unit for controlling and generating the system clocks and resets and powerdown mechanisms PSS Power Save Storage Storage retained while system is powered down USB Universal Serial Bus Device USB device controller for interfacing with the host USB. ISI Inter-SoPEC Interface ISI controller for data and control communication with other SoPECs in a multi-SoPEC system SCB Serial Communication Block Contains both the USB and ISI blocks. Print Engine PCU PEP controller Provides external CPU with the means Pipeline to read and write PEP Unit registers, (PEP) and read and write DRAM in single 32- bit chunks. CDU Contone Decoder Unit Expands JPEG compressed contone layer and writes decompressed contone to DRAM CFU Contone FIFO Unit Provides line buffering between CDU and HCU LBD Lossless Bi-level Decoder Expands compressed bi-level layer. SFU Spot FIFO Unit Provides line buffering between LBD and HCU TE Tag Encoder Encodes tag data into line of tag dots. TFU Tag FIFO Unit Provides tag data storage between TE and HCU HCU Halftoner Compositor Unit Dithers contone layer and composites the bi-level spot and position tag dots. DNC Dead Nozzle Compensator Compensates for dead nozzles by color redundancy and error diffusing dead nozzle data into surrounding dots. DWU Dotline Writer Unit Writes out the 6 channels of dot data for a given printline to the line store DRAM LLU Line Loader Unit Reads the expanded page image from line store, formatting the data appropriately for the bi-lithic printhead. PHI PrintHead Interface Responsible for sending dot data to the bi-lithic printheads and for providing line synchronization between multiple SoPECs. Also provides test interface to printhead such as temperature monitoring and Dead Nozzle Identification.
[0141] Ink Refill Cartridge
[0142] As previously explained, printhead cartridge 56 includes an ink storage membrane 26 that contains internal ink reservoirs 28 - 34 that are connected to an ink refill port 8 formed in the top of cover molding 36 . In order to refill reservoirs 28 - 34 an ink dispenser in the form of an ink refill cartridge is provided as shown in FIGS. 35 to 42 . The structure of refill cartridge 160 will be explained primarily with reference to FIG. 37 being an exploded view of the cartridge.
[0143] Ink cartridge 160 has an outer molding 162 which acts as an operation handle or “plunger” and which contains an internal spring assembly 164 . Spring assembly 164 includes a platform 178 from which spring members 180 extend to abut the inside of cover molding 162 . The spring members bias platform 178 against a deformable ink membrane 166 that is typically made of polyethylene and contains a printing fluid, for example a colored ink or fixative. Ink membrane 166 is housed within a polyethylene base molding 170 that slides within outer molding 162 , as can be most readily seen in FIGS. 38 and 39 . An ink outlet pipe 182 extends from membrane 166 and fits within an elastomeric collar 172 formed in the bottom of base molding 170 . A seal 174 covers collar 172 prior to use of the ink refill cartridge.
[0144] At the bottom of base molding 170 there extends a lug 190 , which acts as a locating feature, shaped to mate with refill port of an inkjet printer component such as the ink refill port 8 of printer cartridge 6 . The position of outlet pipe 182 and collar 172 relative to lug 190 is varied depending on the type of printing fluid which the ink refill cartridge is intended to contain. Accordingly, a printing fluid system is provided comprising a number of printing fluid dispensers each having an outlet positioned relative to lug 190 depending upon the type of printing fluid contained within the dispenser. As a result, upon mating the refill cartridge to port 8 , outlet 192 mates with the appropriate inlet 42 A- 42 E and hence refills the particular storage reservoir 28 , 30 , 32 , 34 dedicated to storing the same type of printing fluid.
[0145] Extending from one side of the bottom of base molding 170 is a flange 184 to which an authentication means in the form of quality assurance (QA) chip 176 is mounted. Upon inserting ink cartridge 160 into ink refill port 8 , QA chip 176 is brought into contact with QA chip contact 132 located on cradle 4 .
[0146] From the outside wall of base molding 170 there extends a retaining protrusion 168 that is received into an indentation being either pre-plunge recess 165 or post-plunge recess 169 , both of which are formed around the inner wall of top cover molding 162 as shown in FIGS. 37 and 38 . Pre-plunge recess 165 is located close to the opening of the top-cover molding whereas post-plunge recess 169 is located further up the inner wall. When ink cartridge 160 is fully charged, retaining protrusion 168 is engaged by pre-plunge recess 165 . As will be more fully explained shortly, in order to overcome the engagement a deliberate plunging force, exceeding a predetermined threshold, must be applied to the top cover molding. Plunging discharges the ink through outlet 172 , and overcomes the bias of spring assembly 164 so that base molding 170 is urged into top cover molding 162 until retaining protrusion 168 is received into post-plunge recess 169 .
[0147] Example of Use
[0148] In use printer cartridge 6 is correctly aligned above cradle 4 as shown in FIG. 3 and then inserted into recess 89 of upper cradle molding 80 . As the cartridge unit is inserted into cradle 4 , data and power contacts 84 A and 84 B on the cradle electrically connect with data and power contacts 58 A and 58 B of cartridge 6 . Simultaneously air nozzle 124 of air compressor assembly 122 penetrates air seal 44 and enters air inlet port 76 of cartridge 6 .
[0149] As can be seen in FIG. 27 , the inner walls of recess 89 form a seat or shelf upon which cartridge 6 rests after insertion. A number of resilient members in the form of springs 190 are provided to act against the cartridge as it is brought into position and also against the retainer catch, as it is locked over the cartridge. Consequently the springs act to absorb shocks during insertion and then to hold the cartridge fast with the cradle 4 and latch 7 by securely bias the cartridge in place against the latch. In an alternative the springs might instead be located on latch 7 in which case cartridge 6 would be biased against cradle 4 .
[0150] Any attempt to insert the cartridge the wrong way around will fail due to the presence of orientating slots 86 and ribs 78 of cradle 4 and cartridge 6 . Similarly, a cartridge that is not intended for use with the cradle will not have ribs corresponding to orientating slots 86 and so will not be received irrespective of orientation. In particular, a cartridge that requires driving by a cradle having a twin SoPEC chip controller board will not have the correct rib configuration to be received by a cradle having a single SoPEC chip controller board.
[0151] When the cartridge unit is first inserted into cradle unit 4 , and during transportation, rotor element 60 is orientated so that its capping face engages printhead 52 thereby sealing the nozzle apertures of the printhead. Similarly, when the printer unit is not in use the capping surface is also brought into contact with the bottom of printhead 52 in order to seal it. Sealing the printhead reduces evaporation of the ink solvent, which is usually water, and so reduces drying of the ink on the print nozzles while the printer is not in use.
[0152] A remote computational device, such as a digital camera or personal computer, is connected to USB port 130 in order to provide power and print data signals to cradle 4 . In response to the provision of power, the processing circuitry of controller board 82 performs various initialization routines including: verifying the manufacturer codes stored in QA chip 57 ; checking the state of ink reservoirs 28 - 34 by means of the ink reservoir sensor 35 ; checking the state of rotor element 60 by means of sensor 156 ; checking by means of paper sensor 192 whether or not paper or other print media has been inserted into the cradle; and tricolor indicator LED 135 to externally indicate, via lightpipe 136 , the status of the unit.
[0153] Prior to carrying out a printing operation a piece of paper, or other print media, must be introduced into cradle 4 . Upon receiving a signal to commence printing from the external computational device, controller board 82 checks for the presence of the paper by means of paper sensor 192 . If the paper is missing then tricolor LED 135 is set to indicate that attention is required and the controller does not attempt to commence printing. Alternatively, if paper sensor 192 indicates the presence of a print media then controller board 82 responds by rotating rotor element 60 to a predetermined position for printing.
[0154] In this regard, upon detection of a printing mode of operation at start-up or during a maintenance routine, rotor element 60 is rotated so that its blotting face is located in the ink ejection path of printhead 52 . The blotting surface can then act as a type of spittoon to receive ink from the print nozzles, with the ink received ink being drawn into the body of rotor element 60 due to the absorbent nature of the material provided on the blotting surface. Since rotor element 60 is part of the printer cartridge 6 , the rotor element is replaced at the time of replacing the cartridge thereby ensuring that the blotting surface does not fill with ink and become messy.
[0155] Subsequent to detecting a print command at USB port 130 and confirming the presence of print media, controller board 82 drives motor 110 so that drive roller 96 begins to rotate and, in cooperation with pinch roller 98 , draws the print media past printhead 52 . Simultaneously, controller board 82 processes print data from the external computational device in order to generate control signals for printhead 52 . The control signals are applied to the printhead via cradle interfaces 84 A, 84 B, carriage interfaces 58 A, 58 B and flex PCB contacts at either end of printhead chip 52 . Printhead chip 52 is bilithic, i.e. has two elongate chips that extend the length of the printhead, data is provided at either end of the printhead where it is transferred along the length of each chip to each individual nozzle. Power is provided to the individual nozzles of the printhead chips via the busbars that extend along the length of the chips. In response to received data and power, the individual nozzles of the printhead selectively eject ink onto the print media as it is drawn over the platen face of rotor element 60 thereby printing the image encoded in the data signal transmitted to USB port 130 .
[0156] Operation of motor 110 causes air compressor 122 to direct air into the cartridge base molding. The air is channeled via fluid delivery paths in cartridge base molding 20 into the space behind air filter 51 . Upon the air pressure building up to a sufficient level to overcome the resistance of the air filter 51 , air is directed out through pores in air filter 51 along the length of the bottom of the cartridge base molding. The directed air is received between printhead chip 52 and air coverplate 54 whilst the printer is operating and is directed past the printhead chip surface, thereby serving to prevent degradation of the printhead by keeping it free of dust and debris.
[0157] Referring now to FIG. 40 , the first step of the ink refilling procedure is initiated by refill sensor 35 indicating to controller board 82 that there is a deficiency of printing fluid in storage reservoirs 28 , 30 , 32 , 34 . In response to the signal from refill sensor 35 , controller board 82 activates indicator LED 135 . Alternatively, the detection of whether there is a deficiency of printing ink might instead be calculated by the electronics of the controller board. As the volume of ink per nozzle injection is known and is consistent throughout the operation of the printhead (approximately 1 picolitre) the amount of ink delivered by the printhead can be calculated as well as the consumption of each color or type of ink. In this regard controller board 82 is able to monitor the consumption of each printing fluid and once this level has reached a predetermined level, the tricolor indicator LED can be asserted to indicate to a user that there is a need to replenish the printing fluids.
[0158] Light from the indicator LED is transmitted by lightpipe 136 in order for an external indication to be presented to an operator of the printer at indicator port 138 of cradle 4 . This indication can convey to the user the color or type of ink that requires replenishing. The controller board can also send a signal via USB port 130 to the remote computational device to display to the user via the computational device the type of ink that requires replenishment.
[0159] In order for the refilling procedure to proceed, printer cartridge 6 must be in place in printer cradle 4 . An ink refill cartridge 160 of the required type of ink is then brought into position over the ink refill port 8 that is situated on the upper surface of printer cartridge 6 . As previously described, ink refill port 8 includes a series of inlets 42 A- 42 E protected by a sealing film 40 . Beneath sealing film 40 there are located a number of printing fluid conduits 42 A- 42 E which provide direct access to ink storage reservoirs 28 , 30 , 32 , 34 . An ink inlet is provided for each of the printing fluids, namely C, M, Y, K and Infrared and fixative where required. The position of the inlet for each of the different fluids is strategically placed laterally along inlet port 8 so that the ink outlet pin 182 of refill cartridge 160 automatically aligns and communicates with the particular one of inlets 42 A- 42 E for the specific printing fluid that cartridge 160 contains and which is to be is to be replenished.
[0160] The second step of the ink refilling stage is shown in FIG. 41 . In this figure, refill cartridge 160 has been docked into refill port 8 in the cartridge unit. Upon docking of refill cartridge 160 into refill port 8 , ink refill QA chip 176 automatically aligns with QA contact 132 on the cradle unit. Controller board 82 interrogates the various codes stored in QA chip 176 in order to verify the integrity and authenticity of ink refill cartridge 160 . If controller board 82 determines that QA chip 176 verifies the presence of authentic ink, namely from the appropriate manufacturer and of the required color or type, then it sets indicator LED 135 to show yellow, thereby indicating that refill cartridge 160 is accepted. Alternatively, controller board 82 may determine that an error state exists and in response set LED 135 to red in order to indicate that there is a problem with the refill cartridge. For example, an error state may be determined to exist if QA chip 176 failed to pass the verification step. Furthermore, it will often be the case that only one of reservoirs 28 , 30 , 32 , 34 is in need of replenishment. For example, a reservoir that is assigned to store cyan colored ink may require refilling. In that case, should QA chip 176 indicates that ink refill cartridge 160 contains non-cyan ink then controller board 82 will set indicator LED 135 to red in order to flag an error state.
[0161] It will be realized that in order for a QA assured refill to occur, communication between all parts of the printer unit is required. That is, printer cartridge 6 must be positioned in printer cradle 4 and ink refill cartridge 160 must be docked with cartridge 6 so that ink refill QA chip 176 is in contact with ink QA chip contact 132 . This ensures that each refilling action is controlled and reduces the potential for incorrect refilling which may damage the working of the printer.
[0162] As shown in FIG. 41 , when ink refill cartridge 160 is docked in refill port 8 of cartridge unit 6 , ink outlet pin 28 penetrates sealing film 40 and one of apertures 42 A- 42 E of the refill port to communicate with a corresponding one of ink inlets 24 . Ink inlet 24 is provided as an elastomeric molding so that penetration of ink seal 32 , which is located over ink refill cartridge outlet pin 28 , occurs automatically. As a consequence, self-sealing fluid communication is ensured between the ink stored in refill cartridge 160 , ink delivery conduits 43 A- 43 E and storage reservoirs 28 - 34 . The self-sealing fluid communication results in a pressurised fluid flow of ink into one of reservoirs 28 , 30 , 32 , 34 occurring upon outer molding 162 being depressed.
[0163] As shown in FIG. 42 , the third stage of the ink refilling procedure occurs when top cover molding 162 is depressed thereby expelling the ink present within the ink refill cartridge 160 into one of printer cartridge reservoirs 28 - 34 . Following depressing of outer molding 162 it is apparent to an operator that the ink refill cartridge 160 has been spent and can therefore be removed from printer cartridge 6 as the refill stage is now complete. Upon completion of the refill stage refill sensor 35 generates a signal indicating that the printing fluid level in each of reservoirs 28 - 34 is greater than a predetermined level. In response to the signal from the refill sensor, controller board 82 sets indicator LED 135 to shine green thereby indicating to the operator that the refill process has been successfully completed.
[0164] The force with which ink is expelled from ink refill cartridge 160 is determined by the degree of plunging force applied to the top cover molding 162 by an operator. Accordingly top cover molding 162 acts as an operation handle or plunger for the ink refill cartridge. Consequently it is possible that if the refilling step is not done carefully or done in haste, that the ink may be delivered to printer cartridge 6 at an unduly high pressure. Such a pressure could cause the ink stored within printer cartridge 6 to burst the ink storage membrane 26 and hence cause an ink spill within the cartridge unit that might irreparably damage the printer cartridge. The internal spring molding 164 prevents inadvertent bursting of the membrane by providing a safety mechanism against over pressurizing the ink being expelled from the refill unit. In this regard spring molding 164 is designed to limit the maximum force transmitted from the plunging of top cover molding 14 to deformable ink membrane 26 . Any force applied to top cover molding 14 which would cause ink to be expelled at a pressure above a maximum allowable level is taken up by spring molding 164 and stored within the spring members 180 . Spring molding 164 is suitably designed to prevent undue force being instantaneously applied to refill ink membrane 166 . That is, its deformation and/or elastic characteristics are selected so that it limits pressure in the membrane to a predetermined level.
[0165] As shown most clearly in FIGS. 38 and 39 a retaining protrusion 168 is located on the side of base molding 170 . Whilst ink cartridge 160 is in its pre-plunged state, retaining protrusion 168 mates with pre-plunge recess 165 . Engagement of protrusion 168 with the pre-plunge recess provides an additional measure of security during the refill process. This is because the engagement prevents unintended forces being applied from the top cover molding onto the internal ink membrane 166 and so prevents inadvertent plunging of the top cover during transport or delivery. Subsequent to docking of ink refill cartridge 160 with refill port 8 , top cover 162 is plunged with sufficient force to overcome the engagement of retaining protrusion 168 by pre-plunge recess 165 . Plunging top cover molding 162 causes platform 178 of the spring assembly 164 against ink membrane 166 thereby expelling the ink through outlet pipe 182 and into printer cartridge ink reservoir membrane 166 . In order to overcome the initial engagement of retaining protrusion 168 , an initial high force may have to be applied. Spring member 164 momentarily acts to protect ink membrane 166 from being over pressurized for this instance. Following the initial application of force normal plunging proceeds. As shown in FIG. 38 , upon completion of the refilling step, retaining protrusion 168 comes into engagement with a locking feature in the form of post-plunge recess 169 which is located towards the top of the inside wall of ink cartridge outer molding 169 . Mating of retaining protrusion 168 with upper recess 169 locks ink cartridge outer molding 169 to base molding 170 subsequent to discharging of the ink. It will be realized that this arrangement overcomes the potential for a user to attempt to replenish ink refill cartridge 162 with an inferior ink which could cause damage to the nozzles of the printer cartridge as well as the ink refill cartridge. In its post-plunged configuration, the spent ink refill cartridge may be returned to a supplier. The supplier will be provided with a tool to unlock the refill cartridge and return the top cover to its upper position wherein authentic ink can be refilled into the refill unit for re-use and QA chip 176 reprogrammed to verify the authenticity of the ink.
[0166] It will, of course, be realized that the above has been given only by way of illustrative example of the invention and that all such modifications and variations thereto, as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of the invention as defined by the following claims.
[0167] While the present invention has been illustrated and described with reference to exemplary embodiments thereof, various modifications will be apparent to and might readily be made by those skilled in the art without departing from the scope and spirit of the present invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the description as set forth herein, but, rather, that the claims be broadly construed. | A method for facilitating maintenance of an inkjet printer of a type having a pagewidth printhead, the method including the steps of providing the inkjet printer in at least first and second portions detachable from each other, the first portion requiring replacement more frequently than the second portion in use, wherein the first portion includes the pagewidth printhead. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to seed planters for dispensing individual seeds at a controlled rate into a seed furrow, and specifically to seed planters that employ vacuum systems for metering the seeds.
Seed planters dispense seeds at a controlled rate into a seed furrow as a planter is advanced along the ground. In a typical arrangement, a tractor is coupled to tow a tool bar to which is attached, in a parallel spaced part relationship, a plurality of planting units.
Each planting unit typically includes a seed hopper holding seeds and communicating with a seed meter for dispensing seeds at a controlled rate as the planting unit moves over the ground. The planting unit may include on its lower surface a furrow opening disk for opening a furrow for the seeds, a furrow closing disk for closing the furrow about the seeds, and a trailing wheel that tamps down the earth about the furrow.
The seed metering unit must pick individual seeds from the hopper and deliver them between the furrow opening disk and the furrow closing disk at a controlled rate. One method of accomplishing this task with seeds of different sizes and shapes uses a disk with a plurality of openings that rotates past a seed chamber. A vacuum draws air through the openings in the disk to trap individual seeds within each opening for delivery into a second location for release.
The vacuum for the seed metering device may be provided, for example, by a blower driven by an hydraulic motor attached to the hydraulic system of the tractor. The motor is sized to provide a sufficient vacuum pressure at an air flow rate that might be anticipated when each disk for each planting unit is empty of seeds, and therefore under a condition of minimum back resistance to the blower. After seeds begin to fill the holes, a lower flow rate is required.
BRIEF SUMMARY OF THE INVENTION
Some embodiments include a vacuum manifold for a seed planter comprising a series of seed planting units receiving vacuum to pull seeds into pockets within a metering plate, a vacuum source, a manifold attached to the vacuum source to distribute a vacuum to the series of seed planting units through multiple manifold branches, at least a first valve within a manifold branch and an actuator communicating with the first valve to delay opening of the manifold branch with respect to at least one other manifold branch during initial stages of establishing a vacuum in the manifold.
In some cases the actuator is a vacuum sensitive actuator communicating with the manifold to actuate the first valve only after a predetermined vacuum level is achieved in the manifold. In some cases the first actuator is a piston movable within a cylinder. In some cases the manifold further includes a spring biasing the valve closed in an absence of a vacuum applied to the cylinder.
In some cases the actuator provides a continuous opening of the valve as a function of the manifold pressure. In some embodiments the actuator includes a timer delaying a predetermined time after starting of the vacuum source to infer the predetermined vacuum level. In some cases the manifold includes a second valve within a second manifold branch coordinating with the first valve to delay opening of a second manifold branch with respect to the opening of the first manifold branch.
In some cases the second valve has a second actuator coordinated opening the second valve. In some cases the first and second actuators are pistons within cylinders receiving vacuum lines and wherein the second actuator receives a vacuum line through a pressure switch communicating with a vacuum line of the first actuator, the pressure switch being closed until a predetermined pressure is reached and then opening. In some cases the second valve is driven by the actuator through a linkage connecting the first actuator to the first and second valves. In some cases the linkage is a cam plate rotated by the first actuator and driving cam follower on the first and second valves.
Other embodiments include a method of planting seeds comprising the steps of (a) providing a series of seed planting units having a metering plate including a series of pockets for receiving seeds, (b) attaching the seed planting units to a manifold communicating with a vacuum source and having multiple manifold branches connected with different seed planting units and including at least one valve in one manifold passage and (c) controlling the valve to sequentially applying a vacuum source to groups of the seed planting units to draw seeds into the series of pockets upon starting of a planting operation to limit a maximum air flow to the vacuum source.
In some cases each group is a single seed planting unit. In some cases the step of sequentially applying the vacuum source to groups of the seed planting units controls the valve according to a vacuum level in the manifold. In some cases the valve closes the manifold passage in an absence of a vacuum in the manifold. In some embodiments the valve provides continuously variable restriction of the manifold passage. In some embodiments the valve closes a predetermined time after starting of the vacuum source to infer the predetermined vacuum level in the manifold. In some embodiments the vacuum is sequentially applied through greater than two manifold passages.
In some cases each of the valves is sequenced by variations of vacuum sensed within at least one portion of the manifold. In some cases at least one of the valves is sequenced by a timer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified schematic view of a planting system receiving vacuum lines from a manifold driven by a single vacuum source;
FIG. 2 is a perspective view of the vacuum source and manifold of FIG. 1 showing an actuator for sequencing air flow in two manifold branches;
FIG. 3 is an elevational cross-section of the manifold and actuator of FIG. 1 showing the connection of the actuator to an internal plate valve;
FIG. 4 is a simplified representation of the manifold of FIGS. 2 and 3 showing multiple actuators linked with vacuum lines for sequencing of four manifold branches; and
FIG. 5 shows four stages of operation of an alternative embodiment of the application of vacuum to four manifold branches.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , a planting system 10 suitable for use with the present invention may provide for a number of planting units 12 a through 12 d arrayed along a toolbar 11 towed by a tractor or the like.
Each planting unit 12 may include a seed metering unit 14 including a rotating metering disk 16 driven by a drive 17 (e.g., a motor) having a series of circumferentially displaced orifices 18 that may receive seeds 20 drawn into the orifice by a vacuum applied to the opposite side of metering disk 16 . Metering systems of this type are described in U.S. Pat. No. 6,564,730 assigned to the same assignee as the present invention and hereby incorporated by reference.
Each of the seed metering units 14 connects via a vacuum line 22 to a manifold 24 connected with one or more vacuum sources 26 . The vacuum sources 26 provide for a discharge of air through a discharge outlet 28 and an application of a vacuum through an inlet 30 to manifold 24 . Generally, the amount of air discharged from discharge outlet 28 , and thus the capacity of the vacuum source 26 , must be sufficient to create a negative pressure (henceforth vacuum pressure) to draw seeds 20 into the orifices 18 when the orifices are completely empty, for example, at the startup of the planting operation.
In the present invention, in order to reduce the peak air flow required of the vacuum sources 26 , a series of valves 32 a through 32 d are provided located within corresponding branches 36 of the manifold 24 to control the air flow through individual vacuum lines 22 . The valves 32 are rotating plate valves providing a continuous throttling of air flow as a function of rotation of the plates such as may allow smooth control reducing pressure shocks to the system such as may create control or seed retention problems.
Referring now to FIG. 2 , each vacuum source 26 may be a blower 34 powered by a hydraulic motor or the like (not shown) attached to the toolbar 11 to be easily attached to the planting units 12 through vacuum lines 22 formed of flexible hoses or the like. The vacuum source 26 may have a manifold 24 providing for four manifold branches 36 extending radially from a common center at 90 degree increments. In a first embodiment as shown in FIG. 2 , two of the manifold branches 36 b and 36 c are capped with caps 40 , and two of the manifold branches 36 a and 36 d are open to provide vacuum lines 22 to one or more planting units 12 .
Referring now also to FIG. 3 , a first open manifold branch 36 a in this embodiment may have no valve 32 or that valve 32 may be fixed in an open position. The valve 32 in manifold branch 36 d may be connected by an external actuator arm 44 to a piston shaft 46 of the vacuum cylinder 48 . The cylinder 48 is attached with respect to manifold branch 36 d so when actuated, it opens valve 32 in branch 36 d.
A vacuum line 50 is connected to the vacuum cylinder 48 to decrease the pressure in a distal portion of the cylinder 48 removed from the piston shaft 46 when vacuum is applied to the vacuum line 50 . This negative pressure draws a piston 52 within the vacuum cylinder toward that distal portion and opens valve 32 . Conversely, loss of the vacuum in line 50 causes a return of the piston 52 toward the valve 32 under the influence of a contained spring 54 closing the valve 32 . The spring 54 provides a system that automatically resets upon loss of vacuum.
The vacuum line 50 may be connected to manifold branch 36 a or other convenient location of the manifold 24 so as to allow the piston 52 to be responsive to a predetermined pressure within the manifold 24 to open valve 32 . Thus, upon initial startup, the pressure in the manifold 24 will be low as seeds are drawn into a metering disk 16 associated with branch 36 a or multiple metering disks. As those metering disks fill up, the vacuum pressure within manifold 24 decreases causing actuation of the cylinder 48 and opening of valve 32 . At this point, a sufficient number of seeds have blocked the orifices of disks attached to manifold branch 36 a so that the opening of valve 32 will not unduly decrease the vacuum pressure within the manifold 24 . Note that the operation of cylinder 48 is to gradually open valve 32 as the pressure in manifold 24 decreases so as to bring other planting units 12 a online as soon as practical as pressure capacity warrants.
By sequentially engaging the vacuum lines 22 of each planting unit 14 , the peak airflow of the vacuum source is reduced, reducing the necessary size of the motor or the hydraulic power required or reducing the number or size of blowers. In this approach where vacuum in the manifold is sensed, the system may actively respond to periods of vacuum loss for whatever reason and rapidly reengages the planting units when vacuum is obtained.
Referring now to FIG. 4 , the same approach may be extended to each of the branches 36 a through 36 d of an arbitrary manifold 24 , and in this particular example, three additional branches. In this embodiment, manifold branch 36 a has no valve, but a valve 32 and corresponding vacuum cylinder 48 may be associated with each of the branches 36 b , 36 c , and 36 d operating generally as described above with respect to manifold branch 36 d of FIG. 3 . Branch 36 a is connected by a vacuum line 50 b to vacuum cylinder 48 b and to a vacuum switch 56 a associated with manifold branch 36 b and valve 32 b . Vacuum switch 56 a is a snap action type valve that opens at a predetermined pressure difference.
The remaining orifice of vacuum switch 56 a connects via vacuum line 50 b to both vacuum cylinder 48 c associated with manifold branch 36 c and valve 32 c and vacuum switch 56 b.
The remaining port of vacuum switch 56 b in turn connects to vacuum cylinder 48 d associated with manifold branch 36 d and valve 32 d.
In operation, each of the valves 32 b , 32 c and 32 d are initially closed under the influence of internal springs within cylinders 48 b , 48 c and 48 d . As pressure decreases in the manifold 24 , vacuum line 50 a causes the actuation of vacuum cylinder 48 b opening valve 32 b . The actuation begins at a pressure lower than that which would trigger vacuum switch 56 a . Once valve 32 b is opened, the pressure begins to drop again as seeds are drawn into the corresponding holes in metering disk 16 blocking the holes until a pressure sufficient to open vacuum switch 56 a is reached upon which vacuum cylinder 48 c begins actuation. Vacuum switch 56 a has a certain degree of hysteresis to accommodate a slight decrease in pressure at manifold 24 as valve 32 c is opened.
After a period of time with valve 32 c open, the seed metering disk 16 associated with the branch 36 c begins to fill with seeds, and the pressure again decreases in manifold 24 until a second threshold is reached at which time vacuum switch 56 b opens activating vacuum cylinder 48 d to begin opening valve 32 d.
In this way, each of the manifolds and/or associated seed metering units 14 may be sequentially brought online without overwhelming the vacuum source 26 .
It will be recognized that vacuum cylinder 48 may alternatively be electric actuators such as solenoids or motors communicating with the manifold 24 via a pressure sensor of well-known type providing an electrical pressure signal that may be used to control the vacuum cylinder 48 . Alternatively, a timer may be used to sequentially activate the valves 32 according to a predetermined time delay which approximates the time required to reach the pressures expected without a direct measurement of those pressures.
Referring now to FIG. 5 in an alternative embodiment, a single actuator 65 , in this case a motor, may be triggered by a timer 63 activated by an electrical signal associated with the starting of the planting system 10 or a vacuum gauge in the manifold 24 (not shown). The actuator 65 may rotate a cam 60 communicating with cam followers 62 , serving in lieu of the actuator arm 44 , where the cam followers 62 are spring biased or gravity biased against an outer surface of the cam 60 . The cam 60 rotates about a center of the manifold 24 and has an outer surface that is a constant radius about the center of the manifold 24 . As the actuator 65 rotates the cam 60 to a position shown by cam 60 ′ the cam follower 62 associated with the valve 32 b of branch 36 b moves off of the constant radius cam surface allowing the valve 32 to close. Successive rotations to position shown by cam 60 ″ and 60 ′″ allow each of the valves 32 successively to close.
In normal field operation, each of the valves 32 will normally be fully opened.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. For example, while FIGS. 1-5 above show a separate valve 32 associated with each seed meter 12 a - 12 d , in at least some embodiments two, three, four or more seed meters may be downstream of each valve 32 . Here, multiple seed meters would be connected to each port of the fan manifold.
In addition to the concepts described above, according to another inventive aspect, the seed meters can be controlled to effectively precharge all of the meters with seed and pressure prior to seeding activity. To this end, referring again to FIG. 1 , if valves 32 b , 32 c and 32 d are initially closed and valve 32 a is opened to increase pressure in line 22 attached to meter 12 a , if disc 16 continues to be rotated after seed fills holes 18 and pressure builds up therein and during the period when pressure is being built up in the other lines 22 linked to meters 12 b - 12 d , meter 12 a will drop seed to soil therebelow which will either be wasted or will result in non-uniform seeding (i.e., the row of seed corresponding to meter 12 a will be longer than the row corresponding to meter 12 b which will be longer than the row corresponding to meter 12 c and so on).
To avoid this non-uniform seeding problem, in at least some embodiments, after seed is received in the holes 18 of a first disc and pressure builds up, as the valve (e.g. 32 b ) associated with the second seed meter 12 b is opened, disc 16 corresponding to first meter 12 a can be halted.
After seed is deposited in second disc holes 18 and pressure builds up, as the valve 32 c associated with the third seed meter 12 c is opened, disc 16 corresponding to second meter 12 b can be halted. This process can be continued until pressure is built up in all lines 22 after which all of the meter discs 16 can be driven to rotate and begin seeding. Here, as all discs are precharged with seed and pressure, seed rows can be started at the same locations and seed is not wasted. This percharging concept is also applicable where multiple (e.g., 4) meters are downstream of each valve 32 where each bank of four meters can be rotated while pressure in lines associated therewith is increased and can be halted while other meters and associated lines are charged. | A seed planting unit provides a manifold connecting a vacuum to multiple metering disks. The manifold includes valves to sequentially connect the manifold branches to the seed unit so as to moderate the peak air flow necessary to be handled by the vacuum source reducing horsepower drain and cost of the vacuum source itself. | 0 |
FIELD OF THE INVENTION
The present invention relates generally to proteins that bind protein kinase A. More specifically, the present invention relates to novel proteins and nucleotide sequences encoding those proteins which localize protein kinase A within cells.
BACKGROUND OF THE INVENTION
Extracellular signals such as hormones and cytokines modulate many cellular processes by activating adenylate cyclase, increasing intracellular levels of cAMP and ultimately activating the cAMP-dependent kinase (PKA). PKA is a ubiquitous enzyme that functions in many intracellular pathways, for example, regulation of glycogen metabolism by reversible phosphorylation of glycogen phosphorylase Walsh et al., J. Biol. Chem., 243:3763-3765 (1969)!, and regulation of MAP kinase signaling by inhibiting Raf-1 activation by Ras Vojtek et al., Cell, 74:205-214 (1993) and Hafner et al., Mol. Cell Biol., 14:6696-6703 (1994)!. Inactive PKA exists as a tetramer in which two identical catalytic subunits are bound to a dimer of two regulatory subunits. Activation of PKA by cAMP is effected by binding of a cAMP molecule to each of the regulatory subunits (R) causing release of the active catalytic subunit (C). While only one form of the C subunit has been identified, two classes of R subunit exist, RI and RII, with apparently distinct subcellular distributions. The RI isoforms (RIα and RIβ) are reported to be predominantly cytoplasmic and are excluded from the nucleus, whereas up to 75% of the RII isoforms (RIIα or RIIβ) are particulate and associated with either the plasma membrane, cytoskeletal components, secretory granules, golgi apparatuses, centrosomes or possibly nuclei Scott, Pharmac. Ther., 50:123-145 (1991)!. Presumably, differences (either physical or physiological) in the various R subunits provide a means by which cells are able to restrict activity of the C subunit to a desired pathway.
Recent evidence indicates that cells are able to target PKA activity by localizing the inactive enzyme in the vicinity of potential substrates, thereby restricting the activity of the C subunit following release by cAMP binding to the R subunit. This "compartmentalization" segregates PKA with participants in a given signaling pathway and contributes to PKA specificity in response to different extracellular stimuli. Compartmentalization of PKA occurs, at least in part, by interaction or tethering, of the R subunit with specific proteins which localize, or anchor, the inactive holoenzyme at specific intracellular sites. Proteins which specifically segregate PKA have been designated A Kinase Anchor Proteins, or AKAPs Hirsch et al., J. Biol. Chem., 267:2131-2134 (1992)!. In view of the fact that some AKAP have been shown to bind, and anchor, other proteins in addition to PKA, the family of proteins is generally referred to as anchoring proteins.
To date, a number of anchoring proteins have been identified discussed below! which apparently bind PKA by a common carboxy terminal secondary structure motif that includes an amphipathic helix region Scott and McCartney, Mol. Endo., 8:5-11 (1994)!. Binding of PKA to most, if not all, identified anchoring proteins can be blocked in the presence of a peptide (Ht31) that mimics this common secondary helical structure, while a mutant Ht31 peptide, containing a single animo acid substitution that disrupts the helical nature of the peptide, has no effect on PKA/anchoring protein binding Carr et al., J. Biol. Chem., 266:14188-14192 (1991)!. Even though PKA/anchoring protein interaction is effected by a common secondary structure, anchoring proteins (or homologous anchoring proteins found in different species) generally have unique primary structure as evidenced by the growing number of anchoring proteins that have been identified in a variety of organisms. Presumably, the unique amino acid structure, most notable in amino terminal regions of the proteins, accounts in part for anchoring proteins identified as unique to various specific cell types and for the various specific intracellular compartments in which PKA localization has been observed.
For example, anchoring proteins which are predominantly expressed in mammalian brain have been identified in the rat (AKAP 150) and cow (AKAP 75) Bergman, et al., J.Biol. Chem. 266:7207-7213 (1991)!, as well as in humans (AKAP 79) Carr, et al., J.Bio. Chem. 267:16816-16823 (1992)!. Amino acid identity and immunological cross-reactivity between these neuronal-specific proteins suggest that they represent interspecies homologs. As another example, AKAP 100 appears to be specific for human and rat cardiac and skeletal muscle, while being expressed to a lower degree in brain cells of these mammals. As still another example, AKAP Ht31 Carr et al., J. Biol Chem., 267:13376-13382 (1992)! appears to be specific for thyroid cells. Conversely, AKAP 95 has been shown to be expressed in a multitude of cell types, showing no apparent tissue or cell-type specificity.
With regard to localization in specific intracellular compartments, AKAP 75, microtubule-associated protein (MAP-2) Threurkauf and Vallee, J. Biol. Chem., 257:3284-3290 (1982) and DeCamilli et al., J. Cell Biol., 103:189-203 (1986)!, AKAP 79 Glantz et al., J. Biol. Chem., 268:12796-12804 (1993)! and AKAP 150 Glantz et al., Mol. Biol. Cell, 3: 1215-1228 (1992)! are closely associated with cytoskeletal structural proteins, with AKAP 75 more specifically associated with post synaptic densities Carr et al., J. Biol. Chem., 267:16816-16823 (1992)!. Still other anchoring proteins have been shown to localize with less widespread cellular structures, including AKAP 350 association with centrosomes Keryer et al., Exp. Cell Res., 204:230-240 (1993)!, AKAP 100 with the sarcoplasmic reticulum in rat cardiac tissue McCartney, et al., J. Biol. Chem. 270:9327-9333 (1995)!, and an 85 kDa AKAP which links PKA to the Golgi apparatus Rios et al., EMBO J., 11:1723-1731 (1992)!.
AKAP 95, with an apparent zinc finger DNA-binding region, appears to reside exclusively in the nucleus Coghlan et al., J. Biol. Chem., 269:7658-7665 (1994)!. The DNA binding domain of AKAP 95 provides a role for direct involvement of PKA in gene transcription, possible by positioning of PKA for phosphorylation of transcription factors. Other diverse cellular activities shown to be influenced by anchoring protein/PKA binding have been demonstrated by disruption of the interaction, for example, disruption of PKA/anchoring protein binding in T cells has been shown to reverse cAMP-induced suppression of interleukin 2 expression Lockerbie et al., J. Cell Biochem., Suppl. 21A:76, Abstract D2155 (1995)! and disruption of PKA/anchoring protein binding in hippocampal neurons has been shown to attenuate whole cell currents through alpha-amino-3-hydroxy-5-methyl-4- isoxazole propionic acid/kainate glutamate receptors Rosenmund et al., supra.!. The ability of anchoring proteins to regulate IL-2 expression and to regulate glutamate receptor activity, in combination with a previous demonstration that anchoring proteins can bind calcineurin, suggest multiple therapeutic applications for anchoring proteins and molecules which modulate anchoring protein binding to cellular components.
In view of the diversity, both in terms of cell type expression, subcellular localization and physiological activities of anchoring proteins identified to date, there thus exists a need in the art to continue to identify novel anchoring proteins and nucleic acids which encode them. The uniqueness of anchoring protein primary structures provides a target for specifically regulating PKA localization, and thereby its function in specific cellular processes.
SUMMARY OF THE INVENTION
The present invention provides purified and isolated polynucleotide sequences that encode proteins having the biological properties of PKA binding and subcellular compartmentalization. A presently preferred polynucleotide is set forth in SEQ ID NO: 5. Polynucleotides of the invention also encompass polynucleotides that hybridize under stringent hybridization conditions to the polynucleotide of SEQ ID NO: 5. Polynucleotides of the invention may be DNA or RNA and may hybridize to the sense strand or antisense strand of the DNA molecule. The DNA may be cDNA, genomic DNA or chemically synthesized DNA. Polynucleotides of the present invention may be identified by standard techniques such as complementation, low stringency hybridization, and PCR utilizing primers generated based on knowledge of the sequences of polynucleotides of the invention.
Also provided by the present invention are recombinant expression constructs that contain polynucleotides of the invention operably linked to transcriptional regulatory elements such as promoters and transcriptional terminators. The transcriptional regulatory elements may be homologous or heterologous.
Another aspect of the present invention is host cells transformed or transfected with polynucleotides of the invention. The host cells may be procaryotic or eukaryotic. Host cells so transformed or transfected are particularly useful for expression of PKA-binding polypeptides of the present invention, which may be isolated from the cells or the media of their growth.
Yet another aspect of the present invention are PKA-binding polypeptides encoded by the polynucleotides of the present invention. A preferred PKA-binding polypeptide is encoded by the polynucleotide set forth in SEQ ID NO: 5. Polypeptides of the invention may be purified from natural sources or produced by recombinant methods employing the host cells of the present invention. Variant polypeptides which maintain biological activity of a wild-type polypeptide are also contemplated, including analogs wherein additions, deletions or conservative amino acid substitutions have been incorporated which modulate functional or immunological characteristics of the PKA-binding polypeptide. Other variant polypeptides include fusion proteins wherein additional polypeptide sequences are incorporated which facilitate purification or immobilization on assay supports. Additional polypeptides of the present invention may be identified by immunological cross-reactivity with the polypeptide encoded by the polynucleotide of SEQ ID NO: 5.
The present invention also provides polypeptides and non-peptide molecules that specifically bind to the PKA-binding polypeptides described above. Preferred binding molecules include antibodies (e.g., polyclonal, monoclonal, recombinant antibodies or binding fragments thereof). Binding molecules are useful for purification of the PKA-binding polypeptides, identification of cells that express the PKA-binding proteins and modulation of the in vivo interaction between PKA and the PKA-binding polypeptides. Hybridoma cell lines that produce antibodies specifically immunoreactive with the PKA-binding polypeptides of the present invention are also provided. Such hybridomas may be produced and identified by techniques that are well known in the art.
Assays to identify molecules that disrupt the interaction between PKA and the PKA-binding proteins of the present invention are also provided (e.g., immobilized binding assays, solution binding assays, scintillation proximity assays, di-hybrid screening assays, and the like). In some instances, it may be desirable to modulate binding between PKA and the polypeptides of the present invention. In other instances, it may be desirable to specifically modulate the binding between a PKA-binding polypeptide and a cellular component (other than PKA) to which it binds. In either case, the polypeptides of the present invention provide a useful screening target for the assays of the present invention. Assays of the invention may be performed in a variety of formats, including cell-based assays, such as di-hybrid screening or complementation assays as described in U.S. Pat. No. 5,283,173 and Patent Cooperation Treaty (PCT) Publication No. WO 91/16457, respectively. Assays of this type are particularly useful for assessing intracellular efficacy of compounds. Non-cell-based assays of the invention include scintillation proximity assays, cAMP competition assays, ELISA assays, radioimmunoassays, chemiluminescent assays, and the like. Such assay procedures are well known in the art and generally described, e.g., in Boudet et al., J. Immunol. Meth., 142:73-82 (1991); Ngai et al., J. Immunol. Meth., 158:267-276 (1993); Pruslin et al., J. Immunol. Meth., 137:27-35 (1991); Udenfriend et al., Proc. Natl. Acad. Sci. USA, 82:8672-8676 (1985); Udenfriend et al., Anal. Biochem., 161:494-500 (1987); Bosworth and Towers, Nature, 341:167-168 (1989); Gilman, Proc. Natl. Acad. Sci. USA, 67:305-312 (1970);; and U.S. Pat. No. 4,568,649. The utility of compounds which modulate anchoring protein binding is manifest. For example, small molecules may be found to inhibit either PKA/anchoring protein binding or anchoring protein interaction with specific cellular components. Modulators of this type would delocalize specific pools of PKA and affect only a targeted signaling pathway. Identification of modulators of anchoring protein binding to other cellular components may be equally beneficial. For example, factors which affect calcineurin activity in a manner similar to previously identified immunosuppressants, but have fewer side effects may be useful in treatment of conditions now treated with more the toxic immunosuppressants. In addition, identification of factors which modulate anchoring protein participation in cellular activities may also be useful in replacing currently accepted therapeutic intervention. For example, factors which regulate anchoring protein regulation of IL-2 expression may be useful in replacing administration of exogenous, recombinant IL-2.
DETAILED DESCRIPTION OF THE INVENTION
The following examples are offered by way of illustration and not of limitation. Example 1 addresses identification of a T cell-specific anchoring protein proteins from a human cDNA library. Example 2 describes RII binding specificity of the identified anchoring protein. Example 3 relates determination of the anchoring protein nucleotide sequence. Example 4 addresses expression of the anchoring protein clone. Example 5 relates to cellular and tissue distribution of the anchoring protein. Example 6 describes potential therapeutic applications of the anchoring protein and molecules which modulate anchoring protein binding.
EXAMPLE 1
Identification of T Cell-Expressed Anchoring Proteins
In an attempt to identify novel T cell anchoring proteins, a human Jurkat T cell cDNA library subcloned into ZAPII Express (Stratagene, La Jolla, Calif.) was screened by RIIαoverlay techniques as described in Carr et al., J. Biol. Chem., 267:16816-16823 (1992).
Briefly, one μl of the library phage (5×10 4 pfu) was added to 600 μl E.coli strain XL-1 Blue MRF' (Stratagene) in 10 mM MgSO 4 grown to OD 600 =0.5. The bacteria and phage were incubated at 37° C. for 15 minutes, after which time 7.5 ml top agar (NZY media (1% w/v! N-Z-Amine Type A, 0.5% w/v! yeast extract, 86 mM NaCl, 8 mM MgSO 4 7H 2 O, 1.5% w/v! Bacto agar, pH 7.5), 0.7% agarose) was added to the suspension. The resulting mixture was immediately plated onto NZY plates prewarmed to 37° C. The plates were allowed to cool to room temperature and incubated at 42° C. for 4 hours. Nitrocellulose filters, presoaked in 10 mM isopropyl-l-thio-β-D-galactopyranoside (IPTG), were placed on the plates and the plates further incubated for 4 hours at 37° C. The filters were removed and washed 3 times in TBS (50 mM Tris, pH 7.5, 150 mM NaCl), and blocked overnight at 4° C. in Block (TBS, 5% non-fat milk, 0.1% BSA). A second set of similarly prepared nitrocellulose filters was overlaid on the plates and incubated at 4° C overnight. The filters were washed (as described above) and blocked (also as described above) for one hour at room temperature.
Approximately 4 μjg (6 μl) recombinant mouse RIIα were mixed with 2.35 μg (0.5 μl) recombinant bovine catalytic subunit of PKA in a reaction containing 2.5 μl 32 P!ATP (25 μCi, 3000 Ci/mmole), and 1 μl buffer (containing 0.5 M MOPS, pH 7.0, 0.5 M NaCl, 20 mM MgCl 2 , and 10 mM DIT). The reaction was allowed to proceed for thirty minutes at 30° C., after which unincorporated label was removed using an Execellulose GF-5 column (Pierce). Filters were probed with 32 P!RIIα(100,000 cpm/ml in Block) for 6 hours at room temperature. After incubation, the filters were washed 3 times in TBS containing 1 % Tween-20 and exposed to x-ray film for 16 hours.
Of the approximately 1×10 6 plaques screened, one positive plaque, Plaque #11, was identified as binding labeled RIIα. A secondary screen was carried out on Plaque #11, by the techniques described in the initial screen, which indicated that progeny of Plaque #11 were also capable of binding radiolabeled RIIα.
EXAMPLE 2
Specificity of RIIα Binding to Plaque #11
In view of previous reports that peptide Ht31 (SEQ ID NO: 1) is generically capable of blocking PKA binding to anchoring proteins and that a proline mutant of Ht31 (see SEQ ID NO: 2 below wherein the proline substitution is indicated in bold and underlined), also described above, is not, specificity of RIIα binding to Plaque #11 was determined in parallel experiments in which RIIα overlays were performed in the presence of either Ht31peptide. ##STR1##
Briefly, nitrocellulose filter lifts were prepared as described in Example 1, except that the resulting plaque lifts were pre-incubated for 15 minutes at room temperature in Block containing 1 μM of either the Ht31 peptide or the proline mutant Ht3 peptide. Following preincubation, filters were probed with 32 P!RIIα as described in Example 1 and the filters subsequently subjected to autoradiography.
The autoradiograms revealed that pre-incubation of Plaque #11 with the Ht31 peptide blocked binding of 32 P!RIIα, while pre-incubation with the proline mutated Ht31 peptide had no effect. These results indicate that RIIα binding to the polypeptide encoded by Plaque #11 is effected by a secondary structure of Plaque #11 similar to that utilized by previously identified anchoring proteins.
EXAMPLE 3
Cloning of Plaque #11 cDNA
In an attempt to determine the nucleotide sequence of the insert in the phage of Plaque #11 and to deduce the amino acid sequence of the encoded protein, the cDNA insert of Plaque #11 was excised in vivo using an ExAssist/XLOLR System (Stratagene) according to the manufacturers instructions.
Briefly, Plaque #11 was removed from the NZY plate and mixed with 500 μl of SM buffer (100 mM NaCl, 8 mM MgSO 4 7H 2 O, 50 mM Tris-HCl pH 7.5, 0.01% w/v! gelatin) and 20 μl of chloroform. The mixture was vortexed and stored at 4° C. (phage stock). XL-1 Blue MRF' and XLOLR cells (both from Stratagene) were grown separately overnight at 30° C. in LBM medium supplemented with 10 mM MgSO 4 7H 2 O containing 0.2% (v/v) maltose. A 1/100 dilution of XL-1 Blue MRF' cells was prepared with 0.5 ml of the overnight culture medium and 50 ml of LBM media and the dilution was grown at 37° C. for 2-3 hours to mid-log phase (OD 600 =0.2-0.5 for XL-1 Blue MRF' cells, or OD 600 =0.5-1.0 for XLOLR cells). The culture was centrifuged at 1500×g and the resulting pellet resuspended in 10 mM MgSO 4 7H 2 O to a density of OD 600 =1.0.
Two hundred μl of the XL-1 cells, 250 μl of the phage stock suspension as described above, and 1 μl of ExAssist helper phage (Stratagene) were combined and incubated for 15 minutes at 37° C. Three ml of LBM media were added and the mixture was further incubated for 2.5 hours at 37° C. with shaking. After incubation, the mixture was centrifuged for 15 minutes at 2000×g. The supernatant was withdrawn, incubated at 70° C. for 15 minutes, and centrifuged at 4000×g for 15 minutes. The resulting supernatant contained filamentous phage which packaged Plaque #11 DNA in phagemid pBK-CMV. The phagemids were rescued by mixing 200 μl of the XLOLR cells (prepared as described above) with 10 μl of the phagemid stock and incubating for 15 minutes at 37° C. Following incubation, 300 μl of LBM media was added and the mixture was further incubated for 45 minutes at 37° C. The resulting cellular suspension was plated at 200 μl/plate on LBM containing 50 μg/ml kanamycin.
Plasmid preparation was carried out by standard procedures and included use of a Wizard Miniprep Kits (Promega). Plasmid DNA isolated from Plaque #11 was designated clone # 11. The cDNA insert was excised from the vector by digestion with EcoRI and BamHI and the resulting fragments separated using agarose gel electrophoresis. The Clone # 11 insert was determined to be 2850 bp in length. Nested deletions of clone # 11 were generated with an Erase-a-Base System (Promega, Madison, WI) and clone # 11 was sequenced using Universal T3 (ATTAACCCTCACTAAAG SEQ ID NO: 3!) and T7 (GATATCACTCAGCATAA SEQ ID NO: 4!) primers and a Prism Ready Reaction DyeDeoxy Terminator Cycle Kit (Perkin Elmer) in an ABI373 DNA Sequencer (Perkin Elmer, Foster City, Calif.).
The DNA sequence of clone # 11 is set out in SEQ ID NO: 5. Because no appropriate initiation codon could be detected in the nucleotide sequences, a deduced amino acid sequence and a molecular weight for clone # 11 were not possible to determine. A nucleotide level Blast Search (Jun. 16, 1995, 14:01:37 EDT) of the sequence obtained from the T3 primer showed homology to a clone designated "Homo Sapiens cDNA 3'-end similar to none" (accession # T32770), while sequence data obtained from the T7 primer showed 98% homology over a stretch of 343 bases from 1905-2248 of clone # 11 to a clone designated "Homo Sapiens partial cDNA 5 ' end similar to none"; (accession # T31099). In addition, clone # 11 showed 98% homology over a stretch of 332 bases from nucleotides 2308-2640 to a clone designated "Homo Sapiens partial cDNA sequence, clone 66D04 (accession # Z 24883).
EXAMPLE 4
Expression of Clone # 11
In order to determine an approximate molecular weight for the gene product of clone # 11, an overnight culture of clone # 11 in XLOLR cells (prepared as described in Example 3) was grown in LBM media/tetracycline (12.5 μg/ml) and subsequently used to inoculate 250 ml of the same media. Incubation was allowed to proceed at 37° C. to an OD 600 =1.2, after which the bacteria were pelleted at 6000×g for 15 minutes. The pellet was weighed and resuspended in 10 volumes (w/v) FP buffer (1% Triton X-100, 150 mM NaCl, 1 mM EGTA, 1 mM EDTA, 10 mM Tris, pH 7.4, 1% Aprotinin, 0.2% NaN 3 ). The cells were cracked in a French Press and the lysate clarified by centrifuging at 40,000×g for 30 minutes. The lysate was then concentrated using a Centricon-10 (Amicon). An aliquot of the concentrated lysate was loaded onto a 10% Tris-glycine gel (Novex), electrophoresed and transferred to Immobilon (Millipore). The blot was probed with 32 P!RIIα. A single band of approximately 120 kD was detected, which was partially competed away by the HT31 peptide. These results indicate that clone # 11 encodes a PKA-binding protein that can be used in assays to identify inhibitors of binding between PKA-binding polypeptides and PKA.
EXAMPLE 5
Cellular and Tissue Distribution of Clone # 11
In order to determine the cellular and tissue distribution of clone # 11 expression, reverse transcriptase PCR (RT-PCR) was utilized to assess clone # 11 mRNA levels.
Briefly, primers were initially designed to span 300 bp of clone # 11 sequence, based on the nucleic acid sequence determined in Example 3. In the sequence for clone # 11 (SEQ ID NO: 5), primer 2T3 corresponds to nucleotides 266-283, primer M2T3 to nucleotides 434-453, primer R2T3 to nucleotides 601-622, primer R2T7 to nucleotides 2229-2250, primer M2T7 to nucleotides 2337-2400, and primer 2bT7 to nucleotides 2256-2592. RNA was prepared from various cell and tissues types (described below in discussion of the results) using an RNA Isolation Kit (Stratagene). RT-PCR was carried out as follows. RNA (approximately 1 μg in 10 μl water) was initially denatured by incubation at 80° C. for three minutes, after which the RNA was further incubated on ice until reverse transcriptase reactions were carried out as follows. Denatured RNA was mixed with 8 μl 5X MMuLV-RT buffer (Boehringer), 8 μl 2.5 mM dNTP mixture, 1 μl water containing 0.5 μg each of 2T3 and R2T3 primers or 2bT7 and R2T7 primers, 1 μl RNAse inhibitor (Boehringer), 1 μl MMuLV-RT (Boehringer) and 11 μl water and incubated for one hour at 42° C.
PCRs were carried out as follows. Two μl from the preceding reverse transcriptase reaction were mixed with 3 μl 2.5 mM dNTP mixture, 3 μl 10X Taq polymerase buffer (Boehringer), 3 μl (0.3 μg) 2T3 primer with 3 μl (0.3 μg) R2T3 primer, or 3 μl (0.3 μg) 2bT7 primer with 3 μl (0.3 μg) R2T7 primer, 0.5 μl Taq polymerase, and 14.5 μl water. The mixture was heated to 94° C. for four minutes, after which thirty reaction cycles (94° C. for one minute, 60° C. for one minute and 72° C. for one minute) were completed.
Amplification products from the PCRs were separated by electrophoresis on 1% agarose gel, and subsequently transferred to Nytran Plus membrane (S+S) by standard procedures. PCR products were crosslinked to the membrane with UV irradiation and the membrane subsequently prehybridized for three hours at 42° C. in 5X SSPE, 0.5% SDS, 0.1 mM Tris, pH 7.5, and 2X Denhardt's.
Hybridization probes were prepared by end labeling as follows. Two μl (200 ng) of primer M2T3 were mixed with 2 μl primer M2T7 (200 ng), 2 μl 10X polynucleotide kinase buffer (Boehringer), 10 32 P-ATP (100 μCi, 3000 Ci/mmole), 2 μl (20 units) T4 polynucleotide kinase (Boehringer), and 2 μl water. The reaction was allowed to proceed at 37° C. for thirty minutes, after which the reaction was stopped by addition of 2 μl 0.5 M EDTA and unincorporated label was removed by centrifugation with a Centristep column (Princeton Separation, Inc.). The membrane was then probed overnight at 42° C. in the same prehybridization buffer but further containing 400 ng (200 ng each) of 32 P-labeled primers M2T3 and M2T7. After hybridization, membranes were washed at room temperature three times for ten minutes each in 0.5X SSC, with 0.2% SDS, and subsequently autoradiographed.
Cell based results indicated that clone # 11 was expressed Ramos cells (B cell), Jurkat cells T cell), U973 cells (monocyte), T84 cells (colon carcinoma), HL60 cells (promyelocytic leukemia), A549 cells (lung epithelia), and HeLa (epithelial carcinoma). Results from tissue analysis indicated that clone # 11 was expressed in human testes, liver and occipital cortex of the brain.
EXAMPLE 6
Potential Therapeutic Applications
The previous demonstration that AKAP 79 binds calcineurin is relevant in view of the fact that calcineurin is the target of two potent and clinically useful immunosuppressive, cyclosporin and FK506, both of which inhibit calcineurin activity. As described below, both cyclosporin and FK506 are useful in treatment of a variety of diseases, but have significant limiting side effects. Presumably, factors which modulate anchoring protein/calcineurin binding may ultimately modulate calcineurin activity in a manner similar to the activities of cyclosporin or FK506. Identification of such a modulator, particularly with fewer side effects than those observed with other immunosuppressants, would possibly have widespread therapeutic use treatment of a multitude of disease currently treated with cyclosporin or FK506.
Numerous clinical indications of cyclosporin and FK506 have been reported. For example, cyclosporin has defined the standard for post-transplant immunosuppression, making possible liver, lung, intestine, and pancreas transplants, even though FK506 is generally believed to be a stronger immunosuppressive. Transplant patients who do not tolerate or fail on either cyclosporin or FK506 are sometimes successfully changed to the other drug.
As another example, inflammatory bowel disease (IBD) is a common term for two diseases having different clinical appearances, Crohn's disease and ulcerative colitis (UC). Cyclosporin has been successfully used to treat Crohn's disease, with statistically significant results of treatment having been demonstrated in at least one index of disease activity Brynskov, Dan.Med.Bull. 41:332-344 (1994)!. Other indices, however, that correlate best with resolution of acute exacerbations showed non-significant trends toward improvement. Cyclosporin has also shown activity in severe acute steroid-resistant UC (the data are not significant as the trial was stopped for ethical reasons). Another trial of patients with sclerosing cholangitis and UC demonstrated borderline significance toward a milder course of UC. Relapse was common after withdrawal and treatment has been limited by concern for toxicity Choi and Targan, Dig.Dis. and Sci. 39:1885-1892 (1994)!. In addition, other immunosuppressives have been used successfully in IBD, such as methotrexate, azathioprine, and 6-MP.
As another example, cyclosporin has been demonstrated to be effective in treating rheumatoid arthritis in several trials when used as a second or third line therapy of the disease, i.e., in patients that have failed other established therapies and have severe disease. In these trails, cyclosporin was found to be generally as effective and toxic as other second-line agents, such as gold, antimalarials, azathioprine, D-penicillamine, and methotrexate Wells and Tugwell, Br.J.Rheum., 32(suppl 1):51-56 (1993); Forre et al., Arth.Rheum., 30:88-92 (1987)!. The trials only report treatment of "very severe, refractory active RA" because of cyclosporin's "potentially irreversible toxicity" Dougados and Torley, Br.J.Rheum., 32(suppl 1):57-59 (1993)!. The renal toxicity is thought to have been primarily mediated through renal vasoconstriction that exacerbates NSAID nephrotoxicity and renal disease inherent in rheumatoid arthritis Leaker and Cairns, Br. J.Hosp.Med., 52:520-534 (1994); Sturrocketal., Nephrol.DiaL Transplant, 9:1149-1156 (1994); Ludwin and Alexopolulou, Br.J.Rheum., 32(suppl1):60-64 (1993)!. About 10% of renal biopsies from RA patients treated with cyclosporin showed morphological features of cyclosporin toxicity International Kidney Biopsy Registry of Cyclosporin in Autoimmune Diseases, Br.J.Rheum., 32(suppl 1):65-71 (1993)!.
As still another example, cyclosporin has been reported to be effective for treatment of steroid-dependent asthma. In one trial, a small number of patients were randomized to cyclosporin or placebo, and the cyclosporin group exhibited increased airflow and FVC as well as fewer rescue courses of prednisolone.
As another example, cyclosporin was shown to be effective in the treatment of steroid-dependent minimal change disease nephrotic syndrome. Patients in this trail were shown to have lower steroid requirements on low dose cyclosporin, but all relapsed when cyclosporin was discontinued. Steroid-resistant forms of nephrotic syndrome have only a 20-30% response rate to cyclosporin Meyrier, Nephrol. Dial. Transplant, 9:596-598 (1994); Hulton et al., Pediatr.Nephrol., 8:401-403 (1994)!.
With regard to treatment of systemic lupus erythematosus (SLE), one study reported significant decrease of SLE activity indices in a prospective non-randomized, non-controlled study Tokuda et al., Arthr.Rheumat., 37:551-558 (1994)!. Other studies, however, have not demonstrated efficacy in SLE.
As another example, cyclosporin has been shown to induce remission in insulin-dependent diabetes mellitus when instituted early after initial presentation. Remissions averaged about one year, although some were extended up to 850 days Jenner et al., Diabetologia, 35:884-888 (1992); Bougneres et al., Diabetes, 39:1264-1272 (1990)!. No long-lasting effect of cyclosporin was noted in extended follow-up of one study Martin et al., Diabetologia, 34:429-434 (1991)!. In another study, however, renal function deteriorated during treatment for 12-18 months and did not return completely to placebo level indicating that some chronic renal injury may have occurred Feldt-Rasmussen et al., Diabetes Medicine, 7:429-433 (1990)!. Earlier intervention would be needed to enhance the effect of immunosuppressive therapy on the course of insulin-dependent diabetes mellitus. Some investigators are screening first degree relatives and successfully prophylactically treating those with diabetic markers Elliott and Chase, Diabetologia, 34:362-365 (1991)!.
As still another example, psoriasis has been effectively treated by cyclosporin Cuellar et al., Balliere's Clin.Rheum., 8:483-498 (1994); Ellis et al., JAMA 256:3110-3116 (1986)!. High dose therapy was effective for treatment of psoriatic arthritis, a particularly serve form of destructive arthritis, and discontinuation of therapy was generally followed by exacerbation of skin and joint disease. In view of the potential side effects and the need for continuous long term treatment, cyclosporin is only indicated for refractory psoriatic arthritis that is not adequately treated by other means.
In addition, cyclosporin has been demonstrated to be effective for treatment of severe atopic dermatitis in placebo-controlled and double-blinded studies Van Joost et al., Br.J.Derm., 130:634-640 (1994); Cooper, J.Invest.Denn., 102:128-137 (1994)!. Side effects of nausea, abdominal discomfort, paresthesias, cholestasis, and renal insufficiency from the drug were preferred by patients to their untreated disease. Another randomized double-blind, placebo-controlled study found that cyclosporin treatment significantly increased the quality of life for patients with severe atopic dermatitis Salek et al., Br.J.Dern., 129:422-430 (1993)!. Skin lesions quickly relapsed following cessation of cyclosporin, but quality of life remained improved.
As still another example, cyclosporin has been used in treatment of chronic dermatitis of the hands, a disease with a reported prevalence of 4-22%, and typically treated with topical steroids to which many patients, however, do not respond. Low dose cyclosporin has been shown to effectively treated 6/7 patients in an open study Reitamo and Granlund, Br.J.Derm., 130:75-78 (1994)!. Approximately half of the patients relapsed after cyclosporin was discontinued.
As still another example, cyclosporin has been utilized in treatment of urticaria and angioedema, idiopathic skin diseases that present as hives and subcutaneous swelling. The pathology is related to mast cells, and treatment is often ineffective. IN one trail, three patients with refractory urticaria and angioedema were treated with cyclosporin and all symptoms resolved within one week Fradin et al., J.Am.Acad.Denn., 25:1065-1067 (1991)!. All patients had to stop therapy because of side effects, and symptoms recurred after therapy was discontinued.
With regard to other rheumatological diseases, studies report effective cyclosporin treatment of other less common autoimmune diseases, including Behcet's Disease Pacor et al., Clin.Rheum., 13:224-227 (1994)!, Wegner's Granulomatosis Allen et al., Cyclospornin A Therapy for Wegner's Granulomatosis in ANCA-Associated Vasculidites: Immunological and Clinical Aspects, Gross ed. Plenum Press (1993)!, and immune-mediated thrombocytopenia Schultz et al., Blood 85:1406-1408 (1995)!.
In many of the trials described above, use of cyclosporin or FK506 was associated with many undesired side effects. In general, increased risk of infection and malignancy are associated with general immunosuppression, and it is unlikely that an anchoring protein-related immunosuppressive would not have similar risks. Other side effects may be avoided or reduced, however, by anchoring protein tissue specificity. The most common serious side effect of both cyclosporin and FK506 is nephrotoxicity, which at least to some degree is dose related and occurs in most patients, generally in the form of a decrease in the glomerular filtration rate during treatment. This side effect, however, is at least partially reversible when the drug is discontinued Leaker and Cairns, supra!. Typically, progressive renal insufficiency does not develop, although more follow-up is needed for definitive evaluation. Chronic injury has also been observed in patients receiving low dose cyclosporin (3-4 mg/kg/d), about 40% of biopsies of these patients showed changes of interstitial fibrosis, tubular atrophy, and arteriolopathy Svarstad et al., Nephrol.Dial. Transplant, 9:1462-1467 (1994); Young et al., Kidney International, 46:1216-1222 (1994)!. Changes in endothelial cells were also apparent in histological sections Kahan, N.Engl.J.Med., 321:1725-1748 (1989)!. The nephrotoxicity was postulated to have resulted primarily due to arteriolar vasoconstriction and chronic low-grade ischemia Leaker and Carins, supra!, although the drugs were also shown to be directly toxic to tubular cells and vascular interstitial cells Platz et al., Transplantation, 58:170-178 (1994)!. Some reports indicate that the incidence and severity of nephrotoxicity may be slightly higher with FKSO6 Platz et al., supra!.
Another reported significant toxicity of both cyclosporin and FK506 was neurotoxicity, with clinical manifestations including seizures, confusion, blindness, coma, headache, ataxia, Parkinson's syndrome, paresthesias, psychosis, focal deficits, akinetic mutism, tremors, neuropathy, and sleep disturbances Shimizu et al., Pediatr. Nephrol., 8:483-385 (1994); Wilson et al., Muscle and Nerve, 17:528-532 (1994); Reece et al., Bone Marrow Transpl., 8:393-401 (1991); Eidelman et al., Transpl.Proc., 23:3175-3178 (1991); de Groen et al., N.Engl.J.Med., 317:861-566 (1987)!. Following liver transplantation, moderate to severe neurotoxicity has been shown to occur in 10-20% of patients treated with FK506 and 3-12% of patients treated with cyclosporin. Neurotoxicity has also been associated with serum lipid abnormalities and liver dysfunction.
Other side effects of cyclosporin and/or FK506 include hepatotoxicity, glucose intolerance, hypertension, hirsutism, gastrointestinal symptoms, venous thrombosis, pancreatitis, and gingival hyperplasia Morris, J.Heart Lung Transplant, 12:S275-S286 (1993); Fung et al., Transpl. Proc., 23:3105-3108 (1991); Mason, Pharmacol. Rev., 42:423-434 (1989); Kahan, N.Engl.J.Med., 321:1725-1738 (1989); Thomason et al., Renal Failure, 16:731-745 (1994)!. Therefore, in view of the widespread utilization of cyclosporin and FK506 and the inherent side effects of their use, development of alternative immunosuppressives could be extremely beneficial.
For example, it is possible that delocalization of calcineurin from a putative T cell anchoring protein might inhibit calcineurin activity in T cell activation, and thereby providing a T cell-specific immunosuppressive having the utility of cyclosporin or FK506, but fewer side effects. The previous observation that delocalization of PKA from a T cell anchoring protein enhanced IL-2 expression in stimulated cells indicated that anchoring protein-localized PKA in some way contributes to a regulatory role in IL-2 expression during T cell activation. T cell-specific delocalization of PKA may therefore provide a means for enhancing IL-2 secretion in vivo, thereby mimicking recombinant IL-2 administration and possibly reducing previously reported toxicity of IL-2 treatment as described below.
IL-2 has been approved for treatment of metastatic renal carcinoma and approximately 15-20% of patients with metastatic renal cell carcinoma or malignant melanoma respond to IL-2 therapy. Some of these responses are durable, lasting more than 66 months Dillman, Cancer Biotherapy, 9:183-209 (1994); Whittington and Faulds, Drugs 46:446-514 (1993)!. While high dose bolus therapy has been associated with several severe side effects (as described below), low dose subcutaneous or continuous infusion therapy produced a modest response rate (12%) while reducing toxicity Vogelzang et al., J. Clin. Oncol., 11: 1809-1816 (1993)!.
IL-2 therapy (with and without interferon-αand other agents) has been investigated in the treatment of other malignancies. For example, sustained clinical responses, but no cures, have been obtained in direct application of IL-2 to tumor beds following glioma resection Merchant et al., J.Neuro., 8:173-188 (1990)!. In still other trails, limited efficacy has been reported in lymphoma Dillman, supra!, colorectal carcinoma Whittington and Faulds, supra!, limited AML Bruton and Koeller, Pharmacotherapy, 14:635-656 (1994)!, ovarian cancer and early bladder cancer Whittington and Faulds, supra.!. The number of participants in each of these studies was too small to permit significant conclusions regarding effectiveness, however.
IL-2 has also been used in combination with adoptive immunotherapy, and been demonstrated to be effective for treatment of metastatic renal carcinoma Pierce et al., Sem. Oncol., 22:74-80 (1995); Belldegrun et al., J. Urol., 150:1384-1390 (1993)!. In addition, IL-2 may also be effective for treatment of certain infectious diseases, by decreasing skin bacterial load and levels of antigen in patients with leprosy following by intradermal injection Kaplan, J.Infect.Dis., 167(suppl 1):S18-22 (1993)!. Also it has been observed that, as compared to PPD-positive healthy controls, lymphocytes from patients with tuberculosis produce lower levels of IL-2 Sanchez et al., Inf.Immun., 62:5673-5678 (1994)!, suggesting that IL-2 therapy may be of value in treatment of mycobacterial infections.
Despite the potential therapeutic value of IL-2, the cytokine is also associated with significant toxicity unless otherwise noted, sources are Whittington and Faulds, Dillman and Bruton and Koeller, supra!. The major treatment-limiting side effects is capillary leak syndrome. IL-2 administration increases vascular permeability causing interstitial and pulmonary edema, with patients developing hypotension with a substantial number requiring pressors. Vigorous fluid resuscitation can cause life-threatening pulmonary edema. Up to 20% of patients may require intubation and mechanical ventilation. High does bolus administration causes more severe leak than low dose or slow continuous infusions, and in some regiments, 100% of patients require ICU support during IL-2 treatment. Myocarditis, cardiomyopathies and cardiac arrhythmias have also been observed. Acute renal failure may occur as a result of the capillary leak syndrome-induced sypotension.
IL-2 can also cause severe diarrhea with electrolyte imbalances, cholestasis, thyroid abnormalities, and acute pancreatitis. Anemia requiring transfusions occurs in 15-20% of treated patients MacFarlane et al., Cancer 75:1030-1037 (1995)!. Thrombocytopenia with hemorrhage can occur and coagulation pathway defects are common. Over 70% of patients experience changes in mental status, including paranoid delusions, hallucinations, loss of interest, sleep disturbances, and drowsiness. Coma, visual defects, transient ischemic attacks, and paresthesias have also been reported. These drawbacks associated with exogenous with exogenous IL-2 suggest that alternatives, wherein, for example, endogenous IL-2 production can be modulated and thus eliminate the requirement for exogenous IL-2 treatment, should be explored as potential therapeutics.
In addition to providing possible means to identify immunosuppressive drugs and modulators of IL-2 production, identification of anchoring proteins makes regulation of other cellular activity possible in view of the diverse metabolic pathways in which anchoring proteins have been shown to participate. For example, AKAP 79 is important in regulation of glutamate receptor-regulated ion channels in the post-synaptic density of neurons, presumably via binding PKA, PKC, and calcineurin. PKA regulates activity of AMPA receptor-regulated channels, and delocalization or inhibition of PKA attenuates AMPA ion channel activity. PKC regulates activity of NMDA receptor-regulated channels, and calcineurin has been shown to desensitize the NMDA receptor to stimuli. These observations indicate that localized kinases (PKA and PKC) may regulate activity of glutamate receptors in neurons. Dephosphorylation by calcineurin is the counter-regulatory mechanism of the NMDA receptors. This model agrees physiologically with evidence of seizures induced by cyclosporin or FK506.
In addition, glutamate receptors have been implicated in many neurological diseases. Glutamate and other excitatory amino acids can produce excitotoxicity in neurons, and excessive stimulation of postsynaptic glutamate receptors has been shown to be toxic to the neurons, causing acute neuronal degeneration. Hypoxia (such as following stroke or cardiac arrest) and CNS trauma have been shown to cause a marked outpouring of glutamate into the extracellular space, which then interacts with glutamate receptors and triggers the excitotoxic cascade. Anti-excitatory agents have been shown to protect against brain injury in animals models Olney, Neurobiology of Aging, 15:259-260 (1994)!. Interestingly, NMDA antagonists are toxic to some types of neurons indicating that glutamate may inhibit other excitatory pathways in those cells. Macrolide antibodies, such as FK506, have also been shown to protect against NMDA, but not kainate, excitotoxicity in cultured neurons Manev, et al., Brain Res., 624:331-335 (1993)!.
Glutamate has also been implicated in Parkinson's Disease. NMDA antagonists protect dopaminergic neurons in substantia nigra in monkeys exposed to MPTP, a chemical that induces Parkinson's syndrome in humans and other primates. Amantadine and memantine are NMDA antagonists and have been used in Europe to treat Parkinson's disease, however, both have been shown to cause psychosis in some patients. There is also some evidence that glutamatergic neurons may be hyperactive in Parkinson's disease and inhibition could decrease the motor symptom's of the disease Lange and Riederer, Life Sciences, 55:2067-2075 (1994)!.
Glutamate also plays a role in seizure disorders, participating in initiation, spread, and maintenance of seizure activity. NMDA and non-NMDA antagonists are potent anticonvulsants Meldrum, Neurology, 44(suppl 8):S14-S23 (1994)!. AMPA receptors have also been implicated in ALS and a trial of a receptor antagonist is currently in progress. 49
In view of the total of these observations, it is not surprising that numerous other immunosuppressants are in clinical trials. The following information regarding such trails was obtained from Haydon and Haynes, Balliere's Clin. Gastroentero., 8:455-464 (1994); Thomason and Starzi, Immunol.Rev. 1993, 71-98 (1993); and Morris J.Heart Lung Transplant., 12:S275-S286 (1993). For example, azaspirane is an SKB compound that suppresses graft cellular infiltrates and induction of IL-2R, and also abolishes IL-2 and IFN-γ production. Apparently azaspirane induces some type of suppressor cell and there is some evidence of synergistic effects with cyclosporin.
As another example, mycophenolate mofetial is a Syntex compound which inhibits purine synthesis and has a T and B cell-selective antiproliferative effect. It depletes antibodies. Mycophenolate mofetial may also deplete adhesion molecules from cell surfaces. While the drug apparently has low toxicity, it may cause leukopenia, and has been used to treat psoriasis for 20 years.
As another example, mizoribine in a Sumitomo compound which inhibits DNA synthesis. The mechanism of action is identical to mycophenolate.
As another example, brequinar is a DuPont-Merck compound which inhibits pyrimidine synthesis by blocking dihydoorate dehydrogenase. Full reports of clinical trials are awaited. The drug has been reported to act synergistically with cyclosporin, but can cause thrombocytopenia, dermatitis and mucositis.
As still another example, 15-Deoxyspergualin is a Nippon-Kayaku compound which predominantly affects monocyte/macrophage function, including inhibition of oxidative metabolism, lysosomal enzyme synthesis, IL-1 production, and cell surface expression of MHC class II antigens. It is 70-90% effective in refractory kidney rejection, but bone marrow toxicity may occur at higher doses.
As another example, leflunomide is a Hoechst compound which inhibits cytokine action, blocks T cell activation and antibody synthesis. It is not toxic to the kidneys or bone marrow.
As another example, rapamycin is a Wyeth-Ayerst compound that is related to FK506. It is a prodrug that must bind an immunophillin to be active and does no inhibit calcineurin or block T cell cytokine production. By an unknown mechanism, rapamycin blocks Gl to S transition.
Numerous modifications and variations in the invention as set forth in the above illustrative examples are expected to occur to those skilled in the art. Consequently only such limitations as appear in the appended claims should be placed on the invention.
__________________________________________________________________________SEQUENCE LISTING(1) GENERAL INFORMATION:(iii) NUMBER OF SEQUENCES: 5(2) INFORMATION FOR SEQ ID NO:1:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:1:AspLeuIleGluGluAlaAlaSerArgIleValAspAlaValIleGlu151015GlnValLysAlaAlaGlyAla20(2) INFORMATION FOR SEQ ID NO:2:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 23 amino acids(B) TYPE: amino acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: peptide(xi) SEQUENCE DESCRIPTION: SEQ ID NO:2:AspLeuIleGluGluAlaAlaSerArgProValAspAlaValIleGlu151015GlnValLysAlaAlaGlyAla20(2) INFORMATION FOR SEQ ID NO:3:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 17 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:3:ATTAACCCTCACTAAAG17(2) INFORMATION FOR SEQ ID NO:4:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 17 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:4:GATATCACTCAGCATAA17(2) INFORMATION FOR SEQ ID NO:5:(i) SEQUENCE CHARACTERISTICS:(A) LENGTH: 2850 base pairs(B) TYPE: nucleic acid(C) STRANDEDNESS: single(D) TOPOLOGY: linear(ii) MOLECULE TYPE: cDNA(xi) SEQUENCE DESCRIPTION: SEQ ID NO:5:GGCACGAGGAGCAGCAGGTGGAGGCTGGTGCTGTGCAGCTGAGGGCTGACCCTGCCATCA60AGGAACCTCTCCCCGTGGAAGACGTCTGTCCCAAAGTAGTGTCCACACCCCCCAGTGTCA120CAGAGCCTCCAGAAAAGGAACTGTCCACCGTGAGCAAGCTGCCTGCAGAGCCCCCAGCAT180TGCTCCAGACACACCCACCTTGCCGAAGATCAGAGTCCTCGGGCATTCTTCCTAACACCA240CAGACATGAGATTGCGACCAGGAACACGCAGAGACGACAGTACAAAGCTGGAGCTAGCCC300TGACAGGTGGTGAAGCCAAATCGATTCCTCTAGAGTGCCCCCTTTCATCCCCAAAGGGTG360TACTATTCTCCAGCAAATCAGCTGAGGTGTGTAAGCAAGATTCCCCCTTCAGCAGGGTGC420CAAGGAAGGTCCAGCCAGGCTACCCCGTAGTCCCCGCAGAGAAGCGTAGCTCTGGGGAGA480GGGCAAGAGAGACAGGTGGGGCCGAAGGGACTGGTGATGCCGTGTTGGGGGAAAAGGTGC540TTGAAGAAGCTCTGTTGTCTCGGGAGCATGTCTTGGAATTGGAGAACAGCAAGGGCCCCA600GCCTGGCCTCTTTAGAGGGGGAAGAAGATAAGGGGAAGAGCAGCTCATCCCAGGTTGGTG660GGGCCAGTGCAGGAGGAAGAGTATGTAGCAGAGAAGTTGCCAAGTAGGTTCATCGAGTCG720GCTCACACAGAGCTGGCAAAGGACGATGCGGCGCCAGCACCCCCAGTCGCAGACGCCAAA780GCCCAGGACAGAGGTGTCGAGGGAGAACTGGGCAATGAGGAGAGCTTGGATAGAAATGAG840GAGGGCTTGGATAGAAATGAGGAGGGCTTGGATAGAAATGAGGAGAGCTTGGATAGAAAT900GAGGAGGGCTTGGATAGAAATGAGGAGATTAAGCGGGCTGCCTTCCAGATAATCTCCCAA960GTGATCTCAGAAGCAACCGAACAGGTGCTGGCCACCACGGTTGGCAAGGTTGCAGGTCGT1020GTGTGTCAGGCCAGTCAGCTCCAAGGGCAGAAGGAAGAGAGCTGTGTCCCAGTTCACCAG1080AAAACTGTCTTGGGCCCAGACACTGCGGAGCCTGCCACAGCAGAGGCAGCTGTTGCCCCG1140CCGGATGCTGGCCTCCCCTTGCCAGGCCTACCAGCAGAGGGCTCACCACCACCAAAGACC1200TACGTGAGCTGCCTGAAGAGCCTTCTGTCCAGCCCCACCAAGGACAGTAAGCCAAATATC1260TCTGCACACCACATCTCCCTGGCCTCCTGCCTGGCACTGACCACCCCCAGTGAAGAGTTG1320CCGGACCGGGCAGGCATCCTGGTGGAAGATGCCACCTGTGTCACCTGCATGTCAGACAGC1380AGCCAAAGTGTCCCTTTGGTGGCTTCTCCAGGACACTGCTCAGATTCTTTCAGCACTTCA1440GGGCTTGAAGACTCTTGCACAGAGACCAGCTCGAGCCCCAGGGACAAGGCCATCACCCCG1500CCACTGCCAGAAAGTACTGTGCCCTTCAGCAATGGGGTGCTGAAGGGGGAGTTGTCAGAC1560TTGGGGGCTGAGGATGGATGGACCATGGATGCGGAAGCAGATCATTCAGGAGGTTCTGAC1620AGGAACAGCATGGATTCCGTGGATAGCTGTTGCAGTCTCAAGAAGACTGAGAGCTTCCAA1680AATGCCCAGGCAGGCTCCAACCCTAAGAAGGTCGACCTCATCATCTGGGAGATCGAGGTG1740CCAAAGCACTTAGTCGGTCGGCTAATTGGCAAGCAGGGGCGCTATGTGAGTTTTCTGAAG1800CAAACATCTGGTGCCAAGATCTACATTTCAACCCTGCCTTACACCCAGAGCGTCCAGATC1860TGCCACATAGAAGGCTCTCAACATCATGTAGACAAAGCGCTGAACTTGATTGGGAAGAAG1920TTCAAAGAGCTGAACCTCACCAATATCTACGCTCCCCCATTGCCTTCACTGGCACTGCCT1980TCTCTGCCGATGACATCCTGGCTCATGCTGCCTGATGGCATCACCGTGGAGGTCATTGTG2040GTCAACCAGGTCAATGCCGGGCACCTGTTCGTGCAGCAGCACACACACCCTACCTTCCAC2100GCGCTGCGCAGCCTCGACCAGCAGATGTACCTCTGTTACTCTCAGCCTGGAATCCCCACC2160TTGCCCACCCCAGTGGAAATAACGGTCATCTGTGCCGCCCCTGGTGCGGACGGGGCCTGG2220TGGCGAGCCCAAGTGGTTGCCTCCTACGAGGAGACCAACGAAGTGGAGATTCGATACGTG2280GACTACGGCGGATATAAGAGGGTGAAAGTAGACGTGCTCCGGCAAATCAGGTCTGACTTT2340GTCACCCTGCCGTTTCAGGGAGCAGAAGTCCTTCTGGACAGTGTGATGCCCCTGTCAGAC2400GATGACCAGTTTTCACCGGAAGCAGATGCCGCCATGAGCGAGATGACGGGGAATACAGCA2460CTGCTTGCTCAGGTGACAAGTTACAGTCCAACTGGTCTTCCTCTGATTCAGCTGTGGAGT2520GTGGTTGGAGATGAAGTGGTGTTGATAAACCGGTCCCTGGTGGAGCGAGGCCTTGCCCAG2580TGGGTAGACAGCTACTACACAAGCCTTTGACCCCCATGCTGCTTCCTGAGAGTCTTTTTT2640GCACTGTTGAAATTGGGCTTGGCACTCAAGTCAAAGATGAACATCGGAATAACAAACATT2700GTCCTCTCCAGAAAGTCCTTTCTTTATCCATACTGTAGTCCTATTGAGAAGACATTTCGT2760CTCTGAGAAAAAAGGATGGAACTATGGGTTCTCTTCGCAAAGCCAAAGGATAGTGTTTAA2820CAAGCCAGCTGGCTTATCCTGGCTCGTGCC2850__________________________________________________________________________ | The present invention provides novel PKA-binding polypeptides, nucleic acids that encode the polypeptides and antibodies specifically immunoreactive with the polypeptides. | 0 |
FIELD OF THE INVENTION
This invention concerns methods and compositions for producing shells for investment casting.
BACKGROUND OF THE INVENTION
Dipcoating methods have been used for years to produce shells for investment casting. The first step in the conventional dipcoating process involves preparing slurries comprising suspensions of refractory materials, such as ceramic particles. The second major step requires serially dipping patterns, such as wax patterns or patterns comprising polymeric materials produced by stereolithography, into one or more refractory slurries. This builds up refractory material on the outside surface of the pattern to form a shell in the shape of the pattern.
The slurry-forming step requires preparing multicomponent slurries which include both a flour (i.e., refractory materials) and a binder system. With known methods the binder system includes at least one inorganic binder. The slurry system can be either an aqueous-based system, or a nonaqueous-based system. For aqueous-based systems, the inorganic binder generally comprises nanometer-sized colloidal silica.
Binder particles in a slurry may permanently bond together which, over a period of time, renders the slurries unusable. Binder particle bonding is facilitated by particle drying at the air-slurry interface. Several factors contribute to binder particles coming to air-slurry interfaces. For example, production slurries generally are open to the air and are continuously being mixed. Moreover, air often is continuously bubbled through the slurries to agitate the suspensions. These actions produce air-slurry interfaces, and hence facilitate binder-particle bonding. Once patterns or patterns coated with refractory layers are dipcoated they are removed from the slurry. Excess slurry is allowed to drip off of the shell and back into the container housing the slurry. This also promotes the formation of large air-slurry interfaces. The consequence is that slurries lose their useful properties over time, which is referred to in the industry as "slurry aging" or just "aging".
Besides aging due to the formation of slurry-air interfaces, the different refractory materials used in the slurry also may cause differential slurry aging. For example, yttria-based slurries age very rapidly and may become completely useless within less than a few hours. Alumina-based slurries age slower, and in a similar environment may last a few months.
In aqueous slurries, the soluble species originating from each component of a slurry may specifically adsorb on the surface of silica binder particles. By modifying the surface properties of silica particles, this process can cause aging over time. The degree of interaction among different components of a slurry and the binder particles differs from one slurry to another. For example, Horton et al.'s U.S. Pat. No. 4,947,927 illustrates that in yttria-based slurries, slurries age and become useless in less than a few hours. Yasrebi et al.'s U.S. Pat. No. 5,407,001 teaches that if the yttria used to form yttria-based slurries is fused with a few percent of zirconia, then the solubility of yttria decreases and slurries containing such materials may be used for a period of greater than about a week. The extent of interaction between slurry components and binder is even less in slurries made with less soluble materials, such as alumina, zircon, or fused silica. These slurries can be prevented from aging for extended periods of time, such as months or even longer than a year if the slurries are kept in sealed containers.
In non-aqueous slurries silicon alkoxides often are used as binders. An increase in the pH of non-aqueous slurries as the result of dissolution of components normally reduces the lifetime of these slurries even more dramatically than for their aqueous counterparts. Similar to aqueous systems, the aging behavior of these slurries may differ depending on the amount of dissolution of components in the slurry. For example, yttria-based non-aqueous slurries age very rapidly and may become useless in less than a few hours, whereas alumina-based slurries age slower and in a similar environment may last a few weeks. On the other hand, in some slurries, such as zircon slurries, the pH increase is quite small and slurries may last for many months. Other non-silicon based alkoxides normally go through hydrolysis and condensation reactions very rapidly and age prematurely in the presence of even less reactive refractories such as zircon. For this reason, non-silicon based alkoxides have not been used as binders in the investment casting industry.
Each of the factors discussed above contributes to causing slurry aging. Methods continually are sought to reduce or eliminate slurry aging. One reason for this is that the slurries used to make shells commercially preferably are made in large quantities. It may take many months to use the entire contents of each slurry vessel. If the slurries do not have long shelf lives, they must be disposed of periodically.
Besides slurry aging, there are other problems associated with the conventional shell making process. Such problems include, but are not limited to, reactions between the metal and the shell during the casting process (referred to herein as metal-shell reaction) and undesirable mechanical properties in the shell itself. Concerning metal-shell reaction, the casting process requires first melting the metal and thereafter filling investment casting shells with the molten metal. Some of the metals cast by investment-casting methods are highly reactive. Titanium is an example of such a metal. Furthermore, the reactivity of most metals and metal alloys increases at the high temperatures at which metal articles are cast. The refractory particles used to form the shells therefore may react with the molten metal introduced into the shell. For example, silica binders can react with the molten metal. Silica binders therefore present two considerations. First, the binding properties of silica are the primary reason why conventional shell-making processes work as well as they do, and hence silica binders are an important component in most shell-making compositions. On the other hand, silica causes slurry aging over time. Moreover, silica generally is the least refractory component in a shell, and is the material most likely to react with the metal being cast.
There have been attempts to substitute higher-refractory non-silica binders for silica binders in investment casting slurries. These attempts have proven impractical for use in commercial processes. One reason for this is excessively rapid slurry aging.
The mechanical properties of a shell also are affected by the methods used for their production, as well as by the materials used to construct the shells. For example, green strength, which refers to the strength of the shell before it is fired (i.e., heated to elevated temperatures before being used to cast metals) is an important consideration. An adequate green strength is required to construct a shell around a pattern. An adequate green strength also is important to prevent the shell from cracking as the pattern about which the shell is constructed is separated from the shell. The green strength of a shell appears to correlate with the binder concentration in the slurry. For example, an increase in the concentration of colloidal silica increases the green strength, at least to a point. However, there is a maxima in the curve for green strength versus silica-binder concentration. This is referred to herein as the critical binder concentration, i.e., the binder concentration corresponding to the maxima in the green strength versus binder concentration curve. Shell strength generally decreases when the binder concentration exceeds the critical binder concentration.
High-temperature shell stability is another mechanical property of interest. If the shell deforms at high temperatures, such deformities will be manifested in the metal article being cast. Deformation of the shell at high temperatures is referred to herein as "shell creep" or just "creep." It currently is believed that the main cause of shell creep is the silica binder. Silica is an amorphous material which does not crystalize easily, and this is believed to contribute to shell creep at high temperatures.
Another problem associated with the investment casting process is separating the shell from the cast metal article once the casting process is complete. This is referred to as knockout. Obviously, the easier the shell is to remove from the cast metal article, the better. The need for adequate green strength directly opposes the need to have facile separation of the shell from the cast metal article. That is, for most shells increased green strength makes it more difficult to separate the shell from the cast metal article.
Based on the preceding discussion it is apparent that there is a need for methods and compositions that reduce the aging of slurries used in the investment casting industry. There also is a need to accomplish the goal of reduced slurry aging while maintaining or improving the important physical characteristics of the shell.
SUMMARY OF THE INVENTION
The present invention provides methods and compositions for making shells for investment casting. The method involves forming shells using a binder infiltration process that infiltrates shells with binder as the shell is being formed. This allows for the substantial elimination of inorganic binder from the slurries that are used to deposit refractory material on patterns during the shell-making process. Separating the inorganic binder from the production slurries containing refractory material substantially reduces slurry aging. Moreover, the infiltration process simultaneously maintains or improves the physical characteristics of shells produced by the method relative to shells produced by conventional methods using the same materials.
One embodiment of the method comprises immersing a pattern formed in the shape of a desired article into a first slurry comprising refractory material and from about 0 to about 30 volume percent inorganic binder based on the volume of the slurry. A refractory material is any material that has a high softening point, and a high melting point. A primary example, without limitation, of a refractory material used to form investment casting slurries is metal oxides. After being immersed in a slurry, the pattern is removed from the slurry vessel. Stucco is then applied to the ceramic material, and the pattern with coating material is allowed to dry.
The first immersion step forms a facecoat about the pattern. The pattern having the facecoat is then repeatedly immersed (referred to herein as serially immersing) into the same or different slurries used to form the facecoat, wherein such slurries comprise refractory material and from about 0 to about 30 volume percent inorganic binder based on the volume of the slurry. The stuccoing and drying steps also are repeated. The steps of serially immersing patterns in slurries, followed by the steps of stuccoing and drying, form patterns coated with a refractory facecoat and plural backup refractory layers. The refractory material when deposited about the pattern forms a porous structure. Thus, the facecoat has a porosity. Moreover, the facecoat and at least one backup refractory layer, and more typically plural such backup layers, define a porous shell.
The next method step involves infiltrating at least the facecoat or the porous shell with binder. It should be understood that the infiltration step can involve infiltrating the facecoat with binder solely, infiltrating the shell once with binder after formation of one of the plural backup refractory layers, infiltrating the facecoat and thereafter the shell with binder following the formation of one or more of the plural backup refractory layers, infiltrating the facecoat and then the entire shell with binder after formation of all of the backup layers, or infiltrating the facecoat with binder and then the entire shell with binder following formation of each of the plural backup layers.
One objective of the present invention is to reduce the aging of slurries, which can be accomplished by removing all or a major portion of the inorganic binder from the slurries used to form the facecoat and backup layers. However, the slurries must still be able to deposit refractory material onto the pattern and have such material form a cohesive structure about the pattern. This can be accomplished by using slurries comprising inorganic binder in amounts less than used in conventional approaches, or by using slurries comprising organic binder, such as an emulsion binder, in amounts effective for forming a cohesive shell about the pattern, or by using slurries comprising (1) organic binder and (2) inorganic binder in amounts less than used in conventional approaches.
The present method can be practiced with virtually any slurry used to form shells by investment casting, and hence should not be construed for use with particular refractory materials or binders. However, solely by way of example, a partial list of suitable refractory materials used to form investment casting slurries includes: metal oxides, such as alumina, yttria, zirconia, silica, alumino silicates, zircon, and combinations of such materials; non-oxides, such as silicon carbide, tungsten metal, or mixtures of such materials; and mixtures of metal oxides and non-oxides. Examples, without limitation, of suitable inorganic binders include metal oxides, such as nano-size colloidal silica, nano-size colloidal yttria, nano-size colloidal alumina and nano-size colloidal zirconia, metal salts, metal alkoxides, inorganic polymers, polysilicates, alkylsilicates, and mixtures thereof. When alkyl silicate binders are used, the method may further comprise the step of exposing the shell to gelling agents, such as ammonia, following the infiltration step. An example of a class of suitable organic binders is emulsion binders.
Infiltrating the facecoat and/or backup refractory layers is an important aspect of the invention. This method step can be accomplished in several ways. A first infiltration method involves immersing the pattern having refractory material, such as at least the facecoat, into a binder system. As used herein, "binder system" refers to any material that includes a binder, such as, but without limitation, neat liquid binders, slurries comprising suspensions of binders, and/or emulsions comprising a binder. The binder system can comprise an inorganic binder, an organic binder, particularly emulsion binders, and mixtures thereof. The step of infiltrating generally comprises immersing the pattern having refractory material into a binder system for a period of at least about 10 minutes. Another method for determining the amount of binder infiltrated into the porous structure defined by the refractory material comprises immersing the pattern having refractory material into a binder system for a period of time sufficient to infiltrate from about 10 to about 100 volume percent of the porosity with binder. One method for determining to what extent the pore volume of the facecoat and/or shell is infiltrated with binder is the Archimedes method, although there also are other methods for determining the percent of the pore volume infiltrated with binder. An alternative process for practicing the infiltration step comprises subjecting the pattern having refractory material to a pressure less than ambient while infiltrating the facecoat and/or the shell comprising the facecoat and at least one refractory backup layer with the binder.
The lifetime of slurries used to form shells for investment casting can be substantially increased by eliminating, or substantially eliminating, inorganic binder from the slurries used to deposit refractory material on the pattern. One method for monitoring the useful lifetime of a slurry is to periodically check the viscosity of the slurry, or a component of the slurry, such as the binder system. With conventional systems, the viscosity of the slurry gradually or rapidly increases, depending upon the various factors, over time until the slurry is no longer useful for forming shells. One benefit of practicing the present method is to substantially increase the lifetime of a slurry. The viscosity of investment casting slurries made to practice the present invention increases at a much slower rate relative to conventional slurries made having the same components but including conventional amounts of inorganic binder. The solids concentration should be considered in evaluating viscosity because it is common in the industry to dilute refractory slurries with water over time, which changes the solids concentration as well as the viscosity of the slurry and/or its components. Thus, the method of the present invention allows the formation of slurries which include a binder or a mixture of binders wherein the viscosity of the binder or mixture of binders, at a constant solids concentration, increases less rapidly than with conventional systems.
Another method for determining whether a slurry has aged too much for continued use is to monitor the green strengths of shells made using the slurry. As slurries age, the green strength of shells made with such slurries decreases until such time as the slurries can no longer be used to form shells having adequate green strengths for casting metal articles. The present method allows investment casting slurries to be used to form shells having adequate green strengths for a longer period of time than conventional slurries having the same components except for the amount of inorganic binder added to the slurry. Furthermore, whereas particular green strengths (generally measured in psi) can be provided for shells made using specific investment casting slurries, it is difficult to provide a range of green strengths that would apply to all investment casting shells that can be made using the binder infiltration method of the present invention. Instead, it can be said that the green strength of a shell made using a particular investment casting slurry and the present infiltration process remains adequate for a longer period of time than does the green strengths of shells made with the same materials where the entire amount of inorganic binder used to form the shell is added to the investment casting slurry. More specifically, it currently is believed that shells made by the present method will, over a period of about a month, retain 80% or more of the green strength that shells would exhibit immediately after forming the investment casting slurry (referred to as the initial green strength). By way of comparison, the green strength of articles made by conventional methods over the same period will retain substantially less than 80% of the initial green strength over a period of about a month.
Virtually all methods currently used to form shells for investment casting use silica binders. Silica binder particles tend to bind together, which increases the viscosity and eventually renders slurries containing such particles unusable. However, if the silica binder is removed from the slurry containing refractory material, the lifetime of the slurry can be substantially increased. Moreover, there may be certain situations where it is preferable to use binders other than silica, but for various reasons silica is still required. For example, slurries made with non-silica binders generally age much faster than slurries made using silica binders. Furthermore, some non-silica binders do not age rapidly, but also do not have sufficient binding capability at room temperature to be used successfully as binders. By infiltrating the facecoat and/or backup layers using a binder system, shells can be made without using silica binders. Thus, the present invention provides a method for forming shells for investment casting using non-silica binders. The method comprises immersing the pattern in a first slurry comprising refractory material and from about 0 to about 30 volume percent inorganic binder based on the volume of the slurry, thereby forming a facecoat about the pattern. The pattern with the facecoat is then serially immersed in at least one second slurry, which may be the same slurry or a different slurry than the first slurry, wherein such slurry comprises refractory material and from about 0 to about 30 volume percent inorganic binder based on the volume of the slurry. The facecoat and/or shell is then infiltrated with a non-silica binder.
The shells produced by the method are useful for casting metal articles. The method for casting metal articles comprises forming a shell as discussed above, including infiltrating the refractory material comprising the facecoat and/or shell with a binder. Thereafter, the pattern is separated from the shell to form a shell having an internal void in the shape of an article to be cast. Molten metal is then introduced into the void, and allowed to solidify. The shell is then separated from the metal article.
Not only does the present invention allow the production of slurries with substantially increased shelf lives, but it also results in the production of shells having physical properties at least as good, if not better, than shells produced by conventional methods. Green strength is one example of a physical property that is increased by the present infiltration method. Bars that were infiltrated with colloidal silica binder had green strengths of about 1100 psi at 10 v/o (volume) binder content. Shells made by conventional methods using the same materials had green strengths of only about 550 psi at the same silica binder concentration.
Improved high-temperature shell stability also can be achieved using the infiltration method. High-temperature stability of shells made by the present invention has been evaluated. Test bars infiltrated with zirconium ammonium carbonate solution were prepared and subjected to creep testing, which is a measure of high-temperature stability. Creep was reduced to nearly half in these test bars relative to bars made by conventional methods.
Another benefit of the present invention is that shell knockout can be improved (i.e., the force and/or time required to separate the shell from the cast metal article can be reduced) using the present infiltration method. Moreover, the infiltration process allows for substantial improvement in shell knockout without increasing the occurrence of shell creep.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph illustrating the relative viscosity over time for a yttria suspension and a yttria-silica suspension.
FIG. 2 is a graph illustrating green strength as a function of silica concentration.
FIG. 3 is a graph illustrating weight gain in grams over time for a shell subjected to vacuum and non-vacuum infiltration processes according to the present invention.
FIG. 4 is a graph illustrating shell creep, in inches, as a function of silica concentration in the slurry.
FIG. 5 is a graph illustrating creep, in inches, and fired strength in pounds per square inch as a function of mesh size of the flour and infiltration versus non-infiltration processes.
FIG. 6 is a graph illustrating the deterioration in green strength over time for shells made by conventional methods.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention departs from known methods for producing shells for investment casting in at least two significant ways. First, the slurries containing refractory materials that are used to form the investment casting shells are formulated so as to be devoid, or at least substantially devoid, of inorganic binders. As used herein, substantially devoid means that the slurries contain from about 0 to less than about 30 volume percent inorganic binder. However, in order to construct a shell around a pattern, the slurry must contain some type of binding agent in order to form a cohesive refractory layer about the pattern. This can be accomplished by adding a small amount of inorganic binder and/or organic binder to the investment casting slurry.
Second, once at least one refractory slurry layer coats the pattern, the pattern is then immersed in a binder infiltrating system for a period of time sufficient to infiltrate the shell with an amount of a binder effective to provide sufficient green strength, and/or to reduce the creep in the shell, and/or to reduce the time and effort associated with shell knockout, relative to known methods. The binder infiltrating system can comprise any material useful as a binder, including without limitation, binder slurries, such as slurries of metal oxides, non-oxides, metal salts, neat liquid binders, binder emulsions, and systems comprising mixtures of binders. The binder infiltrating system can be either totally substituted for conventional binder systems used in most commercial investment casting slurries, or can be partially substituted for the conventional binder. In other words, the concentration of inorganic binder used in the investment casting slurry may be reduced substantially relative to that used in conventional casting methods. It is not necessary that the mold be dipped into an infiltrating binder system after the first and each subsequent layer that is placed about the pattern by serially dipping the pattern into slurries.
By removing the inorganic binder from the investment casting slurry, slurry aging is reduced and the lifetime of investment casting slurries is increased. The present method also improves the physical properties, such as increased green strength and decreased creep, of shells made by the method. Moreover, shell knockout can be improved.
The following paragraphs describe how to make investment casting slurries that are completely or substantially devoid of binder, how to serially coat patterns with one or more of such slurries to form shells, and how to infiltrate the facecoat solely, or facecoat and shell, with binders, particularly inorganic binders. Examples also are provided to demonstrate the results that are achieved by using the infiltration method described herein relative to the traditional investment casting process.
I. INVESTMENT CASTING SLURRIES
It should be generally understood that the present method is applicable to virtually any process and any slurry now known or hereafter discovered for producing shells for investment casting. The following paragraphs provide details concerning particular components of slurries and methods for forming shells using such slurries, but the invention is not limited to the particular features described.
Slurries are known in the art of investment casting. Virtually any known slurry can be used to practice the present invention, if such slurry is modified to substantially reduce or eliminate the inorganic binder from the slurry. The investment casting slurries used for the present invention generally, but not necessarily, are aqueous-based suspensions of refractory materials. Such slurries may include an organic binder, and may also include minor portions of inorganic binders. For simplicity, the following discussion will focus on the formation of aqueous slurries. It should be understood, however, that an organic material, such as a lower alkyl alcohol, can be used to form investment casting slurries.
A. Flours
Slurries useful for investment casting include particles of refractory materials that are referred to herein as flours. A refractory material is any material having a high softening point, and a high melting point. The flours used to form the slurry might comprise refractory materials such as, without limitation: metal oxides, including yttria, zirconia, alumina, silica, zircon, alumino silicates, and mixtures thereof; non-oxides, such as silicon carbide, tungsten metal, and mixtures of such materials; and mixtures of metal oxides and non-oxides.
B. Organic Binder
An organic binder may be added to slurries of the present invention to aid in the formation of shells. A partial list of suitable organic binders would include acrylic-based emulsions, vinyl chloride emulsions, vinyl pyridine emulsions, polyethylene glycols, polyethylene oxides, polyvinyl alcohols, polyacrylic acids, polymethacrylic acids, polyacrylamides, polyvinyl pyrrolidones, alginates, alkyl and hydroxyalkyl celluloses, carboxymethyl celluloses, hydroxyethyl celluloses, hydroxypropyl celluloses, starches, modified starches, and mixtures thereof. A particularly suitable class of organic binders is emulsion binders. Several factors can be considered for selecting an appropriate emulsion binder, including cost, toxicity, and how readily and cleanly the binder can be pyrolyzed. The binder preferably is substantially completely pyrolyzed so that little or no residual binder combustion products are left on the finished product. The charge associated with the binder and its film-forming temperature also may be important. Preferably, the binder should have an anionic or nonionic charge and should form a continuous film at ambient temperatures, such as a temperature of less than about 70° F.
The amount of organic binder added to the slurry may vary. However, by way of example, a presently preferred amount of emulsion binder for formulating investment casting slurries typically is from about 1 to about 15 percent, and more typically is from about 1 to about 10 weight percent.
C. Surfactants
A surfactant also may be added to the investment casting slurries, primarily to reduce the surface tension of the slurry. The surfactant enables patterns, particularly wax patterns, that typically are used in the formation of shells, to be wetted by the slurry. To form a mold facecoat, a pattern is dipped into the slurry to wet the pattern with a thin, uniform slurry layer. The surface tension of water is about 73 dynes/cm, whereas a typical surface tension for wax is about 25 dynes/cm. Because the surface tension of water is greater than that of wax, the wax pattern will not be sufficiently wetted by the slurry. A surfactant therefore may be added to the investment casting slurries to reduce the surface tension of the slurry to a level facilitating pattern wetting.
The amount of surfactant added to the slurries of the present invention may vary depending upon the components added to the slurry, the pattern being coated, and the desired properties of shells made using the slurries. However, a presently suitable amount of surfactant for addition to the slurries, based on weight percent, is from about 0.1 weight percent to about 1.0 weight percent. A presently preferred amount of surfactant is about 0.2 weight percent.
D. Antifoaming Agent
Investment casting slurries also may include an antifoaming agent. The addition of different components to the slurry may enhance the formation of bubbles. Hence, an antifoaming agent also may be added to substantially reduce the occurrence of, or substantially eliminate, the formation of bubbles. Virtually any defoamer may be used for the present invention. As with the other components of the slurry, the amount of an antifoaming agent added to the slurry may vary, although the amount of antifoaming agent generally is from about 0.1 weight percent to about 1.0 weight percent.
E. Slurry Viscosity
The viscosity of the slurry typically is adjusted, by increasing or decreasing the water content, each time a new slurry is produced. A slurry viscosity suitable for the present invention is from about 100 centipoise to about 600 centipoise at 0.1 s -1 , and even more preferably from about 450 to about 550 centipoise.
II. SERIALLY DIPPING PATTERNS IN SLURRIES AND STUCCOING
Patterns in the shape of an article to be cast are dipped plural times into one or more investment casting slurries produced as described above. The slurry material is then coated with stucco material. Stucco materials are known in the art and any such stucco materials can be used. The slurry material having stucco applied thereto is allowed to dry after each dipcoating. Patterns can be made by methods known in the art. The first refractory layer to coat the pattern generally is referred to as a facecoat. The pattern with the facecoat is then reimmersed in suitable investment casting slurries to apply additional backup layers of refractory material to the facecoat. Plural such layers generally are applied to the pattern in order to build a shell about the pattern.
III. BINDER INFILTRATION SYSTEM
Following the first and/or subsequent layer-forming steps comprising dipping patterns into the investment casting slurry, the porous structure provided by the refractory material may then be infiltrated using a binder system comprising a neat binder, such as a liquid binder, a binder emulsion, and/or a binder system. The binder system may comprise an inorganic binder, a combination of two or more different inorganic binders, an organic binder, a combination of two or more different organic binders, and combinations of inorganic binders and organic binders. Working methods generally have used inorganic binders to infiltrate the porous structure defined by the refractory material with binder. Any inorganic or organic binder now known or hereafter discovered can be used to infiltrate the refractory layer or layers with binder.
Without limitation, working embodiments of the invention infiltrated the refractory layer or layers with colloidal silica binders. Additional examples of binders useful for infiltrating the shell layers include, without limitation, metal oxides, such as alumina, yttria, and zirconia, metal salts, metal alkoxides, inorganic polymers, polysilicate binders, alkylsilicate binders, such as ethyl silicate, and mixtures thereof.
A presently preferred inorganic binder is a colloidal silica produced by the DuPont Chemical Company. DuPont sells this material as Dupont Ludox SM.
The amount of binder added to the binder system may vary. Perhaps the best way to determine the amount of binder to be used for a particular application is to empirically determine the binder concentration in the binder system, and amount of binder infiltrated into the shell, that provides the desired results. This can be done by considering the physical characteristics desired in the shell (e.g., green strength, mold knockout, etc.) Presently, a preferred amount of colloidal silica in the binder system is from about 5 weight percent to about 50 weight percent, and even more preferably from about 20 weight percent to about 30 weight percent.
IV. INFILTRATING SHELL LAYERS WITH BINDER
The binder can be infiltrated into the shell simply by dipping the shell into the binder system. The amount of time that the shell is immersed in the binder system may have a profound impact upon the physical characteristics of the shell. A first method for infiltrating the shell with a binder system comprises simply immersing the shell into the binder system for a period of time sufficient to provide the desired results. Best results currently appear to be obtained if the shell is immersed in the binder system for a period of at least about ten minutes. More typically, the shell/pattern composite is immersed in the binder system for a period of greater than one hour, and even more typically for periods of from about two to about four hours. These time periods are provided solely as guidance, as the time period required to infiltrate the binder system into the shell depends on a number of factors, including the materials found in the binder system, the size of the flour particles, the size of the binder system particles, shell porosity, thickness of individual refractory layers, and the thickness of the entire shell.
A second method for infiltrating shell layers with a binder comprises first subjecting the pattern coated with at least one, and likely plural, coating layers to reduced pressures, such as by placing the pattern/refractory layer composite article in an evacuated chamber. This helps reduce the pressure exerted by any fluid situated inside the pores of the shell, which tends to preclude the binder system from infiltrating the shell. The shell is immersed into a binder system as discussed above while the shell and the binder system are at pressures less than ambient. The results of using immersion techniques versus vacuum techniques are exemplified more fully in Example 4 below.
V. EXAMPLES
The following examples are provided to exemplify certain aspects of the present invention. These examples should not be construed to limit the invention to the specific features described.
Example 1
This example shows that aqueous yttria slurries generally used for investment casting age very rapidly. A yttria flour having an average particle diameter of about 15 μm was obtained from the Treibacher Company. The flour was added to deionized water with stirring, using a high-shear mixer at 3000 rpm. The weight percent of the flour, based on the total weight of the suspension, was about 80 weight percent. Emulsion binder (Dow 460 NA), surfactant (Aerosol OT), antifoaming agent (Dow Corning 65 Additive) and colloidal silica binder (Du pont Ludox SM) were then added to the slurry with continued stirring.
The weight percent of each material in the resulting slurry is shown below in Table 1.
TABLE 1______________________________________Material Weight Percent______________________________________deionized water 5Emulsion binder (Dow 460NA) 1.8surfactant (Aerosol OT) 0.2colloidal silica (Ludox SM) 7.9yttria flour 85defoamer (Dow Corning 65 0.1additive)______________________________________
FIG. 1 shows a graph of the relative viscosity of the slurry described above versus time. The relevant curve on FIG. 1 for this example is identified as "yttria-silica suspension." The viscosity of the slurry was measured using a Brookfield table-top viscometer. FIG. 1 shows that slurries made using yttria and colloidal silica binders age rapidly. More specifically, in about 5 days the viscosity increased more than 10 fold. A constant viscosity is desired, and is indicative of a non-aging slurry. Currently, production slurries wherein the viscosity does not vary by much more than ±10 percent are desired.
Example 2
This example illustrates that the aging of yttria slurries can be substantially reduced, i.e., the slurry lifetime can be increased, by reducing or substantially eliminating colloidal silica binders from the slurry. A yttria slurry was made using a yttria flour having an average particle diameter of about 15 μm which was obtained from the Treibacher Company. The flour was added to deionized water with stirring, using a high-shear mixer at 3000 rpm. Thereafter, emulsion binder (Rohm & Haas Roplex HA-8), surfactant (3M Fluorad FC-430), and an antifoaming agent (Dow Corning 65 additive) were added to the slurry with continued stirring.
The relative weight percent of each material in the resulting slurry is shown below in Table 2.
TABLE 2______________________________________Material Weight Percent______________________________________deionized water 5.5latex (Rohm & Haas Roplex 3.2HA-8)surfactant (3M Fluorad FC- 0.2430)yttria flour 91defoamer (Dow Corning 65 0.1additive)______________________________________
FIG. 1 shows the relative viscosity of the above slurry versus time as measured using a Brookfield table-top viscometer. The slurry made with no inorganic silica binder had a constant viscosity, and hence did not age, at least for the entire 2 month period tested.
Example 3
This example describes how to construct a shell and how shell green strength changes versus the amount of silica binder in the slurry. A series of slurries were made using -325 mesh zircon flour, 70 mesh alumina sand and colloidal silica binder. The weight-ratio of zircon flour to alumina sand was 2.76. The amount of colloidal silica added to each slurry varied in order to adjust the amount of silica binder. The amount of water used to form the slurries was adjusted such that the slurries had a Zahn viscosity of 4 seconds at number 4 cup.
A wax test bar pattern was formed, and then immersed into the slurry. The wax pattern was removed from the slurry and excess material was allowed to drain from the wax pattern to obtain a uniform coating. Subsequently, the slurry-coated wax pattern was covered with 46 mesh alumina stucco and allowed to dry for twelve hours in an environment of about 70° F. at a relative humidity of 52 percent. Six subsequent coatings were applied in a like manner. A final seal-dip coating was applied using the zircon-alumina slurry described above; however, no stucco was applied after draining.
After the shell was formed as described above, test bars were cut to 5×1 inches and were removed from the pattern wax. These bars were then dried at 75° C. for 4 hours using a heated oven and then tested for strength with a three-point bend set up. FIG. 2 shows that as the amount of binder in the slurry increases, the strength increases up to a critical binder concentration. Above the critical binder concentration, the strength decreases.
Example 4
This example describes the infiltration kinetics for infiltrating shells with colloidal silica binder into a shell. A shell was first made with 4 v/o silica as described above in Example 3. The shell was dried by placing it in an oven heated to a temperature of about 40° C. for a period of about 3 hours. After the shell was completely dried, it was then hung from a weighing balance. The shell was then immersed in a tank of Ludox SM and the weight gain associated with infiltrated silica binder was recorded versus time. FIG. 3 illustrates that it takes several hours before a half-inch thick shell is completely infiltrated with binder. Without limiting the present invention to one theory of operation, it currently is believed that the reason for this protracted infiltration time is that air is compressed behind the infiltrating front and it takes time before the air can relocate.
This situation can be alleviated by subjecting the shell and the binder slurry to a vacuum in a vacuum chamber at a pressure of about 30 mm Hg. This pressure was maintained for a period of about 15 minutes. The data illustrated by FIG. 3 indicates that in about 5 minutes the shell can be substantially completely infiltrated, as compared to at least about 4 hours when simple immersion is used as the infiltrating procedure.
Example 5
This example describes how green strength of a shell can be improved by the infiltration process. Test bars were constructed according to the procedure of example 4 using 5 volume percent (v/o) colloidal silica binder. The bars were then infiltrated with Ludox SM, or ethyl silicate binder (SILBOND 40, obtained from Silbond Corporation). For infiltration with colloidal silica, some of the bars were dried, after the first infiltration, for 12 hours at room temperature. The infiltration process was then repeated to investigate the effect of double infiltration. The results are illustrated in FIG. 2, which shows that infiltration substantially increases green strength. Bars that were infiltrated with Ludox SM had green strengths of about 1100 psi at 10 v/o binder content. Shells made by the conventional method, i.e., using investment casting shells having inorganic binder, had green strengths of only about 550 psi at the same silica binder concentration.
Double infiltration sequences also increased the green strength of the shells. After the second infiltration at 16 v/o binder content, shells had green strengths of about 1650 psi. This is compared with about 400 to about 1,000 psi for shells made by conventional methods. It is apparent from this range of strengths that the shell strength depends upon a number of factors. However, the important point is that the strength of shells produced by the present method can be increased relative to a shell produced using the same materials by conventional methods.
Bars that were infiltrated with ethyl silicate binder initially showed lower green strengths. This is not unexpected, because the ethyl silicate binder dissolves some of the colloidal silica binder. This is believed to reduce the bonding between binder particles. However, after the bars were placed in an ammonia gas chamber, the strength gradually increased. Ammonia gelation of ethyl silicate binder is well known in the industry and causes polymerization of hydrated silicon alkoxide molecules, which results in three dimensional bond formation. FIG. 2 shows that bars infiltrated with only 14.5 v/o ethyl silicate binder, and subsequently subjected to ammonia gel treatment, had green strengths of about 2800 psi.
One problem encountered when using ethyl silicate binder in investment casting is that alcohol is used as the media for dissolving the binder in the slurry. Companies that still use ethyl silicate binder must use large quantities of alcohol and may be required to closely control its disposal. The infiltration method, as was illustrated in this example, eliminates the need to use alcohol as a solvent because ethyl silicate, which is a liquid, can be used for infiltration. Therefore, the total amount of alcohol is limited to only a small amount that is produced by hydrolysis of ethyl silicate molecules.
Example 6
This example demonstrates how creep can be minimized in the conventional shell making process. Test bars were prepared according to Example 4 with 5, 20 and 40 v/o binder, and then the bars were fired at 1200° C. for 4 hours. After the bars were cooled down, they were creep tested at a pressure of about 80 psi at 1300° C. for 5 hours. The results of the creep test are illustrated in FIG. 4. Bars with 5 v/o binder creeped significantly, and finally broke under the exerted pressure before the end of the experiment. Bars with 40 v/o binder also showed significant creep. Bars with 20 v/o binder exhibited the smallest creep. These bars are in a region of FIG. 2 where the green strength is close to the maximum.
Example 7
This example shows how creep can be further reduced by the infiltration method. Test bars produced according to Example 6 with 20 v/o binder were infiltrated with zirconium ammonium carbonate solution (BACOTE 20, MEI, Inc.). Zirconium ammonium carbonate was used because, following heat treatment, it precipitates as small crystalline inclusions inside the matrix of amorphous silica binder. After infiltration, samples were prepared and subjected to creep testing similar to that described for Example 6. FIG. 5 shows that creep was reduced to nearly half in these test bars. At the same time, fired strength was 2509 psi which is very similar to uninfiltrated bars.
Example 8
This example illustrates how shell knockout can be improved through the infiltration method without increasing shell creep. Creep test bars were made according to Example 4 using 20 v/o Ludox SM. However, instead of -325 mesh flour, a coarser -250 mesh zircon flour was used. Test bars then were infiltrated with zirconium ammonium carbonate solution as described above in Example 7 and then creep tested as described for Example 7. FIG. 5 shows that creep in these bars was similar to uninfiltrated bars made with -325 mesh flour. However, fired strength was reduced to almost one half. It should be understood that a reduction in green strength, in most cases, directly correlates with easier shell knockout.
Example 9
This example illustrates how investment casting shells with a silica-free facecoat can be prepared using the infiltration method. A slurry was made according to Example 2. A test-bar wax pattern was then coated with this slurry. Next, the coating was dried and consequently was infiltrated with NYACOL colloidal yttria which was obtained from The PQ Corp., or BACOTE 20, or NYACOL colloidal zirconia, which also were obtained from The PQ Corp. After four hours of drying, three more layers were applied to the shell using the slurry of Example 4 with 20 v/o Ludox SM. Test bars were then dried and fired at 1100° C. for 3 hours. None of the bars showed any facecoat chalkiness.
Example 10
This example illustrates that shell green strength deteriorates over time when using conventional investment casting slurries. A slurry having 5 v/o colloidal silica was made as stated in Example 3 and placed in a 20-inch slurry container. Test bars were made in a manner stated above in Example 3 for four weeks following the initial formation of the slurry. The green strengths of test bars made over this four-week period using the slurry were then tested by the three-point bend method. The results are illustrated in FIG. 6. FIG. 6 shows that the green strength of shells made by conventional methods decreases over time. More specifically, FIG. 6 shows that, with the particular shells made using a conventional slurry, green strength decreased from an initial value of about 450 psi to about 225 psi over a period of four weeks. In contrast, shells made by the present infiltration method maintain about 80% of the initial green strength over the same period of time.
The preceding invention has been described with respect to certain preferred embodiments. It will be apparent to those of ordinary skill in the art that the invention may depart from that described herein, and still be within the scope of the following claims. We claim all inventions and modifications coming within the scope of the following claims. | Methods and compositions for forming shells for investment casting and methods for casting metal articles using the shells are described. One embodiment of the method comprises serially immersing a pattern in at least one, and perhaps several different slurries, each of which slurries comprises refractory material and from about 0 to about 30 volume percent inorganic binder. This forms a facecoat and plural refractory backup layers about the pattern, the facecoat and at least one backup layer defining a shell. The facecoat and/or the shell is then infiltrated with a binder. Infiltrating the shell with a binder is a key feature of the present invention. Infiltration refers to any process whereby a binder can be introduced into the facecoat and/or the subsequent layers built up about the shell. One method of infiltrating the facecoat and/or layers with binder comprises immersing the pattern having refractory material into a slurry comprising a binder, including inorganic binders, organic binders, and mixtures thereof. The pattern then is separated from the shell, forming a shell having an internal void in the shape of an article to be cast. Molten metal is then introduced into the void and allowed to solidify. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] --
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] --
BACKGROUND OF THE INVENTION
[0003] Low-cost, electric, linear actuators are used in a variety of consumer products, including home appliances and automobiles, to move various components, including lock bolts, valve plates and the like, on the occurrence of an electrical signal.
[0004] Common linear actuators include solenoids, wax motors, and DC motors driving gear trains or screw threads. In a solenoid, a metal plunger loosely surrounded by a coil of wire is moved under the influence of a magnetic field produced by an electrical current in the coil. A wax motor employs an electrical current to heat wax contained in a closed volume so that the expanding wax drives a piston out of the volume.
[0005] Conventional solenoids and wax motors use a return spring to return the plunger or piston to its unactuated state, and thus require continued power to retain their actuated state. In contrast, small DC (direct current) motors, driving a rack-and-pinion gear or screw and nut, can be reversed by changing the polarity of the driving current, avoiding the need for a return spring and allowing the actuator to retain its actuated state after power is withdrawn.
[0006] One problem with DC motor linear actuators is friction in the gear train or screw and nut, particularly when the latter become contaminated during use. The high mechanical advantage typically present in a screw and nut design can cause jamming of the screw and nut at the end of travel under the momentum of the motor.
SUMMARY OF THE INVENTION
[0007] The present invention provides an improved DC motor linear actuator in which a screw and nut are replaced by a helical wire spring and a follower. The wire helix may be given a large pitch to prevent excessive force on the follower that might lead to jamming. Further, the flexibility of the wire of the helix can cushion the shock at the end of travel. The open construction of the wire helix resists the build up of contamination that can cause excessive friction. The wire helix further lends itself to simple fabrication and attachment to a motor.
[0008] Specifically then, the present invention provides an electrical actuator having an electric motor with a motor shaft rotating about an axis. A wire helix is attached to the shaft to rotate therewith and a helix follower interfits with the wire helix to translate along a path with rotation of the wire helix.
[0009] Thus, it is an object of the invention to provide for a simple and cost-effective mechanism for converting the rotary motion of a small DC electric motor into linear motion.
[0010] The wire helix may have a lead angle of between 5 and 55 degrees.
[0011] Thus, it is an object of the invention to permit relatively large helix lead angles that reduce jamming forces while providing rapid actuation.
[0012] The wire of the helix may be sized to flex under a force of the motor when the helix follower is restrained.
[0013] It is thus another object of the invention to provide a mechanism that naturally absorbs shocks, for example, when the helix follower reaches stop points, and that readily accommodates axial misalignment.
[0014] The wire helix may provide a first portion having a first diameter engaging the helix follower, and a second portion having a second diameter conforming to the diameter of the motor shaft.
[0015] Thus, it is an object of the invention to provide a simple means of attaching the helix to the shaft by using helical coils of the wire.
[0016] The wire helix may provide a first portion with a lead angle and a second portion with a second lead angle, the first and second portions at different times engaging the helix follower.
[0017] Thus it is an object of the invention to provide a simple method of changing the lead angle of the helix, and thus the relative mechanical advantage between the helix and the follower over the length of the helix, such as may be used to change the actuation force, for example, near the ends of motion of the helix follower to prevent jamming.
[0018] The second portion may be between the motor shaft and the first portion, and the second lead angle may be larger than the first lead angle.
[0019] Thus, it is an object of the invention to provide for a decrease in actuation force when the helix follower is closest to the motor where the helix itself cannot serve, through its elasticity, to cushion the forces generated when the helix follower confronts a stop.
[0020] The helix follower may be a bar fitting within the coils of the helix.
[0021] Thus it is an object of the invention to provide a simple follower suitable for a wire helix and resistant to jamming.
[0022] The helix follower may contact only one side of the helix.
[0023] It is thus another object of the invention to provide a helix follower that can decouple from the helix, upon direction reversal, to decrease the load on the motor during its startup.
[0024] The helix follower may contact the helix at only a single point.
[0025] It is thus another object of the invention to provide a small contact area between the helix follower and the helix that resists capture of contamination.
[0026] The helix may be a non-magnetic stainless steel.
[0027] It is thus another object of the invention to provide an actuator that is corrosion resistant, durable and which does not divert magnetic flux.
[0028] The motor may be a permanent magnet DC motor.
[0029] It is thus another object of the invention to provide a simple actuation mechanism that may be used with small motors.
[0030] The helix follower may be attached to a switch throw, which may, for example, be a sliding conductive element moving along an axis of the wire helix with the rotation of the helical wire, and pressing outward perpendicularly to the axis of the helical wire against opposed poles.
[0031] It is thus an object of the invention to provide a signal indicating the motion of the actuator and to provide a switch compatible with the present system that does not exert a torque on the follower, such as would require friction-increasing stabilization of the helical coil or follower.
[0032] The switch throw may be a V-shaped metal spring contacting the poles at the ends of the V.
[0033] It is thus another object of the invention to provide a simple throw mechanism that provides balanced outward forces.
[0034] The linear electrical actuator may be employed in an appliance latch where the helix follower attaches to a bolt that may extend from one of the housing or a door of the appliance to engage a strike placed on the other of the housing or door.
[0035] Thus, it is an object of the invention to provide a low cost latch mechanism suitable for use in appliances that provides for rapid engagement and disengagement and which is stable in engagement and disengagement without the application of electrical power (to reduce electrical consumption), and yet may be readily reversed simply by reversal of power to the motor. These particular objects and advantages may apply to only some embodiments falling within the claims, and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a fragmentary perspective view of a washing machine showing the positioning of a latch employing the present invention, such as may extend a bolt to engage a strike in the edge of a door;
[0037] FIG. 2 is a front elevational view of a bezel that may serve to attach the latch of FIG. 1 to the housing of the washing machine;
[0038] FIG. 3 is a cross-sectional view taken along line 3 - 3 of FIG. 1 showing the latch of FIG. 1 as held by the bezel, and showing tipping of the latch prior to a final installation using screws, such as causes blocking of the bolt that may be detected to signal incomplete installation of the latch;
[0039] FIG. 4 is an exploded view of an electrical actuator used in the latch of FIGS. 1-3 showing a DC motor that may turn a helical wire spring engaged by a helix follower bar held below the bolt of the latch;
[0040] FIG. 5 is a top plan view of the wire helix and shaft of the motor of FIG. 4 showing changes in pitch and diameter of the wire helix such as changes the lead angle;
[0041] FIG. 6 is a cross-section along line 6 - 6 of FIG. 4 showing the orientation of the bar of the helix follower as it engages the helix at a single point on a single side of the helix;
[0042] FIG. 7 is a top plan view of a switch having a V-shaped throw compressed between opposing poles of the switch and attached to the bolt of FIG. 4 ;
[0043] FIG. 8 is a detailed fragmentary perspective view of one arm of the V-shaped throw showing a bifurcation of the contact surface and a supporting slider tip;
[0044] FIG. 9 is a fragmentary cross-section taken along line 3 - 3 of FIG. 1 when the washing machine door is closed showing engagement of the bolt in a strike hole of the door to receive an upwardly extending tooth in the door locking the bolt when the door is lifted during engagement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] Referring now to FIG. 1 , an appliance 10 , such as a washing machine, may have a housing 12 having an opening over which a hinged door 14 may close, for example, to cover a wash basket 16 . The door 14 may be locked when closed to prevent injury to a user during the spin cycle of the washing machine. For this purpose, a front edge of the door 14 may include a strike aperture 18 , which may receive a bolt 20 when the door 14 is in the closed position. The bolt 20 may extend from a latch mechanism 22 positioned within the housing 12 under the control of an electrical signal. As used herein, the term “bolt” may embrace any similar locking element such as a hook, pin, latch bar, shaft or the like.
[0046] Referring now to FIGS. 2 and 3 , the latch mechanism 22 may be positioned within the housing 12 behind an aperture 21 through which the bolt 20 (not shown in FIG. 3 ) may extend. The latch mechanism 22 may be held in position by means of a bezel 24 having a central aperture 26 aligning with aperture 21 and a pair of rearwardly extending posts 28 . The posts 28 that may pass through corresponding apertures (not shown) in the housing 12 to be received by sockets 30 molded in the side of the latch housing 23 .
[0047] The rearwardly extending posts 28 include upwardly extending teeth 34 that may engage a lip 36 of the socket 30 holding the bezel 24 and housing 23 loosely engaged so as to prevent the housing 23 from dropping downward free of the bezel 24 during assembly. When the posts 28 are received by the socket 30 , screws 38 may be inserted through bases 40 of the sockets 30 to engage threadable portions of the posts 28 .
[0048] Tightening of the screws 38 draws the bezel 24 tightly down against the housing 12 and to pull the latch housing 23 upward against the inner surface of the housing 12 . When so tightened, the bolt within the latch housing 23 will extend along a bolt axis 42 that is generally horizontal to be received by the strike aperture 18 of the door 14 when the door 14 is closed. Prior to this tightening, however, gravity will pull the latch housing 23 downward, as shown by a dashed outline of latch housing 23 ′, causing the bolt axis 42 ′ to tip upward. This misalignment will prevent the bolt from fitting into the strike aperture 18 . Blockage of the bolt can be detected by a switch attached to the bolt, as will be described below, providing an error signal to a controller within the appliance 10 indicating a problem with the assembly of the latch housing 23 .
[0049] Aperture 26 of the bezel 24 is surrounded by a rearwardly concave and flexible skirt 32 having a curvature with a radius slightly smaller than the radius of curvature of the housing 12 beneath the bezel 24 . Thus, when the bezel 24 is pulled tightly against the housing 12 with the screws 38 , the skirt 32 flexes outward forming a tight seal with the surface of the housing 12 . The housing 23 and bezel 24 are constructed of a flexible thermoplastic material that also provides for electrical insulation and that freely passes magnetic flux.
[0050] Referring now to FIG. 4 , the bolt 20 may be driven by and form part of a linear actuator 44 comprising a permanent magnet DC motor 46 having a shaft 48 that may rotate in one of two directions according to the polarity of electrical voltage applied to the motor 46 over motor leads 50 . Attached to the shaft 48 and axially aligned therewith is a wire helix 52 , both of which are generally parallel to the bolt axis 42 .
[0051] Paddles 54 , extending downward from the bolt 20 , flank the left and right side of the wire helix 52 and receive a transversely extending metal bar 56 passing through corresponding holes 58 in each of the paddles 54 to intersect the wire helix 52 and to be held captive by its coils. The paddles 54 and bar 56 provide a helix follower that moves along the axis 42 with rotation of the wire helix 52 .
[0052] The wire helix 52 is preferably a spiral of spring-tempered stainless steel wire following a three-dimensional curve that lies on a cylinder of a defined diameter and having a central axis parallel to axis 42 . The wire of the wire helix 52 will have a defined angle with respect to a plane perpendicular to the axis 42 termed its lead angle. The lead angle may be controlled simply by spacing between wire coils along the axis of the wire helix 52 .
[0053] Referring now to FIG. 5 , the wire helix 52 provides a number of different pitches and diameters and thus different lead angles, where lead angle 65 , as described above, is the angle between a plane orthogonal to the axis 42 and the wire of the helix 52 . For a given helix diameter, the lead angle will increase as the pitch increases. In a first region 60 , near where the wire helix 52 is attached to the motor shaft 48 , the wire helix 52 is given a small diameter 62 so that it may be press fit and welded directly to the shaft 48 . The pitch 64 in this first region 60 is such that the windings of the wire helix 52 abut each other and thus is approximately equal to the diameter of the wire of the wire helix 52 . Here the lead angle may be relatively low.
[0054] In a second region 66 , displaced from the motor 46 by region 66 , the diameter 61 of the wire helix 52 increases, while the pitch 68 is retained at pitch 64 for the purpose of stable transition.
[0055] In a next region 70 proceeding outward from the motor 46 , the pitch is abruptly increased to an expanded pitch 72 (increasing the lead angle) and then, at succeeding region 74 encompassing the remainder of the wire helix 52 , the pitch decreases slightly to a reduced pitch 76 (and reduced lead angle), both lead angles being typically greater than five degrees and less than fifty-five degrees. These regions 70 and 74 provide drive surfaces for the helix follower of the bar 56 and create a relatively large opening between coils of the wire helix 52 such as to resist entrapment of contaminants.
[0056] Referring also to FIG. 4 , when the bolt 20 is fully extended and the bar 56 is in the region 74 , the bolt 20 may hit a stop 78 . A PTC thermister (not shown) may be placed in series with the motor to prevent over-current of the motor 46 when the motor 46 stalls, but even with current limiting, the interaction of the bolt 20 with the stop 78 can produce a relatively high instantaneous torque (and resulting actuation force) caused by the rapid deceleration of rotating mass of the motor 46 . However, any jamming of the bar 56 and wire helix 52 , such as might prevent reversal of the wire helix 52 , is forestalled by the natural compliance of the wire helix 52 , which compresses slightly to slow the deceleration of the motor 46 decreasing the peak torque.
[0057] When the motor 46 is reversed and the bolt 20 is drawn inward against a second stop 80 adjacent to the motor 46 , there is less length of the wire helix 52 to act as a spring to slow the deceleration of the motor 46 . In this case, the increased lead angle of the wire helix 52 in region 70 , serves to reduce the axial force and to prevent jamming.
[0058] Referring now to FIG. 6 , the bar 56 of the helix follower may be installed at an angle with respect to the axis 42 to contact the coils of the wire helix 52 at a single point only, thus reducing potential entrapment of contaminants. Further, the angle of the bar 56 is such that the bar 56 , at any time, contacts only one side of the wire helix 52 . This allows the load of the bolt 20 to be decoupled from the wire helix 52 upon change in direction of the motor 46 , preventing stalling of the starting motor 46 in a position of low torque. This decoupling also allows the motor to start up in a reversed direction with reduced load to gain speed before the bar 52 recontacts the side of the wire helix 52 . The bar 56 may be molded into paddles 54 or may be a metal bar held by the paddles providing improved wear resistance. In one embodiment, shown in FIG. 4 , the bar 56 may be surrounded with a sleeve 57 (for example a self-lubricating plastic material) that provides a lower-friction contact between the bar 56 and the helix 54 by action of the sleeve 57 rolling about the bar 57 .
[0059] Referring now to FIGS. 4 and 7 , extending axially rearward from the bolt 20 , is a metallic V-shaped throw 84 . The throw 84 has outwardly diverging arms 88 that are flexible and compressed between opposed surfaces of pole 90 on one side, and pole 92 or 94 on the opposite side as the bolt 20 and throw 84 move axially throughout the length of travel of the bolt 20 . The pole 90 is continuous while pole 92 and 94 occupy opposite axial ends of a track 96 . Electrical continuity exists from the pole 90 through spring throw 84 to pole 92 when the bolt 20 is fully retracted and from the pole 90 through spring throw 84 to pole 94 when the bolt 20 is fully extended. Electrical continuity is broken when the bolt 20 is neither fully retracted nor fully extended. In this way, three distinct signals may be generated, one each for when the bolt is fully extended, fully retracted and in transition. Referring now also to FIG. 8 , an outwardly convex dimple 102 may be placed at the ends of the arms 88 where they ride against the poles 90 , 92 , or 94 (only pole 90 is shown), to provide a contact surface. The dimple 102 may include an axial groove, 103 bifurcating the surface of the contact where it connects with one of the poles 90 , 92 , or 94 to provide improved contact reliability.
[0060] The vertex of the V-shaped throw 84 is pivotally attached to a downwardly extending pivot pin 86 on the bolt 20 so that the throw 84 is self-aligning between pole 90 and pole 92 and 94 on track 96 . Referring now also to FIG. 8 , inwardly extending tabs 98 are formed on the ends of the arms 88 to ride on tracks 100 positioned between the ends of the arms 88 . The tabs 98 help stably locate the ends of the arms 88 against rotational movement. It will be understood from this description that there is no rotational torque exerted by the V-shaped throw 84 on the bolt during switching action such as might tend to cam the bolt 20 or divert the wire helix 52 off axis.
[0061] Referring now to FIGS. 1 and 9 , when the bolt 20 is inserted through the strike aperture 18 in the door 14 and the door 14 is lifted upward, as indicated by arrow 104 , a tooth 106 formed in the door 14 behind the strike aperture 18 may engage a corresponding socket 108 formed in the lower side of the bolt 20 . The interengagement of the tooth 106 and socket 108 prevents force on the door 14 possibly sufficient to bend the bolt 20 , or from disengaging the bolt 20 from the strike aperture 18 .
[0062] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments, including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | An electrical linear actuator employs a reversible motor driving a helical wire spring. The coils of the spring engage a follower that moves along the axis of the spring with rotation of the motor to provide linear motion. This actuator may be used as a linear drive in an appliance lock. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Ser. No. 61/019,469 entitled “Compositions for Treating Perioral Dermatitis” by Jay Goldstein, filed on Jan. 7, 2008.
FIELD OF THE INVENTION
[0002] This invention is generally in the field of topical formulations for the treatment of perioral dermatitis.
BACKGROUND OF THE INVENTION
[0003] Perioral dermatitis is a skin condition that affects mostly adult women, typically between the ages of 20 and 50. Perioral dermatitis is characterized by papules, and less often pustules, found chiefly on the lower portion of the face, i.e., around the mouth and along the mandibular line. While perioral dermatitis is often classified as a subset of acne, this is not accurate since occurrences of perioral dermatitis lack comedones (i.e., blackheads and whiteheads) which are indicative of acne.
[0004] The etiology of perioral dermatitis is unknown. It has been hypothesized that a variety of factors and irritants, such as excess washing of the lower portion of the face; use of fluorinated toothpastes; overuse of topical steroids; use of cosmetics; environmental factors, such as exposure to UV light, heat, and wind; microbiological agents, and/or miscellaneous factors, such hormonal changes, use of oral contraceptives, and gastrointestinal disturbances may cause or exacerbate perioral dermatitis. In the case of fluorinated toothpastes, the papules are usually limited to the perioral region and switching brands of toothpaste or taking care to remove any remaining toothpaste from the perioral region of the face typically results in the disappearance of the papules.
[0005] For more serious cases of perioral dermatitis, such as those that affect the mandibular line as well as the perioral region and/or are of unknown etiology, the use of systemic antibiotics had had some success. However, the use of systemic antibiotics is not always successful. Further, the use of systemic antibiotics can require long treatment times in order to control the outbreak and/or can result in adverse side effects.
[0006] There exists a need for compositions and methods of use thereof for the treatment of perioral dermatitis which are clinically effective and alleviate the symptoms in a short period of time, with little or no adverse side effects.
[0007] Therefore, it is an object of the invention to provide topical compositions for the treat of perioral dermatitis that are clinically effective and alleviate the symptoms of perioral dermatitis in a short period of time.
SUMMARY OF THE INVENTION
[0008] Methods for treating perioral dermatitis are described herein. The method includes administering topically a composition containing an effective amount of a systemic or topical antibiotic and a corticosteroid. Suitable antibiotics include, but are not limited to, tetracyclines, such as doxycycline, demecocycline, minocycline, oxytetracycline, and tetracycline; sulfonamides; quinolones; penicillins; monobactams; macrolides, such as erythromycin, azithromycin, clarithromycin, dirithromycin, roxithromycin, and troleandomycin; cephalosporins; clindamycin; lincoamycin; and metronidazole. Suitable corticosteroids include, but are not limited to, desonide, desoximetasone, mometasone, triamcinolone fluocinolone, hydrocortisone, clocortolone, predincarbate, and aclometasone. The concentration of the antibiotic is from about 0.01% to about 5% by weight of the composition and the concentration of the corticosteroid is from about 0.01% to about 5% by weight of the composition. The composition may also contain one or more pharmaceutically acceptable excipients and/or carriers. The compositions can be formulated as a lotion, cream, gel, ointment, paste, powder, solution, suspension, spray, foam, or patch.
[0009] In one embodiment, the composition contains clindamycin hydrochloride at a concentration of 1% by weight of the composition and desonide at a concentration of 0.05% by weight of the composition. In another embodiment, the composition can be administered in varying strengths to treat the initial outbreak and to maintain treatment. For example, a first composition containing 1% clindamycin hydrochloride by weight of the composition and 0.05% desonide by weight of the composition can be administered to treat the initial outbreak, followed by compositions with a decreased concentration of desonide (e.g., 0.025% by weight of the composition and 0.01% by weight of the composition) as the degree of inflammation decreases.
[0010] In another embodiment, the composition is in the form of an ointment wherein the active agents are incorporated into an ointment base containing between 1 and up to 30% by weight, more preferably between 1 and 20%, most preferably between about 5 and 10% by weight particles, such as titanium dioxide or a similar material
DETAILED DESCRIPTION OF THE INVENTION
I. Definitions
[0011] “Perioral dermatitis”, “adult onset acne”, “mandibular acne”, or “perioral dermatitis with mandibular involvement” are used interchangeably and refer to a skin condition characterized by papules, and less often pustules, found chiefly on the lower portion of the face, i.e., around the mouth and along the mandibular line. Perioral dermatitis, as used herein, may include outbreaks resulting from a known etiology, such as an irritant (toothpaste, cosmetics, etc.); however, the outbreaks generally will result from an unknown or undetermined etiology.
II. Compositions
[0012] A. Antibiotics
[0013] The compositions can contain a systemic or topical antibiotic. Suitable antibiotics include, but are not limited to, tetracyclines, such as doxycycline, demecocycline, minocycline, oxytetracycline, and tetracycline; sulfonamides; quinolones; penicillins; monobactams; macrolides, such as erythromycin, azithromycin, clarithromycin, dirithromycin, roxithromycin, troleandomycin; cephalosporins; clindamycin; lincoamycin; and metronidazole. The concentration of the antibiotic is from about 0.01% to about 5% by weight of the composition. In one embodiment, the antibiotic is clindamycin hydrochloride having a concentration of about 1% by weight of the composition.
[0014] B. Corticosteroids
[0015] Suitable corticosteroids include, but are not limited to, desonide, desoximetasone, mometasone, triamcinolone fluocinolone, hydrocortisone, clocortolone, predincarbate, and aclometasone. The concentration of the corticosteroid is from about 0.01% to about 5% by weight of the composition. In one embodiment, the corticosteroid is desonide having a concentration of about 0.05% by weight of the composition. In another embodiment, the corticosteroid is desonide having a concentration of about 0.025% by weight of the composition. In yet another embodiment, the corticosteroid is desonide having a concentration of about 0.01% by weight of the composition.
[0016] C. Pharmaceutical Compositions
[0017] The antibiotic and the corticosteroid can be combined with one or more pharmaceutically acceptable excipients and/or carriers to form a pharmaceutical composition for topical or transdermal delivery. As would be appreciated by one of skill in this art, the excipients and/or carriers may be chosen based on the dosage form used, the active agents being delivered, the disease or disorder to be treated, etc.
[0018] As used herein, the term “pharmaceutically acceptable carrier” means a non-toxic, diluent, encapsulating material or formulation auxiliary of any type. Remington's Pharmaceutical Sciences Ed. by Gennaro, Mack Publishing, Easton, Pa., 1995 discloses various carriers used in formulating pharmaceutical compositions and known techniques for the preparation of such dosage forms.
[0019] 1. Excipients and Carriers
[0020] Suitable excipients include surfactants, emulsifiers, emulsion stabilizers, anti-oxidants, emollients, humectants, chelating agents, suspending agents, thickening agents, occlusive agents, preservatives, stabilizing agents, pH modifying agents, solubilizing agents, solvents, colorants, fragrances, penetration enhancers, and other excipients.
[0021] i. Emulsifiers
[0022] Suitable emulsifiers include, but are not limited to, straight chain or branched fatty acids, polyoxyethylene sorbitan fatty acid esters, sorbitan fatty acid esters, propylene glycol stearate, glyceryl stearate, polyethylene glycol, fatty alcohols, polymeric ethylene oxide-propylene oxide block copolymers, and combinations thereof.
[0023] ii. Surfactants
[0024] Suitable surfactants include, but are not limited to, anionic surfactants, non-ionic surfactants, cationic surfactants, and amphoteric surfactants. Examples of anionic surfactants include, but are not limited to, ammonium lauryl sulfate, sodium lauryl sulfate, ammonium laureth sulfate, sodium laureth sulfate, alkyl glyceryl ether sulfonate, triethylamine lauryl sulfate, triethylamine laureth sulfate, triethanolamine lauryl sulfate, triethanolamine laureth sulfate, monoethanolamine lauryl sulfate, monoethanolamine laureth sulfate, diethanolamine lauryl sulfate, diethanolamine laureth sulfate, lauric monoglyceride sodium sulfate, potassium lauryl sulfate, potassium laureth sulfate, sodium lauryl sarcosinate, sodium lauroyl sarcosinate, lauryl sarcosine, cocoyl sarcosine, ammonium cocoyl sulfate, ammonium lauroyl sulfate, sodium cocoyl sulfate, sodium lauroyl sulfate, potassium cocoyl sulfate, potassium lauryl sulfate, triethanolamine lauryl sulfate, triethanolamine lauryl sulfate, monoethanolamine cocoyl sulfate, monoethanolamine lauryl sulfate, sodium tridecyl benzene sulfonate, sodium dodecyl benzene sulfonate, sodium and ammonium salts of coconut alkyl triethylene glycol ether sulfate; tallow alkyl triethylene glycol ether sulfate, tallow alkyl hexaoxyethylene sulfate, disodium N-octadecylsulfosuccinate, disodium lauryl sulfosuccinate, diammonium lauryl sulfosuccinate, tetrasodium N-(1,2-dicarboxyethyl)-N-octadecylsulfosuccinate, diamyl ester of sodium sulfosuccinic acid, dihexyl ester of sodium sulfosuccinic acid, dioctyl esters of sodium sulfosuccinic acid, docusate sodium, and combinations thereof.
[0025] Examples of nonionic surfactants include, but are not limited to, polyoxyethylene fatty acid esters, sorbitan esters, cetyl octanoate, cocamide DEA, cocamide MEA, cocamido propyl dimethyl amine oxide, coconut fatty acid diethanol amide, coconut fatty acid monoethanol amide, diglyceryl diisostearate, diglyceryl monoisostearate, diglyceryl monolaurate, diglyceryl monooleate, ethylene glycol distearate, ethylene glycol monostearate, ethoxylated castor oil, glyceryl monoisostearate, glyceryl monolaurate, glyceryl monomyristate, glyceryl monooleate, glyceryl monostearate, glyceryl tricaprylate/caprate, glyceryl triisostearate, glyceryl trioleate, glycol distearate, glycol monostearate, isooctyl stearate, lauramide DEA, lauric acid diethanol amide, lauric acid monoethanol amide, lauric/myristic acid diethanol amide, lauryl dimethyl amine oxide, lauryl/myristyl amide DEA, lauryl/myristyl dimethyl amine oxide, methyl gluceth, methyl glucose sesquistearate, oleamide DEA, PEG-distearate, polyoxyethylene butyl ether, polyoxyethylene cetyl ether, polyoxyethylene lauryl amine, polyoxyethylene lauryl ester, polyoxyethylene lauryl ether, polyoxyethylene nonylphenyl ether, polyoxyethylene octyl ether, polyoxyethylene octylphenyl ether, polyoxyethylene oleyl amine, polyoxyethylene oleyl cetyl ether, polyoxyethylene oleyl ester, polyoxyethylene oleyl ether, polyoxyethylene stearyl amine, polyoxyethylene stearyl ester, polyoxyethylene stearyl ether, polyoxyethylene tallow amine, polyoxyethylene tridecyl ether, propylene glycol monostearate, sorbitan monolaurate, sorbitan monooleate, sorbitan monopalmitate, sorbitan monostearate, sorbitan sesquioleate, sorbitan trioleate, stearamide DEA, stearic acid diethanol amide, stearic acid monoethanol amide, laureth-4, and combinations thereof.
[0026] Examples of amphoteric surfactants include, but are not limited to, sodium N-dodecyl-ÿ-alanine, sodium N-lauryl-ÿ-iminodipropionate, myristoamphoacetate, lauryl betaine, lauryl sulfobetaine, sodium 3-dodecyl-aminopropionate, sodium 3-dodecylaminopropane sulfonate, sodium lauroamphoacetate, cocodimethyl carboxymethyl betaine, cocoamidopropyl betaine, cocobetaine, lauryl amidopropyl betaine, oleyl betaine, lauryl dimethyl carboxymethyl betaine, lauryl dimethyl alphacarboxyethyl betaine, cetyl dimethyl carboxymethyl betaine, lauryl bis-(2-hydroxyethyl)carboxymethyl betaine, stearyl bis-(2-hydroxypropyl)carboxymethyl betaine, oleyl dimethyl gamma-carboxypropyl betaine, lauryl bis-(2-hydroxypropyl)alpha-carboxyethyl betaine, oleamidopropyl betaine, coco dimethyl sulfopropyl betaine, stearyl dimethyl sulfopropyl betaine, lauryl dimethyl sulfoethyl betaine, lauryl bis-(2-hydroxyethyl)sulfopropyl betaine, and combinations thereof.
[0027] Examples of cationic surfactants include, but are not limited to, behenyl trimethyl ammonium chloride, bis(acyloxyethyl)hydroxyethyl methyl ammonium methosulfate, cetrimonium bromide, cetrimonium chloride, cetyl trimethyl ammonium chloride, cocamido propylamine oxide, distearyl dimethyl ammonium chloride, ditallowedimonium chloride, guar hydroxypropyltrimonium chloride, lauralkonium chloride, lauryl dimethylamine oxide, lauryl dimethylbenzyl ammonium chloride, lauryl polyoxyethylene dimethylamine oxide, lauryl trimethyl ammonium chloride, lautrimonium chloride, methyl-1-oleyl amide ethyl-2-oleyl imidazolinium methyl sulfate, picolin benzyl ammonium chloride, polyquatemium, stearalkonium chloride, sterayl dimethylbenzyl ammonium chloride, stearyl trimethyl ammonium chloride, trimethylglycine, and combinations thereof.
[0028] iii. Suspending Agents
[0029] Suitable suspending agents include, but are not limited to, alginic acid, bentonite, carbomer, carboxymethylcellulose and salts thereof, colloidal oatmeal, hydroxyethylcellulose, hydroxypropylcellulose, microcrystalline cellulose, colloidal silicon dioxide, dextrin, gelatin, guar gum, xanthan gum, kaolin, magnesium aluminum silicate, maltitol, triglycerides, methylcellulose, polyoxyethylene fatty acid esters, polyvinylpyrrolidone, propylene glycol alginate, sodium alginate, sorbitan fatty acid esters, tragacanth, and combinations thereof.
[0030] iv. Antioxidants
[0031] Suitable antioxidants include, but are not limited to, butylated hydroxytoluene, alpha tocopherol, ascorbic acid, fumaric acid, malic acid, butylated hydroxyanisole, propyl gallate, sodium ascorbate, sodium metabisulfite, ascorbyl palmitate, ascorbyl acetate, ascorbyl phosphate, Vitamin A, folic acid, flavons or flavonoids, histidine, glycine, tyrosine, tryptophan, carotenoids, carotenes, alpha-Carotene, beta-Carotene, uric acid, pharmaceutically acceptable salts thereof, derivatives thereof, and combinations thereof.
[0032] v. Chelating Agents
[0033] Suitable chelating agents include, but are not limited to, EDTA, disodium edetate, trans-1,2-diaminocyclohexane-N,N,N′,N′-tetraaceticacid monohydrate, N,N-bis(2-hydroxyethyl)glycine, 1,3-diamino-2-hydroxypropane-N,N,N′,N′-tetraacetic acid, 1,3-diaminopropane-N,N,N′,N′-tetraacetic acid, ethylenediamine-N,N′-diacetic acid, ethylenediamine-N,N′-dipropionic acid, ethylenediamine-N,N′-bis(methylenephosphonic acid), N-(2-hydroxyethyl)ethylenediamine-N,N′,N′-triacetic acid, ethylenediamine-N,N,N′,N′-tetrakis(methylenephosphonic acid), O,O′-bis(2-aminoethyl)ethyleneglycol-N,N,N′,N′-tetraacetic acid, N,N-bis(2-hydroxybenzyl)ethylenediamine-N,N-diacetic acid, 1,6-hexamethylenediamine-N,N,N′,N′-tetraacetic acid, N-(2-hydroxyethyl)iminodiacetic acid, iminodiacetic acid, 1,2-diaminopropane-N,N,N′,N′-tetraacetic acid, nitrilotriacetic acid, nitrilotripropionic acid, nitrilotris(methylenephosphonic acid), 7,19,30-trioxa-1,4,10,13,16,22,27,33-octaazabicyclo[111,11,1]pentatriacontane hexahydrobromide, triethylenetetramine-N,N,N′,N″,N′″,N′″-hexaacetic acid, and combinations thereof.
[0034] vi. Emollients
[0035] Suitable emollients include, but are not limited to, myristyl lactate, isopropyl palmitate, light liquid paraffin, cetearyl alcohol, lanolin, lanolin derivatives, mineral oil, petrolatum, cetyl esters wax, cholesterol, glycerol, glycerol monostearate, isopropyl myristate, lecithin, and combinations thereof.
[0036] vii. Humectants
[0037] Suitable humectants include, but are not limited to, glycerin, butylene glycol, propylene glycol, sorbitol, triacetin, and combinations thereof.
[0038] viii. pH Modifying Agents
[0039] The compositions described herein may further contain sufficient amounts of at least one pH modifier to ensure that the composition has a final pH of about 3 to about 11. Suitable pH modifying agents include, but are not limited to, sodium hydroxide, citric acid, hydrochloric acid, acetic acid, phosphoric acid, succinic acid, sodium hydroxide, potassium hydroxide, ammonium hydroxide, magnesium oxide, calcium carbonate, magnesium carbonate, magnesium aluminum silicates, malic acid, potassium citrate, sodium citrate, sodium phosphate, lactic acid, gluconic acid, tartaric acid, 1,2,3,4-butane tetracarboxylic acid, fumaric acid, diethanolamine, monoethanolamine, sodium carbonate, sodium bicarbonate, triethanolamine, and combinations thereof.
[0040] ix. Preservatives
[0041] Preservatives can be used to prevent the growth of fungi and other microorganisms. Suitable preservatives include, but are not limited to, benzoic acid, butylparaben, ethyl paraben, methyl paraben, propylparaben, sodium benzoate, sodium propionate, benzalkonium chloride, benzethonium chloride, benzyl alcohol, cetylpyridinium chloride, chlorobutanol, phenol, phenylethyl alcohol, thimerosal, and combinations thereof.
[0042] D. Dosage Forms
[0043] The compositions described herein can be formulated for topical or transdermal administration. Suitable dosage forms for topical or transdermal administration include ointments, pastes, creams, lotions, gels, ointments, pastes, powders, solutions, sprays, foams, or transdermal device, such as patches. Methods for making these dosage forms are well known in the art. See, for example, Ansel, Popovich, and Allen, Pharmaceutical Dosage Forms and Drug Delivery Systems 6 th Ed ., Williams and Wilkins, 1995.
[0044] 1. Creams, Pastes, and Ointments
[0045] i. Creams
[0046] Creams are generally characterized as semisolid dosage forms formed from an oil-in-water emulsion, a water-in-oil emulsion, or an aqueous microcrystalline dispersion. Creams are generally less viscous and lighter than ointments. Creams are considered to have greater esthetic appeal than ointments or pastes due to their non-greasy character and their ability to “vanish” into the skin upon rubbing.
[0047] ii. Ointments
[0048] Ointments are prepared by mixing one or more active agents in an ointment base. The ointment base is semisolid and can be either hydrophobic or hydrophilic. Suitable ointment bases include hydrocarbon bases, such as petrolatum, white petrolatum, yellow ointment, and mineral oil; absorption bases, such as hydrophilic petrolatum, anhydrous lanolin, lanolin, and cold cream; water-removable bases, such as hydrophilic ointments; and water-soluble bases, such as polyethylene glycol ointments. Selection of the ointment base is dependent on a number of factors, such as the desired release rate of the active agent(s) from the ointment base; the desirability for enhancement by the base of the percutaneous absorption of the active agent(s); the advisability of occlusion of moisture from the skin by the base; the short-term and long-term stability of the active agent(s) in the base; and the influence, if any, of the active agent(s) on the consistency or other features of the ointment base.
[0049] In one embodiment, the composition is in the form of an ointment wherein the active agents are incorporated into a pharmaceutically acceptable ointment base containing between 1 and up to 30% by weight, more preferably between 1 and 20%, most preferably between about 5 and 10% by weight particles.
[0050] Suitable bases include, but are not limited to, petrolatum, mineral oil, vegetable oils, and combinations thereof. In a preferred embodiment, the particles are titanium dioxide and the base is petrolatum.
[0051] Suitable particles include zinc oxide, such as an ultrafine grade of micronized zinc oxide, magnesium oxide, talc, and combinations thereof. In a preferred embodiment, the particles are titanium dioxide. The titanium dioxide used to prepare the formulations generally has a diameter less than about 100 microns, preferably between 10 nm and 100 microns. In one embodiment, the diameter of the titanium dioxide particles is 44 microns. In another embodiment, the diameter of the titanium dioxide particles is 0.3 microns. In still another embodiment, the diameter of the titanium dioxide particles is 15 nm (0.015 microns).
[0052] iii. Pastes
[0053] Pastes contain more solid materials than ointments and are therefore stiffer and less penetrating. Pastes are usually employed for their protective action and for their ability to absorb substantial discharges from skin lesions or pustules due to their ability to stay in place after application with little tendency to soften and flow. Because of their large percentage of solids, pastes are generally more absorptive and less greasy than ointments prepared from the same components.
[0054] 2. Lotions
[0055] While creams, pastes, and ointments are classified as semisolid preparations, lotions are characterized as liquids. Lotions are generally suspensions of solid materials (such as active agents) in an aqueous vehicle, although certain emulsions and even some true solutions have been designated as lotions due to their appearance or application. Lotions may be preferred over semisolid formulations due to their non-greasy character and their increased spreadability over large areas of skin. Lotions typically contain finely powdered substances that are insoluble in the dispersion medium and are suspended through the use of suspending agents and dispersing agents. Other lotions can have as the dispersed phase liquid substances that are immiscible with the vehicle and are usually dispersed by means of emulsifying agents or other suitable stabilizers,
[0056] 3. Powders
[0057] Medicinal powders are mixtures of one or more active agents with a solid inert base, such as talcum powder. Depending upon the particle size of the resulting blend, the powder will have varying dusting and covering capabilities. The particle size should be small enough to ensure against grittiness and consequent skin irritation.
[0058] 4. Foams
[0059] Pharmaceutical foams are pressurized dosage forms containing one or more active ingredients that, upon valve actuation, emit a fine dispersion of liquid and/or solid materials in a gaseous medium. Foam formulations are generally easier to apply, are less dense, and spread more easily than other topical dosage forms. Foams may be formulated in various ways to provide emollient or drying functions to the skin, depending on the formulation constituents.
[0060] Foams may contain an emulsion. An emulsion is a preparation of one liquid distributed in small globules throughout the body of a second liquid. The dispersed liquid is the discontinuous phase, and the dispersion medium is the continuous phase. When oil is the dispersed liquid and an aqueous solution is the continuous phase, it is known as an oil-in-water emulsion, whereas when water or aqueous solution is the dispersed phase and oil or oleaginous substance is the continuous phase, it is known as a water-in-oil emulsion. The oil phase may consist at least in part of an HFA propellant. Either or both of the oil phase and the aqueous phase may contain one or more surfactants, emulsifiers, emulsion stabilizers, buffers, and other excipients. Preferred excipients include surfactants, especially non-ionic surfactants; emulsifying agents, especially emulsifying waxes; and liquid non-volatile non-aqueous materials, particularly glycols such as propylene glycol. The oil phase may contain other oily pharmaceutically approved excipients. For example, materials such as hydroxylated castor oil or sesame oil may be used in the oil phase as surfactants or emulsifiers.
[0061] The oil phase can be prepared by mixing together the surfactant(s) and emulsifier(s) and melting. The aqueous phase is prepared separately by dissolving the preservatives in water with heating. The aqueous phase is added to the oil phase with continuous high shear mixing to produce a milky emulsion. The emulsion is cooled and the pH is adjusted by the addition of a buffer. The active agent can be either pre-dissolved in aqueous or organic phase or suspended/dispersed in the final emulsion.
[0062] Foams generally contain a pharmaceutically acceptable propellant. Suitable propellants include, but are not limited to, hydrofluoroalkanes, hydrofluorocarbons, volatile alcohols, hydrocarbon gases, and combinations thereof. Suitable propellants include HFAs such as 1,1,1,2-tetrafluoroethane (HFA 134a) and 1,1,1,2,3,3,3-heptafluoropropane (HFA 227), but mixtures and admixtures of these and other HFAs that are currently approved or may become approved for medical use are suitable.
[0063] The emulsion concentrate is placed in pressure cans, preferably coated aluminum cans to prevent corrosion, such as epoxy-coated cans. The lid and dispensing apparatus are crimped in place. The can is charged with propellant to the stated level, for example, by adding 30 grams of propellant per 70 grams of emulsion. At the time of application, the mixture of the emulsion with the propellant may be insured by shaking, optionally with the aid of a mixing bead. The dispenser may be metered or unmetered (continuous). Metered dispensing is preferred for highly active materials such as hydrocortisone and other steroids. The can may be arranged for either “upside down” spraying with the valve at the bottom, or the can have a dip tube so that the foam can be sprayed while the can is upright with the valve at the top.
III. Methods of Use
[0064] The topical formulations herein can be used to treat perioral dermatitis or known or unknown etiology. The amount of the composition to be administered and the frequency of administration can readily be determined by the treating physician based on a variety of factors, such as the condition to be treated, the severity of the condition, and the age and weight of the patient to be treated. Perioral dermatitis occurs primarily in adult women, typically between the ages of 20 and 50. It is unusual for the disorder to appear in men or teenage girls (unlike acne). While sever case may respond to systemic or topical antibiotics, the addition of a topical corticosteroid, such as desonide, to a topical antibiotic greatly shortens the time necessary to achieve control and increases the efficacy of the treatment. The use of a corticosteroid is counter intuitive since one of the common effects of steroids is the development of acne and acneform eruptions (known as steroid acne).
[0065] Compositions of varying strength can be administered depending on the degree of inflammation. For example, a composition containing 1% clindamycin and 0.05% desonide would be administered initially. Once control of the outbreak has begun, a composition containing 1% clindamycin and 0.025% desonide would be administered. Finally, a composition containing 1% clindamycin and 0.01% desonide would be administered as a maintenance dosage.
[0066] Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of skill in the art to which the disclosed invention belongs. Publications cited herein and the materials for which they are cited are specifically incorporated by reference.
[0067] Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims. | Methods for treating perioral dermatitis are described herein. The method includes administering topically a composition containing an effective amount of a systemic or topical antibiotic and a corticosteroid. The concentration of the antibiotic is from about 0.01% to about 5% by weight of the composition and the concentration of the corticosteroid is from about 0.01% to about 5% by weight of the composition. The composition can contain one or more pharmaceutically acceptable excipients and/or carriers. The compositions can be formulated as a lotion, cream, gel, ointment, paste, powder, solution, suspension, spray, foam, or patch. | 0 |
RELATED APPLICATIONS
This application claims the benefit of pending Provisional Application Ser. No. 60/098,608, filed Aug. 31, 1998.
TECHNICAL FIELD
The present invention generally relates to methods and apparatus for forming programmable interconnections in electrical circuits. More particularly, the present invention relates to an interconnection system using metal-doped chalcogenide elements as part of the interconnection.
BACKGROUND
A single integrated circuit (IC) chip may contain more than 10 million transistors (i.e., components). These components are then connected using interconnection pathways to form various IC devices. Additional interconnection pathways may be used to connect numerous IC chips to form various electrical circuits and devices.
In conventional interconnection systems, the interconnection pathways are generally patterned along with an IC device. Typically, the pathways are formed of conductive material, such as copper, which are situated and embedded within a supporting dielectric base to interconnect the elements of the IC device. One shortcoming of such conventional interconnection systems, however, is that the interconnections cannot be easily altered once fabrication of the IC device has been completed.
Therefore, the ability to form interconnections in IC devices even after fabrication of the IC devices has been completed is highly desirable as it would allow for an unprecedented level of flexibility in testing, debugging, field configuration, and system reconfiguration of IC devices.
SUMMARY OF THE INVENTION
The present invention relates to methods and apparatus for forming programmable interconnections for electrical circuits. In accordance with an exemplary embodiment of the present invention, programmable interconnections are formed in an electrical circuit by patterning metal-doped chalcogenide pathways in dielectric-separated layers. To connect any two points within the circuit, a voltage is applied to either end of the selected pathway to stimulate the growth of a metal feature (e.g., a metal dendrite) between the two points until a connection is completed.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The present invention will hereinafter be described in conjunction with the appended drawing figures, wherein like numerals denote like elements, and:
FIG. 1 is a sectional schematic of a multi-level interconnection system in accordance with a preferred embodiment of the present invention;
FIG. 2 is a schematic of multiple programmable interconnection pathways in an electrical circuit in accordance with another embodiment of the present invention; and
FIG. 3 is a schematic of multiple programmable interconnection pathways in an electrical circuit in accordance with yet another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
In order to provide a more thorough understanding of the present invention, the following description sets forth numerous specific details, such as specific material, parameters, etc. However, these specific details need not be employed to practice the present invention.
With reference to FIG. 1, a multi-level programmable interconnection system 10 in accordance with a preferred embodiment of the present invention is shown. In accordance with one aspect of the present invention, interconnection system 10 includes a plurality of metal-doped chalcogenide pathways 12 , dielectric separation layers 14 , and vias 16 .
In accordance with one aspect of the present invention, metal-doped chalcogenide materials are characterized by relatively high resistivity in thin film form (resistivity greater than approximately 10,000 Ohm cm), but are able to produce metal features with high conductivity when an appropriate bias is applied. A suitable metal-doped chalcogenide material may include any compound containing sulfur, selenium and/or tellurium, whether ternary, quaternary or higher compounds. In a preferred embodiment of the present invention, the chalcogenide material is selected from the croup consisting of arsenic, germanium, selenium, tellurium, bismuth, nickel, sulfur, polonium and zinc (preferably, arsenic sulfide, germanium sulfide, or germanium selenide) and the metal comprises various Group I or Group II metals (preferably, silver, copper, zinc or a combination thereof). The metal-doped chalcogenide material may be obtained by photo dissolution, by depositing from a source comprising the metal and chalcogenide, or by other means known in the art. For a more detailed discussion of metal-doped chalcogenide materials, see U.S. Pat. No. 5,761,115, issued on Jun. 2, 1998 to Kozicki et al, the entire disclosure of which is incorporated herein by reference.
Metal-doped chalcogenide pathways 12 may be patterned using any convenient method. For example, for large geometries, pathways 12 can be patterned using known wet-etching techniques. For small geometries, pathways 12 can be patterned using known dry-etching techniques, such as reactive-ion etching.
An appropriate voltage is applied to either end of a selected pathway to stimulate the growth of a metal feature, such as a metal dendrite, to connect any two points along the pathway. For example, when an arsenic trisulfide/silver chalcogenide material is used, a silver dendrite, several hundred microns long, may be grown in a few seconds along the surface of the metal-doped chalcogenide material, thereby connecting two widely-spaced circuit elements with a silver “wire”. Alternatively, a copper doped chalcogenide material can be use to establish copper connections.
The interconnection pathways may have bends, vias, and branches (multiple in and multiple out), but the metal dendrite will only grow between the points which have the voltage applied, thereby forming a controllable and directed electrical connection. Additionally, in multi-level systems, as particularly depicted in FIG. 1, the metal dendnite may be formed on any surface (top, bottom or sides) on the metal-doped chalcogenide and may even penetrate through one chalcogenide pathway to allow connections to form from one level to another.
With reference to FIG. 2, in accordance with another embodiment of the present invention, interconnection system 20 includes five arbitrary terminal points 24 , 26 , 28 , 30 and 32 formed within one layer of interconnect. Pathways 22 connecting terminal points 24 , 26 , 28 , 30 and 32 are formed by patterning the metal-doped chalcogenide material using any convenient method. While five terminal points are depicted in FIG. 2, any number of terminal points may be formed without deviating from the spirit and scope of the present invention.
Each terminal point, or any combination of terminal points, is then connected to a power supply by means of an external probe, an on-chip transistor, or other suitable switching device such that a voltage can be applied between any pair or combination of points. For example, if point 26 is connected to a positive rail and point 28 is connected to ground, a metal dendrite will grow from point 26 to point 28 on the surface of the chalcogenide material along pathway 22 , between the two points, until the connection is complete.
With reference to FIG. 3, in accordance with yet another embodiment of the present invention, interconnection system 300 includes 18 terminal points 302 , 304 , 306 , 308 , 310 , 312 , 314 , 316 , 318 , 320 , 322 , 324 , 326 , 328 , 330 , 332 , 334 and 336 formed in a dimensionial lattice structure. Alternatively, system 300 may include any number of terminal points formed in any suitable 3-dimensional configuration including amorphous configurations.
Each terminal point, or any combination of terminal points, is connected to a suitable switching device such that a voltage can be applied between any pair or combination of points. For example, if point 306 is connected to a negative rail and point 320 and 324 are connected to ground, a metal dendrite will grow from point 306 to points 320 and 324 , thus simultaneously creating two legs 306 - 320 and 306 - 324 .
In this manner, various interconnections can be established even after fabrication of the circuit. Accordingly, the present programmable interconnection system can be used to increase flexibility in testing, debugging, field programming, and system reconfiguration of electrical circuits.
In accordance with another aspect of the present invention, sacrificial electrodes, consisting of the same metal as used to dope the chalcogenide material, are preferably used to facilitate the growth of stable metal dendrites. These sacrificial electrodes suitably dissolve into the chalcogenide material during growth of the metal dendrites and maintain the metal ion concentration along the length of chalcogenide pathway 22 by a caterpillar mechanism, whereby metal from ions the sacrificial electrodes move in a ripple effect to fill deficiecies created as metal ions leave the chalcogenide material to form the metal dendrite. Additionally, these sacrificial electrodes can be placed at the terminations of the pathways or at isolated points along the pathways to act as stores of metal.
The voltage required to promote the growth the metal dendrites (i.e., the programming voltage) is dependent largely on the initial resistance of the pathway. Thus, the longer the desired connection, the higher the voltage required to form the connection. Additionally, the resistance of the unprogrammed pathways preferably is such that the application of normal operating voltages of the circuit do not stimulate the growth of a connection. In a most preferred embodiment, voltages greater than 10 volts are applied to grow the metal dendrites. Additionally, operating voltages are maintained below 5 volts to prevent unintentional growth of metal dendrites.
While preferred embodiments of the present invention have been shown in the drawings and described above, it will be apparent to one skilled in the art that various embodiments of the present invention are possible. Therefore, the present invention should not be construed as limited to the specific form shown and described above. | A programmable interconnection system and methods of forming interconnections in the system are disclosed. The system generally includes a metal doped chalcogenide pathway. A metal feature is created within the system by applying a voltage bias across the chalcogenide pathway. | 7 |
BACKGROUND OF THE INVENTION
The invention relates to a calender for treating a product web, in particular a paper web, for example a smoothing calender.
A calender of this type is disclosed, for example, by DE-U-295 04 034. In this calender, an intermediate roll in the roll stack is usually driven and drives the other rolls along by means of friction with the product web. In the document cited, it is specified that the normally passively driven rolls are driven actively in order to thread the product web into the nips. This auxiliary drive needs to be designed only for the idling power until the operating speed is reached, whereas the main drive has to be designed for total power output during operation.
Forces that are fed in from the outside act on the rolls in the vertical direction, as does the weight, increasing from top to bottom, of the rolls mounted above. Deformations that are caused by this--in particular deflection--can be compensated for by means of the deflection controlled rolls. However, forces act on the rolls in the horizontal direction as well. These forces can be attributed to the friction-induced torque transmission mentioned, as is explained in the publication Pav/Svenka, "Der Kompaktkalander--die Antwort auf die Herausforderung nach hohen Geschwindigkeiten bei der Glattung und Satinage" [The compact calender--the answer to the challenge of higher speeds in smoothing and calendering], DAS PAPIER 1985, pp. V178 ff. In this publication, mention is also made of a compact calender, in which four resilient rolls with their own drives form nips around a hard base roll that is mounted in a stationary manner. This is intended to dispense with the interlinking of the roll set, as is unavoidable in the case of calenders of this type.
Whereas vertical deformations of the rolls, as explained above, can be compensated for, this does not apply to deformations resulting from horizontally acting forces. This means that the rolls must have minimum diameters in order that horizontal deformations can be kept within tolerable limits. One of these limitations resides in the fact that, in the event of a deformation of a roll in the horizontal direction, the distribution of the line load becomes non-uniform, the regions close to the bearings being loaded more severely. This can lead to over-pressing of the product web in the edge region and to the unequal distribution of the product-web property values in the cross-machine profile. Furthermore, increased wear of the resilient roll covers and, in the extreme case, destruction of the same can occur. At a given line load, the compressive stress is limited by the minimum diameters of the rolls to an appropriate value, which may be increased only by increasing the line load. However, even if the horizontal deformation of the rolls is kept within limits, shear stresses nevertheless act on the product web in the nip and--in the case of paper--can loosen the bonding between the fibres in the web running direction and thereby reduce the strength of the paper.
The object of the invention is to specify a calender in which the compressive stress can be increased at a given line load by the roll diameters being reduced.
Since the roll diameters no longer need to be designed in accordance with the horizontally acting forces, because the effects of the latter are controlled out, it is possible to design the rolls with diameters which are determined by criteria other than the resistance to deflection or the horizontal deformations, for example by the critical inherent frequencies.
Rolls of a smaller diameter have a lower weight, so that the static (gravitation-induced) forces are lower in relative terms and smaller bearings can also be used.
The drives apply the specific power for the respectively driven roll, this power being composed of re-forming, transporting and loss power. In this case, a distribution of 50:50 to the two nip-forming rolls would be only a rough guide, since, for example, a deflection controlled roll has considerably higher friction losses than a normal solid roll.
The forces which are to be controlled out according to the invention can be measured, for example, in the roll bearings; bearings with force-measuring systems incorporated are commercially available. However, it is at least also conceivable to use measurement methods to register the horizontal deformations that are brought about by such forces.
An exemplary embodiment of a calender according to the invention is illustrated in the appended drawings and will be explained below in detail.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a largely schematic side view of a calender according to the invention,
FIG. 2 shows a second embodiment in a similar illustration,
FIG. 3 shows a modification of the second embodiment, and
FIG. 4 is a block diagram of the control of one of the rolls.
DETAILED DESCRIPTION OF THE INVENTION
A calender frame 10 with side uprights is designed as a welded or cast construction. Arranged in the frame 10 is a calender 12, which has eight nip-forming rolls. The top and the bottom rolls 14 and 16, respectively, are deflection controlled rolls, and the yoke of the upper deflection controlled roll is clamped immovably in the frame; the bearings of this roll are also immovable. The roll 14 is provided with a resilient cover, as are the lower deflection controlled roll 16 and the rolls 18, 20 and 22, which are provided in the calender 12. Arranged between the rolls 14 and 18 is a hard, heatable roll 24, which forms a nip in each case with the rolls 14 and 18 respectively arranged above and below it. In addition, between the rolls 18 and 20 there is a hard, heatable roll 26, which defines a nip with each of these rolls. The nip through which the product web 28 passes between the rolls 20 and 22 is used not only for re-forming the product web but also as a reversing nip, in order to turn that side of the product web that previously faced the resilient rolls towards the hard, heatable roll 30, which is arranged between the rolls 22 and 16. (The relevant side of the product web has already passed through four nips albeit facing a resilient roll in each case, but has nevertheless been smoothed to such an extent in the process that passage through two further nips on the heated side is sufficient).
The bearings of all the rolls, with the exception of the upper deflection controlled roll 14, are arranged in the frame 10 such that they can be displaced by sliding. The loading of the nips is carried out by means of hydraulic cylinders 32 and results, for example, in an average line force of 500 N/mm. It should be noted that the line force can also be applied by means of the deflection controlled rolls. The hard rolls may be heated with steam to, for example, up to 200° C. The resilient rolls may be temperature-controlled. The product web 28 is led between the individual nips around guide rolls 34, whose surfaces are provided with spiral grooves in order to ensure that the product web is kept spread out and to prevent the formation of an air cushion on which the product web could float. Pneumatic compensation of the overhanging loads is carried out by means of compensation units 46, in whose stead hydraulic or other servo drives may also be provided.
Normal spreader rolls may also be provided. The calender arrangement shown can be arranged downstream of a paper or coating machine as an "in-line calender", or can operate as an "off-line calender".
The arrangement described thus far largely corresponds to the prior art, apart from the fact that the diameter of the rolls between the deflection controlled rolls, but at least of the hard rolls, is considerably smaller than usual.
According to the first variant of the invention, each nip-forming roll is provided with its own drive, comprising an electric motor, for example a DC motor, which is coupled via a cardan-shaft to the roll assigned to it and which is fed from a regulated supply unit. In FIG. 1, the drives are indicated only by the usual two-quadrant circle symbol.
FIG. 4 shows the drive to one of the rolls. The drive motor is a DC motor 50, fed from a converter 52 via a controller 54, preferably a digital PID controller.
In the start-up phase, the rotational speed is controlled; for this, each motor 50 has an actual-value transmitter in the form, for example, of a tachogenerator 56; the set points can be stored in an electronic memory 58, which is read out sequentially. In the start-up phase, the set points are selected such that the rolls which in each case define a nip have the same circumferential speed.
In the operating phase, the circumferential speed is a suitable parameter only to a limited extent, since the resilient rolls certainly deform in the region of the nip, that is to say there is no longer strict proportionality between rotational speed and circumferential speed. This is correspondingly true for the expansion which occurs when a roll is heated.
For this reason, power control is carried out during operation. Each roll is supplied with an amount of power which, at least approximately, covers half the re-forming and transporting power transmitted to the product web in each nip defined by the said roll, plus the loss power. It should be noted that the drive power of the guide rolls 44 in the embodiment illustrated is transmitted by means of the product web in the manner of a flexible gear mechanism; this power therefore also has to be taken into account when calculating the set points--also stored in the memory 56. However, it is preferred, particularly in the case of larger in-line calenders, to provide the guide rolls with their own drives as well.
The power control arrangement has the special feature that, when metering the power to the motors, which each drive pairs of rolls which bound a nip, the power of both motors is adjusted in the event of a set-point deviation and, since all the rolls are linked to one another, this means a control intervention in all the motors. An overall controller 60 is therefore placed hierarchically above the individual motor controller and in the event of a set-point deviation, even just in the case of a single roll, calculates new set points for the power for all the rolls or takes these set points from a look-up table memory.
Arranged in the bearings of the rolls are force sensors, which sense at least the forces that are transmitted in the horizontal direction from the relevant roll to the frame 10. Such "force-measuring bearings" are offered, for example, by SKF Kugellagerfabriken GmbH, Schweinfurt. As mentioned above, the power or, more precisely, the power distribution is controlled in such a way that these horizontal forces are kept as small as possible.
The calender arrangement according to FIG. 1 can be operated in such a way that the number of nips through which the web passes is predefined; furthermore, the operator is able to influence the technological result by selecting the line load and the roll temperatures.
FIG. 2 shows, as a second embodiment, a double calender having in each case only two nips for calendering one of the product web sides in each case. The elements of the calender on the left in the drawing are designated using the reference symbols of analogous elements in FIG. 1; in the case of the right-hand calender, an index stroke "'" is added in each case. It can be seen that each individual calender also has just two deflection controlled rolls 40 and 42 with a resilient cover, and a hard, heated roll 44 arranged between them.
FIG. 3 illustrates an example of the second variant of the invention, derived from the embodiment according to FIG. 2. Here, the hard, heated, intermediate roll 45 does not have its own drive, but rather is driven along by the covers of the deflection controlled rolls 40, 42. Although the latter transmit the drive torques through the product web to the hard roll 46, the drives of the two resilient rolls are controlled in such a way that the forces acting on the hard roll are equal and opposite.
It is assumed that, for example in the case of smoothing calenders, the extremely high compressive a stresses in the nips, in combination with high temperature, mean that good technological results can be achieved with the configurations illustrated in FIGS. 2 and 3. In addition to such a 3/3 configuration, numerous further configurations in which in each case a hard roll is arranged between two resilient rolls, such as the configurations 5/3, 7/3, 5/5, 8/5 and so on, are conceivable. | The calender disclosed comprises a vertical stack of linked rolls, which are driven individually by controlled electric motors. The control acts on the distribution of the supplied power to the individual rolls in such a way that the forces which act on the rolls in the horizontal direction, and are measured in the roll bearings, are minimized. This allows the use of slimmer rolls. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Reference is made to the following co-pending, commonly assigned applications, the disclosures of which are incorporated herein by reference:
[0002] U.S. Provisional Patent Application Serial No. 60/430,922, filed on Dec. 4, 2002, in the names of Molaire, et al., entitled SELF-DISPERSING TITANYL PHTHALOCYANINE PIGMENT COMPOSITIONS AND ELECTROPHOTOGRAPHIC CHARGE GENERATION LAYERS CONTAINING SAME;
[0003] U.S. Provisional Patent Application Serial No. 60/430,923, filed on Dec. 4, 2002, in the names of Molaire, et al., entitled TWO-STAGE MILLING PROCESS FOR PREPARING COCRYSTALS OF TITANYL FLUOROPHTHALOCYANINE AND TITANYL PHTHALOCYANINE, AND ELECTROPHOTOGRAPHIC ELEMENT CONTAINING SAME;
[0004] U.S. Provisional Patent Application Serial No. 60/430,779, filed on Dec. 4, 2002, in the names of Molaire, et al., entitled COCRYSTALS CONTAINING HIGH-CHLORINE TITANYL PHTHALOCYANINE AND LOW CONCENTRATION OF TITANYL FLUOROPHTHALOCYANINE, AND ELECTROPHOTOGRAPHIC ELEMENT CONTAINING SAME;
[0005] U.S. Provisional Patent Application Serial No. 60/430,777, filed on Dec. 4, 2002, in the names of Molaire, et al., entitled PROCESS FOR FORMING COCRYSTALS CONTAINING CHLORINE-FREE TITANYL PHTHALOCYANINES AND LOW CONCENTRATION OF TITANYL FLUOROPHTHALOCYANINE USING ORGANIC MILLING AID.
FIELD OF THE INVENTION
[0006] The present invention relates to electrophotographic elements and related materials. More particularly, the invention relates to a process for forming nanoparticulate pigment compositions including cocrystalline titanium phthalocyanine pigments, and further to the inclusion of these compositions in the charge generation layers of electrophotographic elements.
BACKGROUND OF THE INVENTION
[0007] In electrophotography, an image including a pattern of electrostatic potential, also referred to as an electrostatic latent image, is formed on a surface of an electrophotographic element including at least two layers: a photoconductive layer and an electrically conductive substrate. The electrostatic latent image can be formed by a variety of means, for example, by imagewise radiation-induced discharge of a uniform potential previously formed on the surface. Typically, the electrostatic latent image is then developed into a toner image by contacting the latent image with an electrographic developer. If desired, the latent image can be transferred to another surface before development.
[0008] Among the many different kinds of photoconductive materials that have been employed in electrophotographic elements are phthalocyanine pigments such as titanyl phthalocyanine and titanyl tetrafluorophthalocyanines. Electrophotographic recording elements containing such pigments as charge-generation materials are useful in electrophotographic laser beam printers because of their capability for providing good photosensitivity in the near infrared region of the electromagnetic spectrum, that is, in the range of 700-900 nm.
[0009] Flocculation of organic pigment dispersions has been a recognized problem, especially in the paint and coating industry, for some time. For example, U.S. Pat. No. 3,589,924 in the names of Giambalvo, et al., describes improved non-crystallizing, non-flocculating phthalocyanine pigment compositions formed by mixing 60-95% of a crystallization-or flocculation-susceptible phthalocyanine pigment with about 5-40% of a sulfonated phthalimidomethyl phthalocyanine derivative. The mixture is prepared by the usual methods, e.g., acid pasting or salt grinding, for converting the phthalocyanine materials to pigmentary size. However techniques that are designed primarily to provide suitable pigments for paints and industrial coatings may not yield materials of sufficient purity or the appropriate crystallinity characteristics to meet the stringent requirements of electrophotographic applications, where high purity is very important for ensuring reliable performance. The crystalline form of the final pigment also has a profound influence on the performance of an electrophotographic element containing it.
[0010] In a photoconductive layer produced from a liquid coating composition that includes the titanyl phthalocyanine pigment and a solvent solution of polymeric binder, it is necessary that the titanyl phthalocyanine pigment be in a highly photoconductive form, either crystalline or amorphous, and in a sufficiently stable dispersion to permit its application as a very thin layer having high electrophotographic speed in the near infrared region.
[0011] A variety of methods have been used to produce suitable forms of titanyl phthalocyanine having differing crystallographic characteristics. U.S. Pat. No. 5,166,339 in the names of Duff, et al., presents a table of polymorphs of unsubstituted titanyl phthalocyanine in which materials bearing multiple designations are grouped as four types. Many phthalocyanine pigments are discussed in P. M. Borsenberger and D. S. Weiss, Organic Photoreceptors for Imaging Systems, Marcel Dekker, Inc., New York, pp. 338-391.
[0012] In one type of preparation, commonly referred to as “acid-pasting”, crude titanyl phthalocyanine is dissolved in an acid solution, which is then diluted with a non-solvent to precipitate the titanyl phthalocyanine product. In another type of procedure, the crude titanyl phthalocyanine is milled, generally with particular milling media. Additionally, some preparations include a combination of techniques or modify a previously prepared titanyl phthalocyanine.
[0013] U.S. Pat. No. 5,132,197 in the names of Iuchi, et al., teaches a method in which titanyl phthalocyanine is acid pasted, treated with methanol, and milled with ether, monoterpene hydrocarbon, or liquid paraffin to produce a titanyl phthalocyanine having main peaks of the Bragg angle 2Θ with respect to X-rays of Cu Kα at 9.0°, 14.2°, 23.9°, and 27.1° (all +/−0.2°).
[0014] U.S. Pat. No. 5,206,359 in the names of Mayo, et al., teaches a process in which titanyl phthalocyanine produced by acid pasting is converted to type IV titanyl phthalocyanine from Type X by treatment with halobenzene.
[0015] U.S. Pat. No. 5,059,355 in the names of Ono, et al., teaches a process in which titanyl phthalocyanine is shaken with glass beads, producing an amorphous material having no substantial peaks detectable by X-ray diffraction. The amorphous material is stirred, with heating, in water and ortho-dichlorobenzene; methanol is added after cooling. A crystalline material having a distinct peak at 27.3° is produced.
[0016] U.S. Pat. No. 4,882,427 in the names of Enokida, et al., teaches a material having noncrystalline titanyl phthalocyanine and pseudo-non-crystalline titanyl phthalocyanine. The pseudo-noncrystalline material can be prepared by acid pasting or acid slurrying. The noncrystalline titanyl phthalocyanine can be prepared by acid pasting or acid slurrying followed by dry or wet milling, or by mechanical milling for a long time without chemical treatment.
[0017] U.S. Pat. No. 5,194,354 in the names of Takai, et al., teaches that amorphous titanyl phthalocyanine prepared by dry pulverization or acid pasting can be converted, by stirring in methanol, to a low crystalline titanyl phthalocyanine having strong peaks of the Bragg angle 2Θ with respect to X-rays of Cu Kα at 7.2°, 14.2°, 24.0°, and 27.2° (all +/−0.2°). It is stated that the low crystalline material can be treated with various organic solvents to produce crystalline materials: methyl cellosolve or ethylene glycol for material having strong peaks at 7.4°, 10.9°, and 17.9°; propylene glycol, 1,3-butanediol, or glycerine for material having strong peaks at 7.6°, 9.7°, 12.7°, 16.2°, and 26.4°; and aqueous mannitol solution for material having strong peaks at 8.5° and 10.2° (all peaks +/−0.2°).
[0018] U.S. Pat. Nos. 4,994,566 and 5,008,173 both in the names of Mimura, et al., teach a process in which non-crystalline particles produced by acid pasting or slurrying, followed by mechanical grinding or sublimation, are treated with tetrahydrofuran to produce a titanyl phthalocyanine having infrared absorption peaks at 1332, 1074, 962, and 783 cm −1 .
[0019] U.S. Pat. No. 5,039,586 in the name of Itami, teaches acid pasting, followed by milling in aromatic or haloaromatic solvent, with or without additional water or other solvents such as alcohols or ethers, at 20-100° C. In an example, crude titanyl phthalocyanine is milled with α-chloronaphthalene or ortho-dichlorobenzene as milling medium, followed by washing with acetone and methanol. The titanyl phthalocyanine produced has a first maximum intensity peak of the Bragg angle 2Θ with respect to X-rays of Cu Kα at a wavelength of 1.541 Å at 27.3°+/−0.2°, and a second maximum intensity peak at 6.8°+/−0.2°. This was contrasted with another titanyl phthalocyanine that is similarly milled, but not acid pasted. This material has a maximum peak at 27.3°+/−0.2° and a second maximum intensity peak at 7.5°+/−0.2°.
[0020] U.S. Pat. No. 5,055,368 in the names of Nguyen, et al., teaches a “salt-milling” procedure in which crude titanyl phthalocyanine is milled, first under moderate shearing conditions with milling media including inorganic salt and non-conducting particles. The milling is then continued at higher shear and temperatures up to 50° C., until the pigment undergoes a perceptible color change. Solvent is substantially absent during the milling steps.
[0021] U.S. Pat. No. 4,701,396 in the names of Hung, et al., teaches near infrared sensitive photoconductive elements made from fluorine-substituted titanylphthalocyanine pigments. While phthalocyanines having only fluorine substituents, and those being equal in number on each aromatic ring, are the preferred pigments of the invention described in that patent, various non-uniformly substituted phthalocyanines are taught.
[0022] U.S. Pat. No. 5,112,711 in the names of Nguyen, et al., teaches an electrophotographic element having a physical mixture of titanyl phthalocyanine crystals and titanyl fluorophthalocyanine crystals. The element provides a synergistic increase in photosensitivity in comparison to an expected additive combination of titanyl phthalocyanine and titanyl fluorophthalocyanine. Similar elements having physical mixtures combining titanyl phthalocyanine and chloro- or bromo-substituted titanyl phthalocyanine crystals produce results in which the photosensitivity is close to that of the least sensitive of the two phthalocyanines used.
[0023] U.S. Pat. Nos. 5,238,764 and 5,238,766, both in the names of Molaire, et al., teach that titanyl fluorophthalocyanine products of acid-pasting and salt-milling procedures, unlike unsubstituted titanyl phthalocyanine, suffer a significant reduction in near infrared sensitivity when they are dispersed in a solvent such as methanol or tetrahydrofuran, which has a gamma c hydrogen bonding parameter value greater than 9.0. These patents further teach that this reduction in sensitivity can be prevented by first contacting the titanyl fluorophthalocyanine with a material having a gamma c hydrogen bonding parameter of less than 8.0.
[0024] Molaire, et al., in U.S. Pat. No. 5,629,418, discloses a method for preparing titanyl fluorophthalocyanine that includes the steps of: dissolving titanyl fluorophthalocyanine in acid to form a solution; admixing the solution and water to precipitate out amorphous titanyl fluorophthalocyanine; washing the amorphous titanyl fluorophthalocyanine until substantially all of the acid is removed and contacting it with an organic solvent, which results in the conversion of the amorphous material to high crystallinity titanyl fluorophthalocyanine, the amorphous titanyl fluorophthalocyanine having been maintained in contact with water continuously from its precipitation to its conversion to a crystalline form.
[0025] The particle size distribution and stability of charge generation dispersions are very important for providing uniform charge generation layer in order to control generation of “breakdown spots” and minimize the granularity of prints. In U.S. Pat. Nos. 5,614,342 and 5,766,810 both in the names of Molaire and Kaeding, disclose a method for preparing cocrystals of titanyl fluorophthalocyanine and unsubstituted titanyl phthalocyanine that includes the steps of: admixing crude titanyl phthalocyanine and crude titanyl fluorophthalocyanine to provide an amorphous pigment mixture, as determined by X-ray crystallography using X-radiation characteristic of Cu Kα at a wavelength of 1.541 Å of the Bragg angle 2Θ; contacting the amorphous pigment mixture with an organic solvent having a gamma c hydrogen bonding parameter of less than 8:0; and, prior to contacting, substantially excluding the amorphous pigment mixture from contact with an organic solvent having a gamma c hydrogen bonding parameter greater than 9.0. The amorphization step must be substantially complete so as to break the large primary particles of the starting crude pigments and thereby lower the average particle size of the final cocrystalline mixture. Substantially complete amorphization of the crude pigments is also necessary to prevent degradation of the dark decay characteristics of the final cocrystal; small amounts of crude pigments having inherently high dark decay that are not amorphized would not be affected by the subsequent solvent treatment and therefore would retain their high dark decay characteristics, causing degradation of the dark decay property of the final cocrystalline product.
[0026] Molaire, et al., in U.S. Pat. No. 5,523,189, discloses an electrophotographic element including a charge generation layer that includes a binder in which is dispersed a physical mixture of a high speed titanyl fluorophthalocyanine having a first intensity peak with respect to X-rays characteristic of Cu Kα at a wavelength of 1.541 Å of the Bragg angle 2Θ at 27°±0.2°, and a second intensity peak at 7.3°±0.2°, the second peak having an intensity relative to the first peak of less than 60 percent; and a low speed titanyl fluorophthalocyanine having a first intensity peak with respect to X-rays characteristic of Cu Kα at a wavelength of 1.541 Å of the Bragg angle 2Θ at 6.7°±0.2°, and a second intensity peak at 23°±0.2°, the second peak having an intensity relative to the first peak of less than 50 percent.
[0027] Molaire, et al., in U.S. Pat. No. 5,773,181, discloses a method for preparing a phthalocyanine composition including the steps of: synthesizing a crystalline product including a mixture of five different unsubstituted or fluorosubstituted phthalocyanines, wherein a central M moiety bonded to the four inner nitrogen atoms of the phthalocyanine nuclei represents a pair of hydrogen atoms or a covalent or coordinate bonded moiety, including an atom selected from the group consisting of Li, Na, K, Be, Mg, Ca, Ba, Sc, Y, La, Ac, Ti, Zr, Hf, V, Nb, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, Hg, Al, Ga, In, Tl, Si, Ge, Sn, Pb, As, and Sb, with M preferably representing Ti=O; increasing the amorphous character of the mixture of phthalocyanines as determined by X-ray crystallography using X-radiation characteristic of Cu Kα at a wavelength of 1.541 Å of the Bragg angle 2Θ to provide an amorphous pigment mixture; contacting the amorphous pigment mixture with organic solvent having a gamma c hydrogen bonding parameter of less than 8.0; and prior to the contacting, substantially excluding the amorphous pigment mixture from contact with organic solvent having a gamma c hydrogen bonding parameter greater than 9.0.
[0028] The procedures for the preparation of titanyl phthalocyanine pigments described in the foregoing patents, all of whose disclosures are incorporated herein by reference, suffer from various deficiencies and disadvantages. For example, the use of acid presents a shortcoming for both environmental and safety concerns, particularly in commercial scale procedures. Also, salt milling avoids the use of acid but requires extensive washing of the milled material to remove salts, which can otherwise cause high dark decay in a photoconductor.
[0029] Procedures that first contact the titanyl fluorophthalocyanine with a solvent such as methanol or tetrahydrofuran that has a gamma c hydrogen bonding parameter value greater than 9.0 cause a significant reduction in near infrared sensitivity. The preparation of titanyl fluorophthalocyanine having good photogeneration characteristics is expensive. It would be desirable to be able to produce a crystalline titanyl phthalocyanine composition that has good photogeneration characteristics when used in an electrophotographic element but is less expensive than titanyl fluorophthalocyanine. A suitable procedure would avoid deleterious contact with high gamma c hydrogen bonding parameter solvents and also not require the use of acid or of salt milling media.
[0030] The present inventors believe that the effect of particle size distribution on photo speed relates more to the breadth of the distribution than the absolute size of the pigment particles. At the same time, the lower the particle size, the less the propensity for breakdown. Thus, there is a need for dispersions with smaller and more uniform particle size distribution.
SUMMARY OF THE INVENTION
[0031] The present invention is directed to a process for forming a nanoparticulate crystalline titanium phthalocyanine pigment composition that includes contacting a titanium phthalocyanine pigment with substantially pure 1,1,2-trichloroethane (TCE) under conditions effective to convert the titanium phthalocyanine pigment to the nanoparticulate crystalline composition.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Unsubstituted titanyl phthalocyanine, abbreviated herein as “TiOPc”, has the following structural formula:
[0033] Titanyl fluorophthalocyanines, abbreviated herein as “TiFOPc”, have the following structural formula:
[0034] wherein each of k, l, m, and n is independently an integer from 1 to 4.
[0035] In the process of the present invention, the titanium phthalocyanine pigment can be contacted with the substantially pure TCE in its vapor or liquid form. Preferably, the pigment is wet milled in TCE using a milling aid such as steel shot. Wet milling is carried out preferably for about 10 minutes to about 96 hours, more preferably, about 30 minutes to about 6 hours.
[0036] Also, in accordance with the present invention, the titanium phthalocyanine pigment can be contacted with the substantially pure TCE using ultrasonication for a time period preferably of about 15 minutes to about 2 hours, more preferably, about 10 minutes to about 1 hour.
[0037] The titanium phthalocyanine pigment employed in the process of the invention preferably includes a cocrystalline mixture of unsubstituted titanyl phthalocyanine (TiOPc) and titanyl fluorophthalocyanine (TiOFPc), wherein the weight ratio of TiOPc:TiOFPc is preferably about 99.5:0.5 to about 70:30, more preferably, about 95:5 to about 75:25.
[0038] Alternatively, the titanium phthalocyanine pigment employed in the process of the invention can include crystalline titanium fluorophthalocyanine (TiOFPc), which can be a mixture including titanyl 2, 9, 16, 23-tetrafluoropthaiocyanine, titanyl 2, 9, 16-trifluorophthalocyanine, titanyl 2-fluorophthalocyanine, titanyl 2, 9-difluorophthalocyanine, and titanyl 2, 16-difluorophthalocyanine.
[0039] The present inventors have discovered that the use of 1,1,2-trichloroethane (TCE) as the sole solvent affords very uniform, substantially monodisperse, nanoparticulate dispersions of cocrystalline titanyl fluorophthalocyanine and unsubstituted titanyl fluorophthalocyanine. Additionally, they have found that dispersions formed using TCE as the sole solvent exhibit unusual stability toward settling. As a further advantage, the nanoparticle dispersions of the present invention can be obtained without the use of a polymeric binder.
[0040] The following examples serve to illustrate the invention:
COMPARATIVE EXAMPLE 1
[0041] A dispersion of a cocrystalline composition of unsubstituted titanyl phthalocyanine (TiOPc) and titanyl fluorophthalocyanine (TiOFPc), using a 1.5 gallon attritor, 3300 ml of 3 mm stainless steel media, 5.9 g of the copolyester ionomer poly{2,2-dimethyl-1,3-propylene-oxydiethylene (80/20) isophthalate-co-5-sodiosulfoiisophthalate (95/5)}, (prepared as described in U.S. Pat. No. 5,523,189), 23.68 g of a cocrystalline mixture of 90/10 TiOPc-TiOFPc prepared from a mixture of the amorphous pigments according to the method described in the previously discussed U.S. Pat. No. 5,614,342, and a solvent mixture of 222.24 g of DCM and 148.16 g of TCE. The concentrated dispersion was mixed with a preformed solution consisting of 17.8 g of binder, 591.6 g of DCM, and 200.62 g of TCE. The resulting dispersion was diluted to 3% solids, and the particle size distribution was determined using a UPA Ultraparticle Analyzer.
EXAMPLE 1
[0042] A TiOPc-TiOFPc dispersion was prepared using the same procedure and materials as described in Comparative Example 1, except that the solvent consisted solely of TCE. The particle size distribution was determined and compared with that of the dispersion of Comparative Example 1. The results are shown in TABLE 1 following:
TABLE 1 Particle Size (microns) Example 10% 50% 90% Comparative Example 1 0.226 0.433 0.736 90/10 TiOPc-TiOFPc in 60:40 DCM:TCE Example 1 0.036 0.086 0.182 90/10 TiOPc-TiOFPc in TCE
[0043] The results given in TABLE 1 illustrate the desirable reduction in particle size at both 10% and 50% when pure TCE is used in place of a mixture of DCM and TCE in the preparation of the TiOPc-TiOFPc dispersion.
COMPARATIVE EXAMPLE 2
[0044] A mixture of 0.2 g of 90/10 cocrystalline TiOPc-TiOFPc and 5 g each of DCM and TCE was mixed in a vial without any polymeric binder and ultrasonicated for 3 hours, following which the particle size distribution of the resulting dispersion was measured.
EXAMPLE 2
[0045] The procedure of Comparative Example 2 was repeated, except that 10 grams of TCE was used in place of the DCM-TCE mixture. Following ultrasonication, the particle size distribution of the resulting dispersion was determined.
EXAMPLE 3
[0046] The procedure employed in Example 2 was repeated, using acid pasted crystalline titanyl fluorophthalocyanine as the pigment in place of 90/10TiOPc-TiOFPc. The particle size distribution of the resulting dispersion was measured and compared with those of the dispersions described in Comparative Example 2 and Example 2; the results are summarized in TABLE 2 following:
TABLE 2 Particle Size (microns) Example 10% 50% 90% Comparative Example 2 0.1071 0.2369 0.401 90/10 TiOPc-TiOFPc in 50:50 DCM:TCE Example 2 0.022 0.0384 0.106 90/10 TiOPc-TiOFPc in TCE Example 3 0.0258 0.049 0.129 TiOFPc (ZP4) In TCE
[0047] The results presented in TABLE 2 demonstrate that nanoparticulate dispersions can be obtained from pigments dispersed in TCE alone, in the absence of a binder polymer.
COMPARATIVE EXAMPLE 3
[0048] A dispersion was made in the same manner as described in Comparative Example 1, except that the polymeric binder was the copolyester ionomer poly{4,4-xylylene-co-2,2′-oxydiethylene (46/54) isophthalate-co-5-sodiosulfoisophthalate (85/15)} (prepared as described in U.S. Pat. No. 5,523,189). The particle size distribution of the dispersion following dilution was determined as described in Comparative Example 1.
EXAMPLE 4
[0049] The same procedure was used as that described in Comparative Example 3, except that the solvent consisted solely of TCE. The particle size distribution was determined and compared with that of the dispersion of Comparative Example 3. The results are shown in TABLE 3 following:
TABLE 3 Particle Size (microns) Example 10% 50% 90% Comparative Example 3 0.386 0.55 0.826 90/10 TiOPc-TiOFPc in 60:40 DCM:TCE Example 4 0.0385 0.0807 0.1449 90/10 TiOPc-TiOFPc in TCE
[0050] The results presented in TABLE 3 are similar to those of TABLE 1 but illustrate the desirable reduction in particle size extending to 90%.
EXAMPLE 5
[0051] A 75/25 TiOPc-TiOFPc cocrystalline pigment, prepared as described in U.S. Pat. No. 5,614,342, was used to prepare a series of dispersions in the following solvents: ethanol, methyl ethyl ketone (MEK), toluene, tetrahydrofuran (THF), dichloromethane (DCM), and 1,1,2 trichloroethane (TCE). The dispersions were ultrasonicated for 15 minutes just prior to transfer of a sample of each to a 10-ml graduated cylinder. The meniscus of the dispersion was adjusted to the 10 ml mark, and the cylinders were sealed with a cork stopper. The dispersions were periodically inspected for settling, the results being summarized in TABLE 4 following:
TABLE 4 Percent of Settled Volume After After After Solvent 5 Hours 74 Hours 98 Hours Ethanol 2 24 27 MEK 1 22 26 Toluene 0 18 22 THF 7 30 31 DCM 0 5 7 TCE 0 0 0
[0052] The results summarized in TABLE 4 demonstrate the very large improvement in settling tendency, even on prolonged standing, provided by dispersions prepared in TCE in accordance with the present invention.
EXAMPLE 6
[0053] Dispersions of cocrystalline compositions of unsubstituted titanyl phthalocyanine (TiOPc) and titanyl fluorophthalocyanine (TiOFPc) were prepared, using a 1.5 gallon attritor, 3300 ml of 3 mm stainless steel media, 5.9 g of the copolyester ionomer poly{2,2-dimethyl-1,3-propylene-oxydiethylene (80/20) isophthalate-co-5-sodiosulfoiisophthalate (95/5)}, (prepared as described in U.S. Pat. No. 5,523,189), and 23.68 g each of five cocrystalline TiOPc-TiOFPc compositions prepared by the method described in the previously discussed U.S. Pat. No. 5,614,342. Four amorphous pigment mixtures were dispersed either in 370 g of TCE or 370 g of a 60/40 (by wt.) mixture of DCM and TCE. The following amorphous mixtures, designated Pigment Mixtures A, B, C, and D, were used to prepare these concentrated dispersions:
[0054] Pigment Mixture A—a 90/10 mixture of crude substantially chlorine-free TiOPc and crude TiOFPc, as described in Example 1 of co-pending related application TWO-STAGE MILLING PROCESS FOR PREPARING COCRYSTALS OF TITANYL FLUOROPHTHALOCYANINE AND TITANYL PHTHALOCYANINE, AND ELECTROPHOTOGRAPHIC ELEMENT CONTAINING SAME.
[0055] Pigment Mixture B—like Pigment Mixture A, but containing an 87.5/12.5 mixture of crude substantially chlorine-free TiOPc and crude TiOFPc.
[0056] Pigment Mixture C—a 90/10 mixture of highly crystalline, substantially chlorine-free TiOPc obtained from H. W. Sands Corporation and crude TiOFPc, as described in Example 2 of co-pending related application TWO-STAGE MILLING PROCESS FOR PREPARING COCRYSTALS OF TITANYL FLUOROPHTHALOCYANINE AND TITANYL PHTHALOCYANINE, AND ELECTROPHOTOGRAPHIC ELEMENT CONTAINING SAME.
[0057] Pigment Mixture D—a 90/10 mixture of lightly chlorinated Cl—TiOPc and crude TiOFPc, as described in Example 2 of co-pending related application COCRYSTALS CONTAINING HIGH-CHLORINE TITANYL PHTHALOCYANINE AND LOW CONCENTRATION OF TITANYL FLUOROPHTHALOCYANINE, AND ELECTROPHOTOGRAPHIC ELEMENT CONTAINING SAME.
[0058] The concentrated dispersions were mixed with corresponding preformed solutions consisting of 17.8 g of binder, and 792 g of either TCE or a 60/40 DCM/TCE mixture. The resulting dispersions were diluted to 3% solids and evaluated for settling using the procedure described in Example 5. The results are summarized in TABLE 5 following:
TABLE 5 Percent of Settled Volume Pigment After After After Dispersion Mixture Solvent 24 Hours 68 Hours 122 Hours 1 (Comparison) A 60/40 5 10 22 DCM/ TCE 2 (Invention) B TCE 0 0 0 3 (Invention) C TCE 0 1 2 4 (Comparison) D 60/40 4 5 8 DCM/ TCE 5 (Invention) D TCE 0 0 0
[0059] The results summarized in TABLE 5 demonstrate the resistance to settling, even on prolonged standing, exhibited by dispersions prepared in substantially pure TCE compared with dispersions prepared in a DCM/TCE mixture.
[0060] The invention has been described in detail for the purpose of illustration, but it is understood that such detail is solely for that purpose, and variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention, which is defined by the following claims. | In a process for forming a nanoparticulate crystalline titanium phthalocyanine pigment composition, a titanium phthalocyanine pigment is contacted with substantially pure 1,1,2-trichloroethane (TCE) under conditions effective to convert the titanium phthalocyanine pigment to the nanoparticulate crystalline composition. | 2 |
FIELD OF INVENTION
This invention relates to protecting means and more particularly to energy absorbing padding used by athletes and others to prevent or reduce the incidents of injuries.
BACKGROUND OF INVENTION
Man has always been concerned with protecting his body from injury caused by outside means. With the advent of contact sports such as gladiator exhibitions in ancient times or the early days of football, leather coverings and pads were used, sometimes even with soft backings. Although these pads helped, injuries were still more the norm than the unusual.
In more recent years hard plastic has been developed with sponge rubber and similar backing used in conjunction therewith to contouringly fit over the areas most frequently subject to injury. Although the incidents of injuries has been drastically reduced, they are still way above acceptable limits.
BRIEF DESCRIPTION OF INVENTION
After much research and study into the above mentioned problems the present invention has been developed to provide a superior padding for the body and appendages of the user therof to greatly reduce the chances of contact sport injuries.
The above is accomplished through the provision of shock absorbing springs and air pockets within the pads. The outer layer of the spring pad is composed of a flexible sheet with an inner flexible sheet spaced with rows of styrene butadine springs. As the springs expand to their normal, relaxed position, they provide space for cushions of air to form. Upon impact, the springs compress to absorb the shock of the blow while the air pockets cushion the blow additionally.
The improved pads of the present invention include four protective means, the outer flexible sheet, the inner flexible sheet, the styrene butadine springs and the air pockets.
In view of the above, it is an object of the present invention to provide an improved pad means particularly adapted for use in conjunction with contact sports.
Another object of the present invention is to provide a blow absorbing means in the form of at least two padded layers having spring like means mounted therebetween.
Another object of the present invention is to provide athletic type padding which utilizes a combination of closed cell foam type material, encapsulated spring means, and air pockets to create a cushion effect.
Another object of the present invention is to provide a pad means including the use of styrene butadine springs as a blow absorbing material.
Another object of the present invention is to provide a plurality of encapsulated styrene butadine springs in an athletic type pad.
Another object of the present invention is to provide an athletic type pad which includes a plurality of different shock absorbing means.
Another object of the present invention is to provide an athletic type pad incorporating at least four distinct shock absorbing means.
Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view of a knee type pad incorporating the cushioning means of the present invention;
FIG. 2 is an enlarged cut away view of the spring loaded air column portion of the present invention;
FIG. 3 is a cutaway view of the cushioning means shown in FIG. 1;
FIG. 4 is a rear perspective view of a combination shoulder and rib pad incorporating the present invention; and
FIG. 5 is a front elevational view of the pads shown in FIG. 4.
DETAILED DESCRIPTION OF INVENTION
With further reference to the drawings, the improved athletic padding of the present invention, indicated generally at 10, can have various exterior configurations depending on the part of the body the pad is designed to protect.
Referring specifically to FIGS. 1 and 3 this embodiment is specifically designed as a knee pad, or with slight modifications, can be used as an elbow pad.
The FIG. 1 embodiment includes an outer or exterior pad 11, preferably formed from a closed cell vinyl or foam rubber type material which is preferably coated on the outer surface 12 thereof with a material such as tear resistant vinyl or neoprene. The thickness of the exterior pad 11 is approximately 3/8 of an inch although it can be either greater or lessor as deemed appropriate.
The interior pad 13 is also formed from a relatively dense, closed cell foam vinyl or rubber with the outer surface or skin 14 (which is adapted to vie juxtaposed to the user 15 thereof) formed from either a tear resistant vinyl or neoprene type material.
The interior pad 13 is fixedly secured about its periphery to the exterior pad 11 as indicated at 16 by any suitable method. Since the joining of pad material of the type described is well known to those skilled in the art, further detailed discussion of this portion of present invention is not deemed necessary.
A plurality of spring columns 17 are provided between the exterior and interior pads as seen clearly in FIG. 3. Each of the spring column 17 is composed of a coil type spring 18 formed from styrene butadine or similar material with a compressable foam sponge type material forming the core 19 thereof as can clearly be seen in FIG. 2.
Each of the spring columns as described above is encapsulated in a flexible material such as tear resistant vinyl or neoprene. The top and bottom of each of the spring columns are permanently fixed to the interior surfaces of the envelope formed between exterior pad 11 and interior pad 13. Since the encapsulating of foam sponge type material and the fixing of vinyl and/or neoprene type material as herein described is well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
As can clearly be seen in the cutaway portion of FIG. 3, air spaces 21 are formed between the encapsulated spring columns 17. These air spaces further cushion exterior blows and protect the user 15 therefrom.
FIG. 4 further illustrates use of the improved athletic padding 10 of the present invention by incorporating the same into protective gear worn over the shoulders and upper torso of the user 15 thereof. These additional pads include shoulder pads 22, back pads 23 and rib pads 24. FIG. 5 additionally discloses chest pads 25. Strap means 26 of the type usually associated with football type shoulder pads are provided and extend from the back pads 23 to the chest pads 25 and are of course adjustable. Also, lace type securing means are provided at the juncture of the chest pads 25 as well as at the front of the rib pads as can clearly be seen in FIG. 5. Since strap means of the type indicated at 26 and lace means at the type indicated at 27 and 28 are well known to those skilled in the art, further detailed discussion of the same is not deemed necessary.
A hot dip tear resistant vinyl or neoprene coating can be applied to the pads of the present invention in a manner similar to vinyl coated water skiing vests. Since coatings of this type are well known to those skilled in the art, further detailed discussion thereof is not deemed necessary.
The improved athletic padding in the present invention can either be secured directly over the portion of the body of the user thereof as disclosed in FIGS. 4 and 5 or can be placed in clothing pockets provided for the purposes such as are knee pads and hip pads in a football pants. It is not the means of mounting the pads juxtaposed to the area to be protected but the superb cushioning capability of the pads that make them so superior.
When the improved athletic padding of the present invention has been put on by the user thereof as described above, such user can engage in whatever athletic or similar activity he has chosen. When an exterior blow is struck against the outer surface or skin 12 of exterior pad 11, the closed cell material from which the pad is formed will compact absorbing some of the forces of the blow.
As the exterior pad 11 begins to give, the encapsulated spring columns 17 adjacent the blow area will begin to absorb energy from such blow as the coil spring 18 and the foam sponge core 19 are compressed.
Since the exterior pad 11 and the interior pad 13 form an air tight envelope, the air spaces 21 between the spring column 17 begin to add resistance to the blow due to the compressing of the air in such spaces.
Finally, the relatively thick interior pad 13 formed from closed cell foam type material and located juxtaposed to the user 15 thereof is compressable absorbing additional forces from the blow.
From the above blow absorbing sequence of the exterior pad compressing, the spring column with associated springs and corer compressing, the air passages building resistance through the increasing air pressure, and the interior pad compressing, a superior means for absorbing the energy from an exterior blow is provided.
From the above it can be seen that the present invention provides a multiple staged energy absorbing means which provides superior protection for the athlete or other person wearing the same.
The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the spirit and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein. | This invention is an improved padding used by athletes and others to prevent or greatly reduce the instances of injury due to blows to the body and its appendages, particularly to the more boney parts thereof such as knees, elbow, shoulders, thighs, hips, and the like. This is accomplished through the utilization of non-metallic spring means encapsulated in a vinyl type material with air pockets formed therebetween with cross-stress means for additional protection. | 0 |
BACKGROUND OF THE INVENTION 1. Field of the Invention
[0001] The present invention relates to an optical lens system, and more particularly to a five-piece optical lens system.
[0002] 2. Description of the Prior Art
[0003] The electronic sensor of a general digital camera is typically a CCD (Charge Coupled Device) or CMOS (Complementary Metal Oxide Semiconductor) sensor. Due to advances in semiconductor manufacturing, the pixel size of sensor has been reduced continuously, and optical lens systems have increasingly higher resolution. Therefore, there's an increasing demand for an imaging lens system with better image quality.
[0004] However, as to the optical lens systems used in biomedicine, car recorder, camera or other electronic products, the requirement for high pixel and big stop needn't be stringent, but the problems of field of view and yield rate are needed to be solved. Conventional lens systems used in the electronic products in the above-mentioned fields mostly consist of four lens elements, however, such lens systems have some defects, such as, the field of view is small, the yield rate is low and so on.
[0005] The present invention mitigates and/or obviates the aforementioned disadvantages.
SUMMARY OF THE INVENTION
[0006] The primary objective of the present invention is to provide a five-piece optical lens system which has a wide field of view and can improve the yield rate.
[0007] A five-piece optical lens system in accordance with the present invention comprises, in order from the object side to the image side: a first lens element with a negative refractive power having a convex object-side surface; a second lens element with a negative refractive power having a concave image-side surface, at least one of an object-side and the image-side surfaces of the second lens element being aspheric; a third lens element with a positive refractive power having a convex object-side surface, at least one of the object-side and an image-side surfaces of the third lens element being aspheric; a stop; a fourth lens element with a positive refractive power having a convex image-side surface, at least one of an object-side and the image-side surfaces of the fourth lens element being aspheric; and a fifth lens element with a negative refractive power having a concave object-side surface, at least one of the object-side and an image-side surfaces of the fifth lens element being aspheric.
[0008] According to one aspect of the present five-piece optical lens system, the focal length of the first lens element is f1, the focal length of the second lens element is f2, and they satisfy the relation: 2.5<|f1|/|f2|<6. If |f1|/|f2| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, If |f1|/|f2| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0009] According to another aspect of the present five-piece optical lens system, the focal length of the second lens element is f2, the focal length of the third lens element is f3, and they satisfy the relation: 0.3<|f2|/|f3|<1. If |f2|/|f3| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, If |f2|/|f3| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0010] According to another aspect of the present five-piece optical lens system, the focal length of the third lens element is f3, the focal length of the fourth lens element is f4, and they satisfy the relation: 1.0<|f3|/|f4|<3.0. If |f3|/|f4| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, If |f3|/|f4| exceeds the above range, the performance and resolution of the optical lens system will be reduced, and the yield rate will be low.
[0011] According to another aspect of the present five-piece optical lens system, the focal length of the fourth lens element is f4, the focal length of the fifth lens element is f5, and they satisfy the relation: |f4|/|f5|<0.7. |f4|/|f5| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, if |f4|/|f5| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0012] According to another aspect of the present five-piece optical lens system, the focal length of the first lens element, the second lens element and the third lens element combined is f123, the focal length of the five-piece optical lens system is f, and they satisfy the relation: 1<|f123|/|f<3. If |f123|/|f| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, if |f123|/|f| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0013] According to another aspect of the present five-piece optical lens system, the focal length of the first lens element is f1, the focal length of the second lens element and the third lens element combined is f23, and they satisfy the relation: 0.5<|f1|/|f23|<2.3. If |f1|/|f23| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, if |f1|/|f23| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0014] According to another aspect of the present five-piece optical lens system, the focal length of the five-piece optical lens system is f, the distance from the object-side surface of the first lens element to the image plane along the optical axis is TL, and they satisfy the relation: |f/TL|<0.4. If |f/TL| satisfies the above relation, a wide field of view and high yield rate can be provided. Contrarily, if |f/TL| exceeds the above range, the performance of the optical lens system will be reduced, and the yield rate will be low.
[0015] According to another aspect of the present five-piece optical lens system, the first lens element is made of plastic and has a concave image-side surface, and the object-side surface and the image-side surface of the first lens element are aspheric. The second lens element is made of plastic and has a convex object-side surface, and the object-side surface and the image-side surface of the second lens element are aspheric. The third lens element is made of plastic and has a concave image-side surface, and the object-side surface and the image-side surface of the third lens element are aspheric. The fourth lens element is made of plastic and has a convex object-side surface, and the object-side surface and the image-side surface of the fourth lens element are aspheric. The fifth lens element is made of plastic and has a convex image-side surface, and the object-side surface and the image-side surface of the fifth lens element are aspheric.
[0016] According to another aspect of the present five-piece optical lens system, the first lens element is made of glass and has a concave image-side surface, and the object-side surface and the image-side surface of the first lens element are aspheric. The second lens element is made of plastic and has a concave object-side surface, and the object-side surface and the image-side surface of the second lens element are aspheric. The third lens element is made of plastic and has a concave image-side surface, and the object-side surface and the image-side surface of the third lens element are aspheric. The fourth lens element is made of plastic and has a convex object-side surface, and the object-side surface and the image-side surface of the fourth lens element are aspheric. The fifth lens element is made of plastic and has a convex image-side surface, and the object-side surface and the image-side surface of the fifth lens element are aspheric.
[0017] The present invention will be presented in further details from the following descriptions with the accompanying drawings, which show, for purpose of illustrations only, the preferred embodiments in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1A shows an optical lens system in accordance with a first embodiment of the present invention;
[0019] FIG. 1B shows the longitudinal spherical aberration curve, the distortion curve, and the image plane curve of the first embodiment of the present invention;
[0020] FIG. 2A shows an optical lens system in accordance with a second embodiment of the present invention;
[0021] FIG. 2B shows the longitudinal spherical aberration curve, the distortion curve, and the image plane curve of the second embodiment of the present invention;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Referring to FIG. 1A , which shows a five-piece optical lens system in accordance with a first embodiment of the present invention, and FIG. 1B shows the longitudinal spherical aberration curves, the astigmatic field curves, and the distortion curve of the first embodiment of the present invention. A five-piece optical lens system in accordance with the first embodiment of the present invention comprises, in order from the object side to the image side:
[0023] A first lens element 110 with a negative refractive power made of plastic has a convex object-side surface 111 and a concave image-side surface 112 , and the object-side surface 111 and the image-side surface 112 of the first lens element 110 are aspheric.
[0024] A second lens element 120 with a negative refractive power made of plastic has a convex object-side surface 121 and a concave image-side surface 122 , and the object-side surface 121 and the image-side surface 122 of the second lens element 120 are aspheric.
[0025] A third lens element 130 with a positive refractive power made of plastic has a convex object-side surface 131 and a concave image-side surface 132 , and the object-side surface 131 and the image-side surface 132 of the third lens element 130 are aspheric.
[0026] A stop 100 .
[0027] A fourth lens element 140 with a positive refractive power made of plastic has a convex object-side surface 141 and a convex image-side surface 142 , and the object-side surface 141 and the image-side surface 142 of the fourth lens element 140 are aspheric.
[0028] A fifth lens element 150 with a negative refractive power made of plastic has a concave object-side surface 151 and a convex image-side surface 152 , and the object-side surface 151 and the image-side surface 152 of the fifth lens element 150 are aspheric.
[0029] An IR cut filter 160 made of glass is located between the image-side surface 152 of the fifth lens element 150 and an image plane 170 and has no influence on the focal length of the five-piece optical lens system.
[0030] The equation for the aspheric surface profiles of the first embodiment is expressed as follows:
[0000]
z
=
ch
2
1
+
[
1
-
(
k
+
1
)
c
2
h
2
]
0.5
+
Ah
4
+
Bh
6
+
Ch
8
+
Dh
10
+
Eh
12
+
Gh
14
+
…
[0031] wherein:
[0032] z represents the value of a reference position with respect to a vertex of the surface of a lens and a position with a height h along the optical axis 180 ;
[0033] k represents the conic constant;
[0034] c represents the reciprocal of the radius of curvature;
[0035] A, B, C, D, E, G, . . . : represent the high-order aspheric coefficients.
[0036] In the first embodiment of the present five-piece optical lens system, the focal length of the five-piece optical lens system is f, and it satisfies the relation:
[0000] f=0.61.
[0037] In the first embodiment of the present five-piece optical lens system, the f-number of the five-piece optical lens system is Fno, and it satisfies the relation:
[0000] Fno=2.8.
[0038] In the first embodiment of the present five-piece optical lens system, the field of view of the five-piece optical lens system is 2ω, and it satisfies the relation:
[0000] 2ω=141°.
[0039] In the first embodiment of the present five-piece optical lens system, the focal length of the first lens element 110 is f1, the focal length of the second lens element 120 is f2, and they satisfy the relation:
[0000] |f1|/|f2|=5.0064.
[0040] In the first embodiment of the present five-piece optical lens system, the focal length of the second lens element 120 is f2, the focal length of the third lens element 130 is f3, and they satisfy the relation:
[0000] |f2|/|f3|=0.571.
[0041] In the first embodiment of the present five-piece optical lens system, the focal length of the third lens element 130 is f3, the focal length of the fourth lens element 140 is f4, and they satisfy the relation:
[0000] |f3|/|f4|=2.4828.
[0042] In the first embodiment of the present five-piece optical lens system, the focal length of the fourth lens element 140 is f4, the focal length of the fifth lens element 150 is f5, and they satisfy the relation:
[0000] |f4|/|f5|=0.519.
[0043] In the first embodiment of the present five-piece optical lens system, the focal length of the first lens element 110 , the second lens element 120 and the third lens element 130 combined is f123, the focal length of the five-piece optical lens system is f, and they satisfy the relation:
[0000] |f123|/|f|=1.907.
[0044] In the first embodiment of the present five-piece optical lens system, the focal length of the first lens element 110 is f1, the focal length of the second lens element 120 and the third lens element 130 combined is f23, and they satisfy the relation:
[0000] |f1|/|f23|=1.8115.
[0045] In the first embodiment of the present five-piece optical lens system, the focal length of the five-piece optical lens system is f, the distance from the object-side surface 111 of the first lens element 110 to the image plane 170 along the optical axis 180 is TL, and they satisfy the relation:
[0000] |f/TL|=0.1427.
[0046] The detailed optical data of the first embodiment is shown in table 1, and the aspheric surface data is shown in table 2, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm. In the tables 1 and 2, the surfaces 1 and 2 represent the object-side surface 111 and the image-side surface 112 of the first lens element 110 , respectively, the surfaces 3 and 4 represent the object-side surface 121 and the image-side surface 122 of the second lens element 120 , respectively, the surfaces 5 and 6 represent the object-side surface 131 and the image-side surface 132 of the third lens element 130 , respectively, the surfaces 8 and 9 represent the object-side surface 141 and the image-side surface 142 of the fourth lens element 140 , respectively, and the surfaces 10 and 11 represent the object-side surface 151 and the image-side surface 152 of the fifth lens element 150 , respectively.
[0000]
TABLE 1
(Embodiment 1)
f(focal length) = 0.61 mm, Fno = 2.8, 2ω = 141°.
Sur-
Curvature
face
Radius
Thickness
Material
nd
vd
0
Object
Infinity
500
1
Lens 1
4.41938(ASP)
0.68489
Plastic
1.535
56
2
1.25089(ASP)
−0.45826
3
Lens 2
2.58748(ASP)
0.29987
Plastic
1.565
56
4
0.31571(ASP)
0.2185
5
Lens 3
0.68931(ASP)
0.72166
Plastic
1.634
23.9
6
3.23146(ASP)
0.07748
7
Stop
Infinity
−0.0138
8
Lens 4
0.85198(ASP)
0.57669
Plastic
1.535
56
9
−0.2952(ASP)
0.05008
10
Lens 5
−0.5069ASP)
0.31932
Plastic
1.634
23.9
11
−3.6892(ASP)
0.46175
12
IR-filter
Infinity
0.4
Glass
1.5168
64.1673
13
Infinity
0.045
14
Image
Infinity
[0000]
TABLE 2
Aspheric Coefficients
Surface
1
2
3
4
5
K =
2.272235
0.383822
4.908257
−0.76256
−0.11158
A =
−0.01443
0.102645
−0.07697
−1.08
−0.24825
B =
−0.0006
−0.102
0.102816
−1.48816
−0.67233
C =
0.000163
−0.00875
−0.04276
−12.5522
−0.47874
D =
2.6E−07
0.31355
−0.3153
8.308509
12.62426
Surface
6
8
9
10
11
K =
−360
−2.01454
−0.679
−4.36488
3.434523
A =
5.178583
0.314421
8.70778
1.409741
−0.52002
B =
−67.7769
27.15316
−86.3479
−53.4321
3.358731
C =
546.8936
−792.666
511.4431
307.2865
−16.5457
D =
517.2056
10057.47
−857.918
−366.686
46.29979
[0047] Referring to FIG. 2A , which shows a five-piece optical lens system in accordance with a second embodiment of the present invention, and FIG. 2B shows the longitudinal spherical aberration curves, the astigmatic field curves, and the distortion curve of the second embodiment of the present invention. A five-piece optical lens system in accordance with the second embodiment of the present invention comprises, in order from the object side to the image side:
[0048] A first lens element 210 with a negative refractive power made of glass has a convex object-side surface 211 and a concave image-side surface 212 , and the object-side surface 211 and the image-side surface 212 of the first lens element 210 are aspheric.
[0049] A second lens element 220 with a negative refractive power made of plastic has a concave object-side surface 221 and a concave image-side surface 222 , and the object-side surface 221 and the image-side surface 222 of the second lens element 220 are aspheric.
[0050] A third lens element 230 with a positive refractive power made of plastic has a convex object-side surface 231 and a concave image-side surface 232 , and the object-side surface 231 and the image-side surface 232 of the third lens element 230 are aspheric.
[0051] A stop 200 .
[0052] A fourth lens element 240 with a positive refractive power made of plastic has a convex object-side surface 241 and a convex image-side surface 242 , and the object-side surface 241 and the image-side surface 242 of the fourth lens element 240 are aspheric.
[0053] A fifth lens element 250 with a negative refractive power made of plastic has a concave object-side surface 251 and a convex image-side surface 252 , and the object-side surface 251 and the image-side surface 252 of the fifth lens element 250 are aspheric.
[0054] An IR cut filter 260 made of glass is located between the image-side surface 252 of the fifth lens element 250 and an image plane 270 and has no influence on the focal length of the five-piece optical lens system.
[0055] A cover glass 290 made of glass is located between the IR cut filter 260 and the image plane 270 to protect a sensor (not shown), and has no influence on the focal length of the optical lens system with a wide field of view.
[0056] The equation for the aspheric surface profiles of the second embodiment is expressed as follows:
[0000]
z
=
ch
2
1
+
[
1
-
(
k
+
1
)
c
2
h
2
]
0.5
+
Ah
4
+
Bh
6
+
Ch
8
+
Dh
10
+
Eh
12
+
Gh
14
+
…
[0057] wherein:
[0058] z represents the value of a reference position with respect to a vertex of the surface of a lens and a position with a height h along the optical axis 280 ;
[0059] k represents the conic constant;
[0060] c represents the reciprocal of the radius of curvature;
[0061] A, B, C, D, E, G, . . . : represent the high-order aspheric coefficients.
[0062] In the second embodiment of the present five-piece optical lens system, the focal length of the five-piece optical lens system is f, and it satisfies the relation:
[0000] f=1.34.
[0063] In the second embodiment of the present five-piece optical lens system, the f-number of the five-piece optical lens system is Fno, and it satisfies the relation:
[0000] Fno=2.4.
[0064] In the second embodiment of the present five-piece optical lens system, the field of view of the five-piece optical lens system is 2ω, and it satisfies the relation:
[0000] 2ω=160°.
[0065] In the second embodiment of the present five-piece optical lens system, the focal length of the first lens element 210 is f1, the focal length of the second lens element 220 is f2, and they satisfy the relation:
[0000] |f1|/|f2|=3.553.
[0066] In the second embodiment of the present five-piece optical lens system, the focal length of the second lens element 220 is f2, the focal length of the third lens element 230 is f3, and they satisfy the relation:
[0000] |f2|/|f3|0.727.
[0067] In the second embodiment of the present five-piece optical lens system, the focal length of the third lens element 230 is f3, the focal length of the fourth lens element 240 is f4, and they satisfy the relation:
[0000] |f3|/|f4|=1.6495.
[0068] In the second embodiment of the present five-piece optical lens system, the focal length of the fourth lens element 240 is f4, the focal length of the fifth lens element 250 is f5, and they satisfy the relation:
[0000] |f4|/|f5|=0.146.
[0069] In the second embodiment of the present five-piece optical lens system, the focal length of the first lens element 210 , the second lens element 220 and the third lens element 230 combined is f123, the focal length of the five-piece optical lens system is f, and they satisfy the relation:
[0000] |f123|/|f|=1.852.
[0070] In the second embodiment of the present five-piece optical lens system, the focal length of the first lens element 210 is f1, the focal length of the second lens element 220 and the third lens element 230 combined is f23, and they satisfy the relation:
[0000] |f1|/|f23|=1.0783.
[0071] In the second embodiment of the present five-piece optical lens system, the focal length of the five-piece optical lens system is f, the distance from the object-side surface 211 of the first lens element 210 to the image plane 270 along the optical axis 280 is TL, and they satisfy the relation:
[0000] |f/TL|=0.0865.
[0072] The detailed optical data of the second embodiment is shown in table 3, and the aspheric surface data is shown in table 4, wherein the units of the radius of curvature, the thickness and the focal length are expressed in mm. In the tables 3 and 4, the surfaces 1 and 2 represent the object-side surface 211 and the image-side surface 212 of the first lens element 210 , respectively, the surfaces 3 and 4 represent the object-side surface 221 and the image-side surface 222 of the second lens element 220 , respectively, the surfaces 5 and 6 represent the object-side surface 231 and the image-side surface 232 of the third lens element 230 , respectively, the surfaces 8 and 9 represent the object-side surface 241 and the image-side surface 242 of the fourth lens element 240 , respectively, and the surfaces 10 and 11 represent the object-side surface 251 and the image-side surface 252 of the fifth lens element 250 , respectively.
[0000]
TABLE 3
(Embodiment 2)
f(focal length) = 1.34 mm, Fno = 2.4, 2ω = 160°.
Sur-
Curvature
face
Radius
Thickness
Material
nd
vd
0
Object
Infinity
Infinity
1
Lens 1
26.7009
1.05674
Glass
1.729
54.67
2
3.93672
2.01719
3
Lens 2
25.7431(ASP)
1.3437
Plastic
1.535
56
4
0.92003(ASP)
0.35203
5
Lens 3
1.55193(ASP)
3.46508
Plastic
1.632
23
6
8.50921(ASP)
0.52379
7
Stop
Infinity
−0.0728
8
Lens 4
2.78381(ASP)
1.76837
Plastic
1.535
56
9
−0.8902(ASP)
0.08366
10
Lens 5
−1.0545ASP)
1.95215
Plastic
1.632
23
11
−2.1605(ASP)
0.11004
13
IR-filter
Infinity
0.3
Glass
1.5168
64.1673
14
Infinity
1.635
15
IR-filter
Infinity
0.55
Glass
1.5168
64.1673
16
Infinity
0.455
17
Image
Infinity
[0000]
TABLE 2
Aspheric Coefficients
Surface #
3
4
5
6
k =
17.91589
−0.84779
−0.53475
−10.3908
A =
−0.00537
−0.11016
−0.0326
0.086261
B =
0.000328
0.021145
0.006204
0.000755
C =
−5.9E−06
−0.00382
−0.00045
−0.00361
D =
−2.4E−07
2.77E−05
−0.00021
0.02645
Surface #
8
9
10
11
k =
0.983636
−1.08124
−4.17953
−8.47063
A =
0.110855
0.390382
0.057261
−0.05632
B =
−0.22591
−0.48338
−0.205
0.023317
C =
0.343388
0.242057
0.059436
−0.00685
D =
−0.21757
−0.03048
0.0096
0.000911
[0000]
TABLE 5
Embodiment 1
Embodiment 2
f
0.61
1.34
Fno
2.8
2.4
2ω
141
160
|f1|/|f2|
5.0064
3.553
|f2|/|f3|
0.571
0.727
|f3|/|f4|
2.4828
1.6495
|f4|/|f5|
0.519
0.146
|f123|/|f|
1.907
1.852
|f1|/|f23|
1.8115
1.0783
|f/TL|
0.1427
0.0865
[0073] It is to be noted that the tables 1-4 show different data from the different embodiments, however, the data of the different embodiments is obtained from experiments. Therefore, any product of the same structure is deemed to be within the scope of the present invention even if it uses different data. Table 5 lists the relevant data for the various embodiments of the present invention.
[0074] In the present five-piece optical lens system, the lens elements can be made of glass or plastic. If the lens elements are made of glass, there is more freedom in distributing the refractive power of the five-piece optical lens system. If the lens elements are made of plastic, the cost will be effectively reduced.
[0075] In the present five-piece optical lens system, if the object-side or the image-side surface of the lens elements is convex, the object-side or the image-side surface of the lens elements in proximity of the optical axis is convex. If the object-side or the image-side surface of the lens elements is concave, the object-side or the image-side surface of the lens elements in proximity of the optical axis is concave.
[0076] While we have shown and described various embodiments in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | A five-piece optical lens system comprises, in order from the object side to the image side: a first lens element with a negative refractive power having a convex object-side surface; a second lens element with a negative refractive power having a concave image-side surface; a third lens element with a positive refractive power having a convex object-side surface; a stop; a fourth lens element with a positive refractive power having a convex image-side surface; a fifth lens element with a negative refractive power having a concave object-side surface, each of the second, third, fourth and fifth lens elements has at least one aspheric surface. Thereby, such a system has a wide field of view and can improve the yield rate when being applied to biomedicine, car recorder, camera or other electronic products. | 6 |
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to sealing and seal members. More particularly, the present invention relates to seal members having members which control the longitudinal elongation of the seal member.
In the automotive, as well as other industries, it is desirous to have seal members that adhesively affix to objects which are to be sealed. Especially in the automotive industry, it is desirous to directly affix seal members to sheet metal work such as doors or the like. To reduce labor costs and increase uniformity, adhesive seals are positioned onto the sheet metal work by robots or the like. The robots, while applying the seal members, have a tendency to stretch and elongate the seal members as they are positioned onto the sheet metal work. Often times, the seals are stretched beyond their desired elongation. Thus, it is desirous to have members, such as a fiberglass, nylon, polyester, Kevlar or the like strands longitudinally positioned in the seal to prevent excessive elongation of the seal members.
Relevant art provides seal members with strands embedded into the seal during manufacturing. The embedding of strands into the rubber seal members requires special machinery to inlay the strands within the seal members during extrusion. While the process works satisfactorily, the tooling is relatively expensive. Also, it is difficult to control the positioning of the strands within the seal member.
Accordingly, it is an object of the present invention to provide the art with seal members which have controlled longitudinal elongation characteristics. Another object of the present invention is to provide the art with a simple and relatively inexpensive method to produce length control seal members. The present invention also provides the art with a seal member that may be easily adhesively affixed to an object such as a vehicle door or the like.
In accordance with the present invention, the sealing member includes a portion for sealing the object such as a vehicle door, window, body or the like. The sealing member is elongated and defines a longitudinal axis. The sealing member is formed from an elastomeric material and includes a surface to couple the sealing member along the longitudinal axis. One or more length control members are positioned on the coupling surface along the longitudinal axis. A heat activated member is positioned on the surface such that the length control members sandwich between the heat activated member and the coupling surface. The heat activated member is heated to bond to the coupling surface such that the heat activated member fixedly secures to the coupling surface forming a laminate sealing member.
From the following detailed description of the preferred embodiments, taken in conjunction with the attached drawings and the appended claims, other objects and advantages of the present invention will become apparent to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view illustrating a sealing member in accordance with the present invention affixed to an object such as a vehicle door or the like.
FIG. 2 is a perspective view of forming a sealing member in accordance with the present invention.
FIG. 3 is a cross-sectional view through a vertical plane taken along line 3--3 in FIG. 2.
DESCRIPTION OF THE INVENTION
Turning to the figures, a seal member 10 is illustrated on an object such as vehicle door 12 or the like. The seal member 10 generally includes a sealing portion 14 and a mounting portion 16.
The sealing portion 14 may be of any desired configuration. The sealing portion 14 is elongated and formed from a polymeric material such as EPDM sponge or dense rubber. Preferably, the sealing portion 14 has an overall "T" shape in cross-section. The vertical leg or lip 18 of the "T" is angled or arcuate with respect to the horizontal portion 20 to affectuate a seal between the door 14 and car body 15. The horizontal portion 20 of the "T" includes a top flat planar surface 22 and defines a longitudinal axis 23 of the sealing portion 14.
One or more length control members 24 are positioned on top of the planar surface 22. The control members 24 are fiberglass, nylon, polyester, Kevlar, rayon, graphite, cotton, metal wire or the like strands which do not substantially elongate along their longitudinal axis. Also, a thin film of mylar, polyester or the like which exhibits minimal elongation characteristics may be used. Woven fabric, such as yarn, which exhibits minimal elongation characteristics likewise may be used. Woven fabric would also provide lateral as well as longitudinal strength. A desired number of control members 24 are positioned at desired spacings on the planar surface 22 of the sealing portion 14.
A heat activated member 26, such as heat bonded tape, is positioned on top of the control members 24 sandwiching the control members 24 between the heat activated member 26 and the top planar surface 22. The heat activated member 26 is heated to bond to the top planar surface 22 to securely affix the heat activated member 26 to the sealing portion 14. The heat activated member 26 also includes a releasable layer 28 and an adhesive 30 maintaining the releasable layer 28 onto the heat activated layer 32. The releasable layer 28 may be a paper layer or the like which may be removed from the adhesive to allow the adhesive 30 to contact the door 12 to affix the seal 10 onto the door 12, as seen in FIG. 1.
Turning to FIG. 2, the sealing portion 14 is extruded or the like from a conventional extrusion die. As the sealing portion 14 is extruded, the length control members 24 are positioned on top of the planar surface 22. The heat activated member 26 is positioned on top of the planar surface 22 to sandwich the length control members 24 between the heat activated layer 32 and sealing portion 14. The heat activated member 26 is heated such that the heat activated layer 32 bonds to the planar surface 22. The bonding securely affixes the heat activated member 26 to the sealing portion 14. The releasable layer 28 may then be removed and the adhesive portion 30 applied to an object such as door 12 to which the sealing member 10 is to be secured.
In another embodiment, the control members may be embedded in the heat activated material. The heat activated material would be placed on the planar surface and heated to secure thereto. Also, adhesive strip materials that permanently or nonremovably bond to the planar surface may be substituted for the heat activated material. In these cases, the length control member may be embedded in the adhesive strip material or placed on the planar surface and secured thereto.
The control length members 24 prevent the sealing member 10 from exceeding a desired elongation. When the sealing member 10 is positioned onto an object, such as door 12, by a robot or the like where there is a tendency for the robot to over stretch or over elongate the sealing member 10. By providing the control length members 24, the sealing member 10 is not over elongated by a robot when it is positioned onto the object.
While the above detailed description sets forth preferred embodiments of the present invention, it will be apparent to those skilled in the art that the present invention is subject to modification, variation and alteration without deviating from the scope and spirit of the following claims. | A seal member has a sealing portion, length control members and a heat activated member securing the length control members to the sealing portion. The length control members prevent excessive elongation of the sealing members during installation when the sealing member is applied by automated equipment. | 1 |
CROSS REFERENCE
This application is a continuation-in-part of my copending U.S. patent application Ser. No. 867,275 filed on Jan. 5, 1978.
BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates to sealing of mine galleries and materials therefore.
II. Description of the Prior Art
Systems are known in which certain mine galleries are protected and consolidated, particularly in certain zones in which the nature of the terrain is liable to jeopardize the stability of the galleries.
The processes recommended for this purpose make use of a lining produced by sprayed concrete, a more rapid and less expensive process than the use of coffered concrete. This technique nevertheless calls for a relatively large number of operators, working under arduous conditions, and involving comparatively lengthy periods when the mine working is shut down.
SUMMARY OF THE INVENTION
The present invention provides a fresh solution to this problem in cases where all that is required is to protect the terrain from deterioration due to the surrounding atmosphere, without any attempt to provide a supporting system.
For example, the material uncovered or cut is very easily liable to crumble as a result of the combined action of air and moisture, and it is important to protect it with an inexpensive lining easy to apply without attempting to give it supporting properties likewise.
According to the invention, a lining of this kind is applied by a process consisting of the operation of spraying onto the wall to be protected a fluid mixture of aminoplast resin powder and water and of leaving the resin to gel on the spot, thus forming a continuous insulating lining coating.
In practice, the process consists of the application of a number of superimposed coatings, at least the central coating containing a certain proportion of glass fibers sprayed at the same time as the resin.
The invention thus aims at a new application for aminoplast resins, i.e., their application to the technique of providing insulating linings for walls of mine galleries, and at the practical conditions required for this application.
It should be noted that aminoplast resins, widely used in the technique of adhesives, have already been suggested for the reinforcement of terrains, but by injection into the cracks and not by their application as linings. A technique of this kind is costly and uncertain, as it involves the injection of large quantities of resin at random, its distribution in the cracks in the terrain being uncertain and hypothetical. In the technique covered by the invention, on the other hand, the resin is applied under precise and well defined conditions which can be adjusted by the operator as desired.
It is true, moreover, that consideration has been given to the use of polyester resins for the same purpose, but these resins are dangerous and inconvenient, being on the one hand toxic and inflammable and on the other hand very difficult to clean with organic solvents.
Aminoplast resins usable in the process of the present invention include the polycondensation resins of melamine and formol; the polycondensation resins of melamine, urea, and formol; and the polycondensation resins of melamine phenol, and formol. Of course, it should be understood that other aminoplast resins with similar properties and constructions are also usable in the invention. The specific examples given above are especially adapted for use in the present process since they are sold in pulverulent form.
Aminoplast resins, on the other hand, are not flammable, and the installation is easy to wash with water.
Finally, experience shows that the cost of a lining of this kind is lower and that the system calls for a number of operators and is more rapid than the techniques adopted at present.
DESCRIPTION OF THE PREFERRED EMBODIMENT
By way of example, the conditions of application forming the basis of a test carried out for the technique covered by the invention will now be described below.
The technique being a new one, the apparatus for its application was provided on the basis of equipment so far available on the market, and a more thorough study of the matter can be made later on. The first requirement was to ascertain the behavior of the lining over a given period of time and under the conditions prevailing in the mine.
1. Delivery pump.
Type: REXON, operated by compressed air, double-acting plunger piston.
Delivery: 200-250 l/h
Pressure: 48 bar.
2. Spray gun.
This is a gun of the type used, for example, for the spraying of polyester resin in the manufacture of hulls for vessels.
This gun is fitted with a rotating knife having a number of blades and serving to cut the cord of glass fiber.
The number of blades governs the length of the fibers sprayed in front of the jet of resin.
3. Compressed air.
A delivery of 5 m 3 /min is required, with a pressure of 6-7 bar, to actuate the pump and feed the gun.
4. Water.
A reserve water supply of 500 liters is sufficient.
5. Mixer.
The resin and water must be very carefully mixed.
The mixer is a screw affixed to the cover of the powder conditioning drum. This screw is actuated by an air drill.
6. Miscellaneous equipment.
Spare parts must be available, in order to enable action to be taken more quickly in the event of a stoppage: nozzles, gun nozzles, pump suction filters.
7. Personnel.
One spray operator.
Two assistants for the preparation of a mixture, the handling operation and the various services required in the event of faulty operation.
There is no doubt that when more advanced equipment has been designed, enabling the handling operations to be mechanized, one sprayer and one assistant should prove sufficient.
8. Products and dosages.
Resin: aminoplast, in powder form, as one single constituent. The aminoplast resin used in this example was a melamine/formol polycondensation resin sold by the company C.I.B.A. under the trademark "MELOCOL FFD".
This is delivered in metal drums containing two bags of 12.5 kg, i.e., 25 kg per drum.
It is mixed with water at the rate of 80% by weight of resin to 20% by weight of water, giving a viscosity of 67 poise.
Under these conditions the gelatinization time is 40 minutes and the sample required is extracted between 1 and 1/2 hours after it has been mixed.
Glass fiber: known as "roving," supplied in the form of a cord of 6 mm in diameter, in 18 kg coils, in a cardboard box.
The roving will be used at the rate of 5-10% by weight in relation to the resin powder.
The optimum proportion will in each case depend on the quality criteria for the finished lining, these being
adhesion to the rock,
compactness and continuity,
where its strength is concerned, and
hermeticity
where its anti-moisture protective action is concerned.
9. Performance of process.
The arched roof to be treated is bolted in the normal operating cycle.
The cleansing must be carried out with care. The surface is washed, if necessary, with the use of a spray gun. The mixture of water and powdered resin is produced by means of a mixer, in two lots of 25 kg of resin powder. This mixing operation must be carefully performed, in order to ensure a homogeneous mixture.
The drum containing this mixture is placed underneath the delivery pump, the suction tube being intended to effect complete suction. A very fine filter is indispensable for this suction operation, in order to avoid obstructions. This filter must be frequently washed; it is desirable to have a number of filters in readiness in order not to have to interrupt the spraying program.
The liquid resin is thus forced as far as the spray gun, by which it is sprayed onto the wall to be treated. The compressed air reaching the gun also serves to turn the knife and spray the particles of fiber in front of the jet of resin. The results obtained in these tests were as follows:
Cost price: 50.14 frs per m 2 of lining, made up of 8.75 for labor and 41.41 for supplies.
This result should be compared with the cost price of a lining of sprayed concrete, i.e., 79.49 frs. per m 2 (50.40 for labor and 29.09 for supplies).
Furthermore, it may be added, from a technical point of view, that
this method is quicker to apply than the sprayed concrete method, the site being immobilized for a 4-5 times shorter period and only two men being required in place of 6;
the spraying operation itself is less arduous than the spraying of concrete, the latter operation involving the creation of dust;
the touching-up operations required on the lining can be effected with ease;
the equipment occupies less space.
In addition to the application which has just been described, the invention can be used for other similar purposes: the construction of dams, ventilation, repair of existing dams, sealing of cracks, air-tight and water-tight coatings, etc. | A process for the protection of the surface of the terrain in mine galleries from deterioration due to the surrounding atmosphere is characterized by the operation of spraying onto the wall to be protected, a fluid mixture of aminoplast resin powder and water and leaving the resin to gel on the spot, thus forming a continuous insulating lining coating. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority of U.S. Provisional Patent Application No. 61/752,674, filed Jan. 15, 2013, entitled “Heat-Dissipating EMI/RFI Shield,” the entire disclosure and contents of which are hereby incorporated by reference herein.
SUMMARY
[0002] A heat-dissipating EMI/RFI shield has a shield base, a shield cap, and a heat sink. The shield base has at least one sidewall which defines an open area, and the sidewall has at least one mounting leg extending from it. The shield cap has a collar which defines an opening in the shield cap. The shield cap is configured to be mated to the shield base. The heat sink is configured to be mated to the shield cap. The heat sink has a boss extending therefrom. The boss is configured to protrude at least partially into the opening in the shield cap to make thermal contact with a heat generating component on a printed circuit board to which the heat-dissipating EMI/RFI shield is attached.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIGS. 1A and 1B are exploded perspective diagrams showing an exemplary heat-dissipating EMI/RFI shield;
[0004] FIG. 2 is a perspective diagram showing an exploded view of the heat-dissipating EMI/RFI shield of FIG. 1 ;
[0005] FIG. 3 is a perspective diagram showing the partially assembled heat-dissipating EMI/RFI shield of FIG. 1 ;
[0006] FIG. 4 is a top view perspective diagram showing an assembled heat-dissipating EMI/RFI shield of FIG. 1 ;
[0007] FIGS. 5 and 6 are bottom and top view perspective diagrams, respectively, showing another exemplary heat-dissipating EMI/RFI shield;
[0008] FIG. 7 is a perspective diagram showing another exemplary heat-dissipating EMI/RFI shield;
[0009] FIG. 8 is a perspective diagram showing another exemplary heat-dissipating EMI/RFI shield; and
[0010] FIG. 9 is a logical flow diagram illustrating a process for manufacturing, assembling, and utilizing an exemplary heat-dissipating EMI/RFI shield.
DETAILED DESCRIPTION
[0011] The following Detailed Description is directed to technologies for heat-dissipating EMI/RFI shields (HDSs). The HDSs disclosed herein are configured to be positioned proximate selected electrical circuit components to limit the transmission of energy, such as electromagnetic interference (EMI) and/or radio frequency interference (RFI) emanating from a selected component (SC). An example of an SC is a semiconductor circuit, such as but not limited to a microprocessor, an RF amplifier, a power regulation circuit, etc. In addition, the HDSs disclosed herein are configured to shield the selected components from EMI and/or RFI emanating from other sources. Further, the HDSs disclosed herein are configured to transfer and dissipate heat emanating from the selected components. Still further, the HDSs are preferably electrically grounded, which protects the SC from static electricity discharges.
[0012] In the following Detailed Description references are made to the accompanying drawings that form a part hereof, and that are shown by way of illustrated embodiments or examples. Referring now to the drawings, in which like numerals represent like elements throughout the several Figures, aspects of apparatuses, systems, and methodologies for HDSs are described.
[0013] FIGS. 1A and 1B are exploded perspective diagrams showing an exemplary heat-dissipating EMI/RFI shield (herein “HDS 100 ”). The illustrated HDS 100 includes a shield base or fence 110 , a shield cap 130 , and a heat sink 150 . Engaging components or structures, such as the illustrated push pins 170 , may be used to secure the HDS 100 to a desired component or object such as, by way of example and not of limitation, the printed circuit board (PCB) 200 illustrated in FIGS. 2-4 .
[0014] The illustrated shield base 110 comprises sidewalls 112 which define a central opening area 113 , mounting legs 114 , sidewall apertures 116 , and sidewall shoulders 118 . The base shield 110 may be constructed of an electrically conductive material, such as but not limited to light-gauge steel, aluminum, copper, combinations thereof, and the like, and is preferably made of an electrically conductive material which can be soldered. The illustrated HDS 100 is configured to enclose one or more selected heat-generating, EMI/RFI generating, and/or EMI/RFI sensitive components, such as, but not limited to, SC 210 , shown in FIGS. 2 and 3 . The illustrated shield base 110 is configured to surround the SC 210 . The shield base 110 is illustrated as a rectangle, but may be configured in any desired or convenient shape in order to be proximate to and surround the SC 210 . The mounting legs 114 mount and preferably ground the shield base 100 to the PCB 200 .
[0015] The sidewall apertures 116 are configured and positioned to matingly engage components of the shield cap 130 . A plurality of sidewall apertures 116 are illustrated at each sidewall 112 . Alternative embodiments comprise a lesser or greater number of sidewall apertures 116 . Further, some alternative embodiments do not include sidewall apertures 116 at each sidewall 112 . In still other alternative embodiments the sidewall apertures 116 may not be used but, rather, other structures may be used that matingly engage components of the shield cap 130 , such as but not limited to clips, pins, springs, arms, lips, hooks, combinations thereof, and the like.
[0016] The location, configuration, and dimensions of the sidewall shoulder 118 are not critical and may, if desired, be reduced to a size which will not substantially deform when the shield cap 130 and heat shield 150 are attached. The shoulder 118 is preferably sufficiently small enough that it does not substantially inhibit the inflow of hot air for soldering operations.
[0017] The illustrated shield cap 130 comprises a shield top 132 , shield flanges 133 shown configured as a plurality of leafs 134 , a collar 136 defining an opening in the shield cap, and a plurality of spring fingers 138 positioned along the collar 136 perimeter. The shield cap 130 is configured to attach to the shield base 110 and, together with other components described herein, encase the SC 210 . The shield cap 130 is illustrated as a rectangle, but alternative embodiments may be configured in any shape whatsoever in order to be proximate the SC 210 . Like the shield base 110 , the shield cap 130 may be constructed of an electrically conductive material. The collar 136 is configured to receive, and the spring fingers 138 are configured to frictionally engage, a component of the heat sink 150 , as described below.
[0018] The plurality of leafs 134 are configured to engage a plurality of sidewall apertures 116 . In an alternative embodiment, the shield cap 130 releasably engages the shield base 110 . In an alternative embodiment the leafs 134 may not be used; rather, other structures may be used to matingly engage components of the shield base 110 , such as but not limited to clips, pins, springs, arms, lips, hooks, combinations thereof, and the like. The illustrated HDS 100 comprises a shield base 110 and shield cap 130 that are constructed separately and assembled after the shield base 110 is soldered to the PC board 200 of FIGS. 2-4 . In another alternative embodiment the shield base 110 and shield cap 130 may be constructed as a single unit.
[0019] The illustrated heat sink 150 comprises a platform 152 , heat dissipating fins 154 , shoe or boss 156 , and apertures 158 . The heat sink 150 may be constructed of a thermally conductive material, such as but not limited to aluminum, copper, steel, combinations thereof, and the like. The platform 152 is configured to be positioned adjacent, and preferably in contact with, the shield cap 130 , with the shoe 156 inserted through the collar 136 and frictionally engaged, and preferably thermally engaged, with the spring fingers 138 .
[0020] Alternative embodiments comprise a lesser or greater number of spring fingers 138 . Further, some alternative embodiments do not include spring fingers 138 along the entire perimeter of the collar 136 . In still other alternative embodiments the spring fingers 138 may not be used; rather, other structures may be used that matingly engage the shoe 156 , such as but not limited to flanges, edges, clips, pins, springs, arms, lips, hooks, metallic tape, thermal interface material (TIM) combinations thereof, and the like. The engagement of the spring fingers 138 around the shoe 150 permits shielding EMI and/or RFI at a point close to the SC 210 , and permits grounding of the heat sink 150 at a point close to the SC 210 .
[0021] FIG. 2 is a perspective diagram showing an exploded view of the heat-dissipating EMI/RFI shield 100 of FIG. 1 . Connected to the PCB 200 is an SC 210 , which may produce and emanate heat and/or EMI and/or RFI. The shield base 110 is shown surrounding the SC 210 and attached to the PCB 200 . The illustrated shield base 110 may be structurally and electrically connected to the PCB 200 by inserting the mounting legs 114 into plated through-holes 211 on the PCB 200 that are connected to a conductive layer (not shown) within the PCB 200 such as, but not limited to, a ground plane. The mounting legs 114 are thus mechanically and electrically connected to the conductive layer (not shown) in the PCB 200 during the soldering process.
[0022] Engaging components, such as push pins 170 , may be used to further secure the HDS 100 to the PCB 200 , and provide a compressive fit between the heat sink 150 , shield cap 130 , shield base 110 and PCB 200 . Here the push pins 170 are inserted through the heat sink apertures 158 ( FIGS. 1A and 1B ), and proximate the shield base 110 are mounting apertures 212 in the PCB 200 ( FIG. 2 ) that are configured to receive and anchor the push pins 170 . In alternative embodiments other types of engaging structures and configurations, such as but not limited to screws, bolts, clips, pins, arms, wires, anchors, soldering, combinations thereof, and the like, may be used to further secure the HDS 100 to the PCB 200 . Accordingly, the heat sink 150 and/or PCB 200 may comprise various engaging structures and configurations.
[0023] Thus, FIGS. 1A, 1B, and 2 show an exemplary heat-dissipating EMI/RFI shield assembly which includes a shield base 110 , a shield cap 130 attached to the shield base 110 , and a heat sink 150 attached to the shield cap 130 . The shield base 110 is electrically connected to a conductive layer of printed circuit board 200 , and may be structurally connected to, or may be part of, an electronic device (not shown). Further, the heat sink 150 comprises a shoe 156 , and the shoe 156 is electromechanically engaged to the shield cap 130 .
[0024] As best seen in FIGS. 1B and 2 , the heat sink 150 may be mounted to the shield cap 130 by inserting the shoe 156 through the collar 136 such that the spring fingers 138 frictionally engage the shoe 156 . The snap-in ends of the push pins 170 are inserted through the PCB apertures 158 . The heat sink 150 may thereby be structurally and electrically connected, and grounded, to the shield cap 130 , shield base 110 , and PCB 200 .
[0025] The illustrated shoe 156 may be configured as an inverted “U”, comprising a channel 180 , top 182 and sidewalls 184 . The SC 210 rests within the channel 180 and may be proximate to or in direct contact with the top 182 and/or sidewalls 184 . In this manner heat generated by and emanated from the SC 210 may be transferred to the heat sink 150 and dissipated from the platform 152 and/or fins 154 . Thermal interface materials (not shown) that increase thermal conductance may be applied to fill any gaps between the SC 210 and shoe 156 , including top 182 or sidewalls 184 . The channel 180 configuration allows for close tolerances between, and contact with, the SC 210 . The shoe 156 may also be configured differently as desired to obtain good thermal contact with the SC 210 . For example, if the SC 210 has a circular shape, the shoe 156 may also have a corresponding or mating circular shape. In that event, the collar 136 may also have a similar circular shape.
[0026] The HDSs 100 illustrated and described herein may perform a plurality of functions. By way of example and not limitation, the HDS 100 limits the transmission of EMI and/or RFI emanating from the SC 210 . The HDS 100 may also shield the SC 210 from EMI and/or RFI emanating from other sources. Further, the HDS 100 is configured to transfer and dissipate heat emanating from the SC 210 . Preferably, when the shield base 110 is connected to a conductive layer (not shown) in the PCB 200 , the HDS 100 is thereby electrically grounded. More specifically, the HDS 100 and each of its components, the shield base 110 , the shield cap 130 , and the heat sink 150 , are likewise electrically grounded. In such a configuration the HDSs illustrated and described herein may have the structure of a Faraday cage, especially where the PCB 200 has a ground plane (not shown) and the SC 210 is between the HDS 100 and the ground plane.
[0027] FIG. 3 is a perspective diagram showing the partially assembled heat-dissipating EMI/RFI shield 100 of FIG. 1 . The shield cap 130 is shown mounted to the shield base 110 , such that the plurality of leafs 134 are engaging a respective plurality of sidewall apertures 116 . The shield cap 130 may thereby be structurally and electrically connected, and grounded, to the shield base 110 and PCB 200 .
[0028] FIG. 4 is a top view perspective diagram showing an assembled heat-dissipating EMI/RFI shield 100 of FIG. 1 . As illustrated in FIGS. 1A-4 , the heat sink 150 is approximately the same size as the shield base 110 and the shield top 130 .
[0029] FIGS. 5 and 6 are bottom and top view perspective diagrams, respectively, showing another exemplary heat-dissipating EMI/RFI shield 100 . In this alternative embodiment, the heat sink 150 is wider than the shield cap 130 and shield base 110 in two directions, that is, the platform 152 and fins 154 of the heat sink 150 overhang the shield cap 130 and shield base 110 on two sides. Although the overhang is shown as being on two opposing sides, the heat sink 150 may be wider than, and overhang, the shield cap 130 or shield base 110 in one or more directions, and any of the sides may be overhanging sides.
[0030] FIG. 7 is a perspective diagram showing another exemplary heat-dissipating EMI/RFI shield 100 . In this alternative embodiment, the heat sink 150 is narrower than the shield cap 130 and shield base 110 in two directions, that is, the platform 152 and fins 154 are inset or indented from the shield cap 130 and shield base 110 on two sides. Although the indentation is shown as being on two opposing sides, the heat sink 150 may be narrower than the shield cap 130 or shield base 110 in one or more directions, and any of the sides may be inset sides.
[0031] FIG. 8 is a perspective diagram showing another exemplary heat-dissipating EMI/RFI shield 150 . In this an alternative embodiment, the heat sink 150 comprises a plurality of shoes 156 ( 156 A, 156 B). The shoes 156 may be of different and various sizes, configurations and positions to further allow for close tolerances between, and contact with, their respective SCs 210 (not shown in FIG. 8 ).
[0032] Although the shield base 110 , the shield cap 130 , and the heat sink 150 have been illustrated as being generally square, this is for purposes of convenience of illustration. These components may be any other shape appropriate, desired, or convenient for a particular SC 210 and/or device including a PCB 200 such as, by way of example and not of limitation, a rectangle, a triangle, a circle, or a polygon. While a square, rectangle or polygon is generally considered as having sides, if a component or opening or area is circular, or some other continuous shape, such a component shape may be considered as having either a single side or a plurality of sides.
[0033] FIG. 9 is a logical flow diagram illustrating a process for manufacturing, assembling, and utilizing an exemplary heat-dissipating EMI/RFI shield 100 . It should be appreciated that the operations described herein can be implemented as a sequence of manufacturing steps, mechanical operations, and physical processes. The implementation may vary depending on the performance and other requirements of a particular manufacturing system or electronic device in which an HDS is utilized. It should also be appreciated that more or fewer operations may be performed than shown in the Figures and described herein. These operations may also be performed in parallel, or in a different order than those described herein.
[0034] The process 300 can begin with operation 302 where an appropriate manufacturing procedure is utilized to construct the HDS components; namely, the shield base 110 , shield cap 130 , heat sink 150 , and engaging components 170 . From operation 302 , the routine 300 proceeds to operation 304 , where the HDS 100 is installed into any type of electronic apparatus. As discussed herein, the HDS 100 may be installed onto a circuit board utilized in an electronic device. More particularly, the shield base 110 is installed onto the PCB 200 and then reflow-soldered to affix it to the PCB. The open area 113 of the shield base 110 and, to a lesser degree, the optional apertures 116 , allows adequate hot air flow for resoldering operations. The shield top 130 is then fitted (pressed) onto the shield base 110 . The heat sink 150 is then mounted on top of the shield top 130 , with the boss 156 protruding through the collar 136 and making thermal contact with the SC 210 . The pins 170 , or other desired fasteners, are then used to secure the heat sink 150 to the PCB 200 . The assembly 100 is therefore fully installed. The routine 300 then proceeds to operation 306 .
[0035] At operation 306 the SC 210 is operational, and emits EMI and/or RFI. The HDS 100 contains the EMI and/or RFI in that the HDS 100 substantially prevents the EMI and/or RFI for emitting beyond the shield base 110 and/or shield cap 130 . Similarly, the HDS substantially prevents EMI and/or RFI emanating from other sources from affecting the SC 210 . The routine 300 proceeds to operation 308 .
[0036] At operation 308 , as the SC 210 operates, it emits heat and may generate EMI/RFI. Heat from the SC 210 is transferred to the heat sink 150 and dissipated. The routine 300 then continues to operation 310 , where it ends after the SC 210 is turned off and the heat is dissipated.
[0037] Based on the foregoing, it should be appreciated that heat-dissipating EMI/RFI shields have been disclosed herein. Although the subject matter presented herein has been described in language specific to systems, methodological acts, mechanical and physical operations, and manufacturing processes, it is to be understood that the concepts disclosed herein are not necessarily limited to the specific features, acts, or media described herein. Rather, the specific features, acts and mediums are disclosed as example forms.
[0038] The subject matter described herein is provided by way of illustration for the purposes of teaching, suggesting, and describing, and not limiting or restricting. Combinations and alternatives to the illustrated embodiments are contemplated, described herein, and set forth in the claims. Various modifications and changes may be made to the subject matter described herein without strictly following the embodiments and applications illustrated and described, and without departing from the scope of the following claims. | A heat-dissipating EMI/RFI shield ( 100 ) has a shield base ( 110 ), a shield cap ( 130 ), and a heat sink ( 150 ). The shield base has at least one sidewall ( 112 ) which defines an open area ( 113 ). At least one mounting leg ( 114 ) extends from the sidewall and is affixed to a printed circuit board ( 200 ). The shield cap has a collar ( 136 ) which defines an opening in the shield cap. The shield cap is configured to be mated to the shield base. The heat sink has a boss ( 156 ) extending therefrom. The heat sink is configured to be mated to the shield cap. The boss is configured to protrude at least partially into the opening in the shield cap and to make thermal contact with a selected heat generating component ( 210 ) on the printed circuit board. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] This application relates generally to systems and method for percutaneously associating adjacent tissue, and more particularly for repairing mitral valve abnormalities.
[0003] 2. The Relevant Technology
[0004] Referring to FIGS. 1A and 1B , the mitral valve 10 of the heart 12 prevents the flow of blood from the left ventricle 14 into the right atrium 16 during ventricular systole. The mitral valve 10 includes two leaflets 18 a , 18 b that spread to permit blood flow into the left ventricle 14 during ventricular diastole and are forced together by pressure within the left ventricle 14 during ventricular systole. Degeneration of the mitral valve 10 or surrounding tissue may result in a gap 20 between the leaflets 18 during ventricular systole, resulting in regurgitation of blood into the left atrium. When severe, mitral regurgitation can lead to heart failure and abnormal heart rhythms.
[0005] Current methods of repairing the mitral valve 10 include the joining of the valve leaflets 18 a , 18 b at one or more locations to decrease the flow cross section and prevent valve regurgitation. This method is generally referred to as the Alfieri method. Currently known devices that permit the Alfieri method to be practiced percutaneously include devices for gripping the valve leaflets 18 a , 18 b and suturing them together. However, these percutaneous methods face considerable drawbacks due to the difficulty in grasping the valve leaflets due to their rapid movement. The methods also require adequate visualization of the valve which is difficult to achieve. Available visualization techniques using fluoroscopy can be difficult to use, since a sufficient bolus of contrast is difficult to administer. Echocardiography is likewise unable to provide adequate visualization of the mitral valve.
BRIEF SUMMARY OF THE INVENTION
[0006] These and other limitations are overcome by embodiments of the disclosure, which relates to apparatuses and methods for repairing a mitral valve, patent foramen ovale, or a puncture site in a blood vessel or wall of another body lumen are disclosed. In particular, apparatuses and methods are disclosed for inserting a portion of an inflatable member encircled by an elastically expandable member through the mitral valve, or other opening in a wall of a body lumen. The elastically expandable member bears projections adapted to penetrate the wall or valve. The inflatable member may be inflated to expand the expandable member. The inflatable member may then be drawn through the valve or opening such that the projections are driven into the valve or opening. The inflatable member may then be withdrawn and the expandable member allowed to contract in order to reduce the size of the opening in the valve or wall. The inflatable member may be deflated either before or after withdrawal.
[0007] In one aspect of the invention, the elastically expandable member includes a thin circuitous member defining a base line lying in a plane and circumscribing the inflatable member. The thin circuitous member may be bent to define a first plurality of peaks extending a first distance measured from the base line parallel to the inflatable member and a second plurality of peaks extending a second distance measured from the base line parallel to the inflatable member, the second distance being substantially greater than the first distance.
[0008] In another aspect of the invention, a catch is secured adjacent the inflatable member and has a diameter greater than that of an adjacent portion of the elastically expandable member when the inflatable member is not inflated.
[0009] In another aspect of the invention, the inflatable member includes a first portion and a second portion, the elastically expandable member encircling the first portion and the second portion having an inflated diameter substantially greater than the first portion.
[0010] Additional features and advantages of the disclosure will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] To further clarify some of the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0012] FIG. 1A is a partial cutaway view of a heart;
[0013] FIG. 1B is an illustration of a mitral valve;
[0014] FIG. 2 is a side view of a device for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0015] FIG. 3 is an isometric view of the device for implanting an elastically expandable member positioned within a mitral valve in accordance with an embodiment of the present invention;
[0016] FIG. 4 is a schematic diagram of an inflation system for use with the device for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0017] FIGS. 5A and 5B are isometric views of an elastically expandable member in accordance with an embodiment of the present invention;
[0018] FIG. 6 is a partial side view of the device for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0019] FIG. 7 is a front end view of the device for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0020] FIGS. 8A through 8F illustrate a method for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0021] FIG. 9 is a side view of a device for implanting an elastically expandable member having multiple inflatable portions in accordance with an embodiment of the present invention;
[0022] FIG. 10 is a schematic diagram of an inflation system for use with the device of FIG. 9 in accordance with an embodiment of the present invention;
[0023] FIGS. 11A through 11C illustrate another method for implanting an elastically expandable member in accordance with an embodiment of the present invention;
[0024] FIGS. 12A through 16B illustrate a method for implanting an elastically expandable member in an opening within a wall of a body lumen in accordance with an embodiment of the present invention;
[0025] FIG. 17 illustrates an alternative embodiment of an elastically expandable member in accordance with an embodiment of the present invention; and
[0026] FIGS. 18A through 18C illustrate a method for implanting the elastically expandable member of FIG. 17 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Embodiments of the invention relate to associating adjacent tissue including joining adjacent tissue. Tissue can be brought together by an expandable medical device that can be expanded during deployment. The device includes attachment means to grasp or connect to the adjacent tissue. The medical device then collapses to reduce in profile and bring adjacent tissue together. By way of example only, embodiments of the invention can be used to repair mitral valves, perform vessel closure, perform PFO (Patent Foramen Ovale) closure, and repair other septal defects.
[0028] Referring to FIG. 2 , an apparatus 30 for repairing a mitral valve may include an inflatable member 32 , an elastically expandable member 34 encircling or disposed around the inflatable member 32 , and a catheter 36 . The inflatable member 32 includes a distal end 40 and a proximal end 38 secured to the catheter. An inflation medium may be delivered through the catheter 36 to the inflatable member through the proximal end 38 . The inflatable member 32 may have an uninflated diameter less than that of the lumen of the catheter 36 .
[0029] A safety catch 42 may be secured near the distal end of the inflatable member 32 and prevent the expandable member 34 from sliding off of the inflatable member before placement as described hereinbelow. In some embodiments, the safety catch may cover a distal end 40 of the inflatable member 34 . The safety catch 42 may include a structure having an outer diameter greater than an undeformed outer diameter of the immediately adjacent portion of the inflatable member 34 to which it secures, such as near the distal end 40 thereof. For example, at least a length of the inflatable member 32 immediately adjacent the safety catch 42 may have a relaxed outer diameter less than the outer diameter of the safety catch. The length may be at least half as wide as the expandable member 34 along the longitudinal axis of the inflatable member 32 . The safety catch 42 preferably includes a structure having an outer diameter greater than an undeformed inner diameter of the expandable member 34 . Alternatively, the safety catch 42 has an outer diameter greater than an uninflated diameter of the inflatable member 32 . In the illustrated embodiment, the safety catch 42 is a cylindrical structure. However, other shapes having different cross section may be used having at least a portion therefore with a diameter greater than either the undeformed inner diameter of the expandable member 34 or the uninflated diameter of the inflatable member 32 .
[0030] The inflatable member 32 may define a lumen for receiving a guide wire 44 . The guide wire 44 may be guided to an operation site as known in the art. The catheter 36 and inflatable member 32 may then be guided along the guide wire 44 to the operation site. In some embodiments, the inflatable member 32 is positioned within the catheter 36 during insertion proximate the distal end 40 thereof during insertion of the catheter. In other embodiments, the catheter 36 is first inserted to the operation site after which the inflatable member 32 and expandable member 34 are fed through the catheter 36 to the operation site.
[0031] Referring to FIG. 3 , while still referring to FIG. 2 , the inflatable member 32 may bear markers 46 including a radiopaque material. Examples of biocompatible radiopaque materials include platinum, iridium, tungsten, tantalum, gold, and alloys thereof. In an alternative embodiment, the markers 46 are designed to be highly visible using echocardiography, such as by forming the markers 46 of a very dense material. The markers 46 may be elongate in shape having a direction of elongation extending parallel to a distal direction 48 in which the inflatable member 32 is moved during placement in the operation site as described hereinbelow.
[0032] During placement in a mitral valve 10 the radiopaque markers 46 are approximately aligned with a midline 50 of the mitral valve 10 using fluoroscopy or other visualization technique. For example, the inflatable member 32 may be inserted within the mitral valve 10 and then rotated into the position shown in FIG. 3 . Alternatively, the markers 46 may be positioned on or adjacent the midline 50 prior to insertion such that rotation is not necessary.
[0033] As is readily apparent, the high visibility of the markers 46 using fluoroscopic or echocardiographic imaging enables ready positioning of the inflatable member 32 without the need for detailed imaging of the mitral valve 10 . The opening between the leaflets 18 a , 18 b of the mitral valve 10 may be readily apparent using echocardiography or fluoroscopy equipment. The high visibility of the markers 46 therefore enables them to be readily aligned such that they both lie on a midline 50 perpendicular to the opening between the leaflets 18 a , 18 b.
[0034] Referring to FIG. 4 , inflatable member 32 may be inflated by means of a pressure source 52 external to the patient's body and coupled to the inflatable member 32 by means of a tube 54 extending from the pressure source 52 , through the catheter 36 , and to the inflatable member 32 . In some embodiments, the lumen 36 of the catheter provides a seal with the proximal end 38 of the inflatable member, such that a separate tube 56 is not needed within the catheter 36 . An inflation medium supplied from the source 52 may be controlled by a valve 56 that is selectively opened by the operator to inflate the inflatable member according to the method described hereinbelow. The valve 56 may also control selective release of the inflation medium from the inflation member 32 . In accordance with this invention, the inflation medium provided by pressure source 52 may be a gas or a liquid. For example, it may be any biocompatible gas, such as carbon dioxide, that is typically used in medical procedures, or it may be a fluid, such as saline, which also is also widely used in medical procedures such as those contemplated in this disclosure.
[0035] Referring to FIG. 5A , the expandable member 34 encircles the inflatable member 32 and elastically deforms as the inflatable member 32 is inflated. The expandable member 34 includes one or more projections 60 adapted to pierce the leaflets 18 a , 18 b of the mitral valve 10 . Accordingly, the projections 60 may have a converging profile such that the ends 62 of the projections 60 or of selected projections 60 are sharp enough to readily penetrate the leaflets 18 a , 18 b.
[0036] In the illustrated embodiment, the expandable member 34 is formed from a thin elastic material bent or shaped to form first peaks 64 and second peaks 66 . For example, the expandable member 34 may be formed from a resilient wire including a material such as nitinol.
[0037] Referring to FIG. 5B , in some embodiments the peaks 66 are not themselves expandable in order to reduce tissue spreading when the expandable member 34 is inserted into the leaflets 18 a , 18 b . As shown in FIG. 5B , in such embodiments, the peaks 66 may be secured to the expandable member due to monolithic formation therewith or by means of welding. Alternatively, peaks 66 may be formed by undulations in the expandable member that have been welded or otherwise fastened to prevent spreading of the peaks 66 when the expandable member 34 is expanded.
[0038] Referring to FIG. 6 , the second peaks 66 may be longer than the first peaks 64 and serve as the projections 60 for piercing the leaflets 18 a , 18 b of the mitral valve or of the tissue to be closed, joined, or associated. The second peaks 66 may include one or more beveled edges 70 at their ends to provide a sharper point for penetrating the leaflets 18 a , 18 b or for penetrating other tissue, such as vessel walls by way of example only. The second peaks 66 may be separated from one another by means of one or more first peaks 64 . The expandable member 34 may define a base line 68 , which is a base circle 68 in the illustrated embodiment. However, the base line 68 may have any shape forming a closed loop. The base line 68 lies in a plane perpendicular to the longitudinal axis of the inflatable member 32 , or in other words perpendicular to the distal direction 48 .
[0039] The first peaks 64 may extend up to a first distance 72 from the base circle 68 and the second peaks 66 may extend at least a second distance 74 from the base circle 68 . The second distance 74 may be substantially greater than the first distance 72 . For example, the second distance 74 may be between 1.1 and 2 times the first distance 72 , or between about 1.2 and 1.6 times the first distance 72 . The second distance 74 may also be measured relative to the diameter of base circle 68 . For example, second distance 74 may be between about 0.3 and 0.8 of the diameter of base circle 68 , although any ratio may be contemplated within this invention.
[0040] The second peaks 66 may also project away from the inflatable member 32 with distance from the base circle 68 . For example, the second peaks 66 may define an angle 76 with respect to the inflatable member that is between 5 and 25 degrees, or between about 5 and 15 degrees. The angled second peaks 66 enable the member to engage the tissue to be joined by providing a separation between the second peaks 66 and the inflatable member 32 . The angle 76 may also change as the expandable member is expanded by the inflatable member.
[0041] Referring to FIG. 7 , in the illustrated embodiments, the second peaks 66 are positioned an angular distance 78 from the markers 46 such that they will be adjacent to the leaflets 18 a , 18 b when the markers 46 are aligned with the midline 50 of the mitral valve 10 . For example, projections 60 may be within an angular distance 78 from the marker 46 equal to between about 5 and 30 degrees, or between about 5 and 15 degrees. In the illustrated embodiment, at least two of the projections 60 engage each leaflet 18 a , 18 b . However, in other embodiments, at least three or more projections 60 may engage each leaflet 18 a , 18 b . In some embodiments, some of the first peaks 64 may also engage the tissue in certain instances.
[0042] For example, the device 30 illustrated in FIGS. 2-7 depict an expandable medical device 30 in both an expanded an unexpanded state. In an unexpanded state, the device is positioned at an operational site, such as at a mitral valve. The device 30 can include a generally tubular body formed from a material such as a shape memory material as described below. The device 30 may comprise a ring that may be circular in shape. One will appreciate that the device 30 can include a pattern or configuration that permits the device 30 to be placed into a delivery configuration having a first diameter and radially expanded to at least a deployment configuration having a second, larger diameter as explained in greater detail below. In one embodiment, the first diameter corresponds to an unconstrained configuration of the device 30 and the device 30 may be configured to return to the unconstrained configuration after being subject to a deforming force, such as applied by the inflatable member to expand the device 30 during deployment.
[0043] The device 30 can have a serpentine or undulating configuration formed from a plurality of peaks and corresponding valleys. As previously described, some of the peaks are longer than other peaks. As illustrated in FIG. 5 , for example, the projections 60 may correspond to peaks that are longer that other peaks. These peaks are also configured to engage tissue in order to bring adjacent tissue closer together. The serpentine or undulating configuration can be sinusoidal, triangular, square, and the like. In some instances, the serpentine or undulating configuration can include multiple shapes that are repeated in series and/or have a similar shape that varies in size.
[0044] A device 30 such as is described with respect to FIGS. 2 through 7 , may be used in accordance with a method illustrated in FIGS. 8A through 8F . Referring specifically to FIG. 8A , a portion of the inflatable member 32 encircled by the expandable member 34 is urged through the mitral valve 10 into the left ventricle 14 along the distal direction 48 such that the proximal end 38 and distal end 40 of the inflatable member 32 are positioned on opposite sides of the mitral valve 10 . In some embodiments, the inflatable member 32 is extended from the catheter 36 prior to insertion through the mitral valve 10 . In other embodiments, the catheter 36 is inserted through the mitral valve 10 and then withdrawn as the inflatable member 32 is forced out of the catheter 36 , leaving the inflatable member in the position shown in FIG. 8A .
[0045] Referring to FIG. 8B , the inflatable member 32 may then be inflated in order to expand the expandable member 34 . Expansion of the inflatable member 32 may also aid in positioning of the leaflets 18 a , 18 b of the mitral valve 10 , which would otherwise be prone to rapid movement responsive to beating of the heart 12 . In some embodiments inflation of the inflatable member 32 results in an inflated diameter that is between 1.5 and three times either the uninflated diameter of the inflatable member 32 or the inner diameter of the lumen of the catheter 36 . In one embodiment, the inflated diameter is between about two and three times either the uninflated diameter of the inflatable member 32 or the inner diameter of the catheter 36 .
[0046] Referring to FIG. 8C , the inflatable member 32 and expandable member 34 may then be urged in proximal direction 80 such that at least some of the projections 60 penetrate the leaflets 18 a , 18 b of the mitral valve 10 . In some embodiments, only the second peaks 66 penetrate into the leaflets 18 a , 18 b . In other embodiments, some of the first peaks 64 also penetrate the leaflets 18 a , 18 b.
[0047] Referring to FIG. 8D , the inflatable member 32 may then be urged further along the proximal direction 80 such that the expandable member 34 is moved off of the inflatable member 32 . The inflatable member 32 may be partially or completely deflated prior to urging the inflatable member 32 away from the expandable member 34 . For example, the inflatable member 32 may remain partially inflated such that the partially inflated diameter is greater than a largest outer diameter of the safety catch 42 such that the expandable member 34 is able to slide over the catch 42 .
[0048] Referring to FIG. 8E , following removal of the inflatable member 32 , the expandable member 34 may contract due to biasing forces within the expandable member 34 . As shown in FIG. 8F , contraction of the expandable member 34 tends to draw the leaflets 18 a , 18 b together, thereby reducing mitral valve regurgitation. In some embodiments, two or more expandable members 34 may be placed within a mitral valve according to the method illustrated in FIGS. 8A through 8F in order to further reduce regurgitation.
[0049] Referring to FIG. 9 , in an alternative embodiment, the inflatable member 32 includes a first portion 90 and a second portion 92 . The first portion 90 is located nearer the proximal end 38 and the second portion 92 is located nearer the distal end 40 of the inflatable member 32 . The second portion 92 has an inflated diameter 94 that is larger than the inflated diameter 96 of the first portion. For example, the inflated diameter 94 of the second portion 92 may be between 1.3 and four times, or between about 1.4 and two times, the inflated diameter 96 of the first portion 90 . Inasmuch as the left ventricle has a profile that is considerably larger than the mitral valve diameter a device may be used with a second portion 92 having diameter that is considerably larger than the ranges specified above.
[0050] The uninflated diameters of both the first portion 90 and second portion 92 may both be less than an inner diameter of the lumen of the catheter 36 . In the illustrated embodiment, the second portion 92 also has a longer length 98 along the distal direction 48 than the length 100 of the first portion. For example, the inflated length 98 of the second portion 92 may be between 1.3 and four times, or between about 1.4 and two times the length 100 of the first portion. However, it will be appreciated that the left ventricle has a length that is considerably greater than the left atrium length and therefore a device may be used with a second portion 92 diameter that is considerably larger than the ranges specified above. The first portion 90 and second portion 92 may be in fluid communication with one another or may be isolated from one another and filled by means of separately controlled inflation channels extending through the catheter 36 .
[0051] Referring to FIG. 10 , in embodiments where the first portion 90 and second portion 92 are separate chambers, each portion 90 , 92 , may be coupled to a separate inflation line 54 a , 54 b coupled to the pressure source 52 and controlled by separate valves 56 a , 56 b , respectively to allow inflation medium to enter and leave the portions 90 , 92 . By selectively opening and closing one or both of the valves 56 a , 56 b , the diameters of the portions 90 , 92 may be independently controlled in order to deploy the expandable member 34 according to the methods described hereinbelow.
[0052] Referring to FIG. 11A , following insertion of the apparatus 30 into the mitral valve 10 , such as is shown in FIG. 8A , the portions 90 and 92 may be inflated such that the diameter of the second portion 92 is substantially greater than that of the first portion 90 . The difference in the diameters of the first portion 90 and second portion 92 may be sufficiently large to prevent the expandable member 34 from sliding toward the distal end 40 .
[0053] Referring to FIG. 11B , the inflatable member 32 and expandable member 34 may then be drawn in the proximal direction 80 a sufficient distance that the projections 60 of the expandable member 34 penetrate the leaflets 18 a , 18 b of the mitral valve 10 . The portions 90 and 92 may then be deflated as shown in FIG. 11C and the inflatable member 32 drawn in the proximal direction 80 , leaving the expandable member in the position shown in FIG. 8F . In some instances, the second portion 92 can be used to push the projections 60 into the leaflets 18 a and 18 b prior to being deflated. This can ensure that the device 30 is securely engaged with the tissue to be brought together.
[0054] Referring to FIG. 12A through 15B , the apparatus 30 may also be used for associating other types of tissue. For example, the apparatus may be used to close a patent foramen ovale (PFO), a septal defect, or a puncture site in a wall of a body lumen, such as a blood vessel.
[0055] Referring to FIGS. 12A and 12B , an opening 110 in a wall 112 of tissue may be irregular in shape, particularly if formed as the result of accidental trauma. The wall 112 may represent the wall of a blood vessel, organ, the atrial or ventricular septum of the heart, or other structure. The inflatable member 32 and expandable member may be inserted through the opening 110 , as shown in FIG. 12B , such that the distal end 40 and expandable member 34 are located on an opposite side of the wall 112 than the proximal end 38 .
[0056] Referring to FIGS. 13A and 13B , the inflatable member 32 may then be inflated to substantially and/or partially occupy the entire opening 110 (e.g. between 70% and 100%, preferably greater than 90%, of the opening). Where the inflatable member 32 has a first portion 90 and second portion 92 with different inflated diameters, inflating the inflatable member may include inflating both portions 90 and 92 .
[0057] Referring to FIG. 14 , the inflatable member 32 may then be urged in the proximal direction 80 such that the peaks 60 of the expandable member 34 are urged into the wall 112 . The expandable member 34 may be the same as in other embodiments described herein. In some embodiments, where the expandable member is used for closing apertures other than the mitral valve, the projections 60 , such as the second peaks 66 , may be distributed along the entire circumference of the expandable member at regular intervals (e.g. between 15 and 45 degrees). In some embodiments, after the expandable member 34 is urged into the wall 112 , the inflatable member 32 may be further inflated (as shown by the dotted lines in FIG. 14 ) in order to prevent bleeding through the opening 110 .
[0058] Referring to FIG. 15 , after the expandable member 34 is implanted in the wall 112 , the inflatable member 32 may then be deflated and withdrawn along the proximal direction 80 to leave the expandable member 34 in the configuration shown in FIGS. 16A and 16B . As is readily apparent, the expandable member 34 is able to significantly decrease the size of the opening 110 , despite the irregular shape of the opening 110 .
[0059] The expandable member 34 , of the present invention can be made of a variety of materials, such as, but not limited to, those materials which are well known in the art of medical device manufacturing. Generally, the materials for the expandable member 34 can be selected according to the structural performance and biological characteristics that are desired. Materials well known in the art for preparing medical devices (e.g., endoprostheses), such as polymers and metals, can be employed in preparing the expandable member 34 .
[0060] In one embodiment, the medical device can include a material made from any of a variety of known suitable materials, such as a shaped memory material (“SMM”) or superelastic material. For example, the SMM can be shaped in a manner that allows for restriction to induce a substantially tubular, linear orientation while within a delivery shaft (e.g., delivery catheter or encircling an expandable member), but can automatically retain the memory shape of the medical device once extended from the delivery shaft. SMMs have a shape memory effect in which they can be made to remember a particular shape. Once a shape has been remembered, the SMM may be bent out of shape or deformed and then returned to its original shape by unloading from strain or heating. SMMs can be shape memory alloys (“SMA”) or superelastic metals comprised of metal alloys, or shape memory plastics (“SMP”) comprised of polymers.
[0061] An SMA can have any non-characteristic initial shape that can then be configured into a memory shape by heating the SMA and conforming the SMA into the desired memory shape. After the SMA is cooled, the desired memory shape can be retained. This allows for the SMA to be bent, straightened, compacted, and placed into various contortions by the application of requisite forces; however, after the forces are released, the SMA can be capable of returning to the memory shape. The main types of SMAs are as follows: copper-zinc-aluminium; copper-aluminium-nickel; nickel-titanium (“NiTi”) alloys known as nitinol; and cobalt-chromium-nickel alloys or cobalt-chromium-nickel-molybdenum alloys known as elgiloy. The nitinol and elgiloy alloys can be more expensive, but have superior mechanical characteristics in comparison with the copper-based SMAs. The temperatures at which the SMA changes its crystallographic structure are characteristic of the alloy, and can be tuned by varying the elemental ratios.
[0062] For example, the primary material of the expandable member 34 can be of a NiTi alloy that forms superelastic nitinol. Nitinol materials can be trained to remember a certain shape, straightened in a shaft, catheter, or other tube, and then released from the catheter or tube to return to its trained shape. Also, additional materials can be added to the nitinol depending on the desired characteristic.
[0063] An SMP is a shape-shifting plastic that can be fashioned into the expandable member 34 in accordance with the present invention. When an SMP encounters a temperature above the lowest melting point of the individual polymers, the blend makes a transition to a rubbery state. The elastic modulus can change more than two orders of magnitude across the transition temperature (“T tr ”). As such, an SMP can be formed into a desired shape of expandable member 34 by heating it above the T tr , fixing the SMP into the new shape, and cooling the material below T tr . The SMP can then be arranged into a temporary shape by force and then resume the memory shape once the force has been applied. Examples of SMPs include, but are not limited to, biodegradable polymers, such as oligo(ε-caprolactone)diol, oligo(ρ-dioxanone)diol, and non-biodegradable polymers such as, polynorborene, polyisoprene, styrene butadiene, polyurethane-based materials, vinyl acetate-polyester-based compounds, and others yet to be determined. As such, any SMP can be used in accordance with the present invention.
[0064] Also, it can be beneficial to include at least one layer of an SMA and at least one layer of an SMP to form a multilayered body; however, any appropriate combination of materials can be used to form a multilayered medical device.
[0065] The expandable member 34 can be comprised of a variety of known suitable deformable materials, including stainless steel, silver, platinum, tantalum, palladium, cobalt-chromium alloys such as L605, MP35N, or MP20N, niobium, iridium, any equivalents thereof, alloys thereof, and combinations thereof. The alloy L605 is understood to be a trade name for an alloy available from UTI Corporation of Collegeville, Pa., including about 53% cobalt, 20% chromium and 10% nickel. The alloys MP35N and MP20N are understood to be trade names for alloys of cobalt, nickel, chromium and molybdenum available from Standard Press Steel Co., Jenkintown, Pa. More particularly, MP35N generally includes about 35% cobalt, 35% nickel, 20% chromium, and 10% molybdenum, and MP20N generally includes about 50% cobalt, 20% nickel, 20% chromium and 10% molybdenum.
[0066] Also, the expandable member 34 can include a suitable biocompatible polymer in addition to or in place of a suitable metal. The polymeric expandable member 34 can include a biocompatible material, such as biostable, biodegradable, or bioabsorbable materials, which can be either plastically deformable or capable of being set in the deployed configuration. If plastically deformable, the material can be selected to allow the medical device (e.g., stent) to be expanded in a similar manner using an expandable member so as to have sufficient radial strength and scaffolding and also to minimize recoil once expanded. If the polymer is to be set in the deployed configuration, the expandable member 34 can be provided with a heat source or infusion ports to provide the required catalyst to set or cure the polymer. Biocompatible polymers are well known in the art, and examples are recited with respect to the polymeric matrix. Thus, the expandable member 34 can be prepared from a biocompatible polymer.
[0067] Moreover, the expandable member 34 can include a radiopaque material to increase visibility during placement. Optionally, the radiopaque material can be a layer or coating any portion of the expandable member 34 . The radiopaque materials can be platinum, tungsten, silver, stainless steel, gold, tantalum, bismuth, barium sulfate, or a similar material.
[0068] Referring to FIG. 17 , in some embodiments the expandable member 34 may be embodied as a ring member 120 having a single projection 122 with a sharpened distal tip 124 . The ring member 120 may include an elastic material that can expand upon inflation of the inflatable member 32 . The ring member may also be formed of an undulating wire or other thin member in order to facilitate expansion upon inflation. The single projection 122 may have a relaxed of shape-memory shape that is curved in shape.
[0069] As shown in FIGS. 18A and 18B , the expandable member 34 of FIG. 17 may be placed on an inflatable member 32 , such as any of the inflatable members illustrated herein. Upon inflation of the inflatable member 32 , the projection 122 is urged into a straightened configuration such that the sharpened distal tip 124 may be urged in the distal direction 40 through one of the leaflets 18 a . Referring to FIG. 18C , upon deflation of the inflatable member 32 , the projection 122 is allowed to relax to its circular configuration, causing the sharpened distal tip 124 to be driven through the opposing leaflet 18 b . The inflatable member 32 may then be removed.
[0070] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Apparatuses and methods are disclosed for reducing the size of openings within a heart valve or other opening in the wall of a body lumen by implanting an elastically expanded member around the opening and then permitting the expandable member to contract. The expandable member may encircle a portion of an inflatable member, the distal end of which is inserted through the opening along with the expandable member. The inflatable member is inflated to expand the expandable member and then drawn proximally form the opening to drive projections formed on the expandable member into the valve or wall. The inflatable member is then withdrawn, allowing the expandable member to elastically contract. The inflatable member may have first and second stages, where the second stage is distal of the first stage and has a larger inflated diameter. | 0 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to computed tomography (CT) imaging apparatus; and more particularly, to a method for reconstructing images from acquired x-ray attenuation measurements.
[0002] In a current computed tomography system, an x-ray source projects a fan-shaped beam which is collimated to lie within an X-Y plane of a Cartesian coordinate system, termed the “imaging plane.” The x-ray beam passes through the object being imaged, such as a medical patient, and impinges upon an array of radiation detectors. The intensity of the transmitted radiation is dependent upon the attenuation of the x-ray beam by the object and each detector produces a separate electrical signal that is a measurement of the beam attenuation. The attenuation measurements from all the detectors are acquired separately to produce the transmission profile.
[0003] The source and detector array in a conventional CT system are rotated on a gantry within the imaging plane and around the object so that the angle at which the x-ray beam intersects the object constantly changes. A group of x-ray attenuation measurements from the detector array at a given angle is referred to as a “view” and a “scan” of the object comprises a set of views made at different angular orientations during one revolution of the x-ray source and detector. In a 2D scan, data is processed to construct an image that corresponds to a two dimensional slice taken through the object. The prevailing method for reconstructing an image from 2D data is referred to in the art as the filtered backprojection technique. This process converts the attenuation measurements from a scan into integers called “CT numbers” or “Hounsfield units”, which are used to control the brightness of a corresponding pixel on a display.
[0004] The term “generation” is used in CT to describe successively commercially available types of CT systems utilizing different modes of scanning motion and x-ray detection. More specifically, each generation is characterized by a particular geometry of scanning motion, scanning time, shape of the x-ray beam, and detector system.
[0005] As shown in FIG. 1 , the first generation utilized a single pencil x-ray beam and a single scintillation crystal-photomultiplier tube detector for each tomographic slice. After a single linear motion or traversal of the x-ray tube and detector, during which time 160 separate x-ray attenuation or detector readings are typically taken, the x-ray tube and detector are rotated through 1° and another linear scan is performed to acquire another view. This is repeated typically to acquire 180 views.
[0006] A second generation of devices developed to shorten the scanning times by gathering data more quickly is shown in FIG. 2 . In these units a modified fan beam in which anywhere from three to 52 individual collimated x-ray beams and an equal number of detectors are used. Individual beams resemble the single beam of a first generation scanner. However, a collection of from three to 52 of these beams contiguous to one another allows multiple adjacent cores of tissue to be examined simultaneously. The configuration of these contiguous cores of tissue resembles a fan, with the thickness of the fan material determined by the collimation of the beam and in turn determining the slice thickness. Because of the angular difference of each beam relative to the others, several different angular views through the body slice are being examined simultaneously. Superimposed on this is a linear translation or scan of the x-ray tube and detectors through the body slice. Thus, at the end of a single translational scan, during which time 160 readings may be made by each detector, the total number of readings obtained is equal to the number of detectors times 160. The increment of angular rotation between views can be significantly larger than with a first generation unit, up to as much as 36°. Thus, the number of distinct rotations of the scanning apparatus can be significantly reduced, with a coincidental reduction in scanning time. By gathering more data per translation, fewer translations are needed.
[0007] To obtain even faster scanning times it is necessary to eliminate the complex translational-rotational motion of the first two generations. As shown in FIG. 3 , third generation scanners therefore use a much wider fan beam. In fact, the angle of the beam may be wide enough to encompass most or all of an entire patient section without the need for a linear translation of the x-ray tube and detectors. As in the first two generations, the detectors, now in the form of a large array, are rigidly aligned relative to the x-ray beam, and there are no translational motions at all. The tube and detector array are synchronously rotated about the patient through an angle of 180-360°. Thus, there is only one type of motion, allowing a much faster scanning time to be achieved. After one rotation, a single tomographic section is obtained.
[0008] Fourth generation scanners feature a wide fan beam similar to the third generation CT system as shown in FIG. 4 . As before, the x-ray tube rotates through 360° without having to make any translational motion. However, unlike in the other scanners, the detectors are not aligned rigidly relative to the x-ray beam. In this system only the x-ray tube rotates. A large ring of detectors are fixed in an outer circle in the scanning plane. The necessity of rotating only the tube, but not the detectors, allows faster scan time.
[0009] Most of the commercially available CT systems employ image reconstruction methods based on the concepts of Radon space and the Radon transform. For the pencil beam case, the data is automatically acquired in Radon space. Therefore a Fourier transform can directly solve the image reconstruction problem by employing the well-known Fourier-slice theorem. Such an image reconstruction procedure is called filtered backprojection (FBP). The success of FBP reconstruction is due to the translational and rotational symmetry of the acquired projection data. In other words, in a parallel beam data acquisition, the projection data are invariant under a translation and/or a rotation about the object to be imaged. For the fan beam case, one can solve the image reconstruction problem in a similar fashion, however, to do this an additional “rebinning” step is required to transform the fan beam data into parallel beam data. The overwhelming acceptance of the concepts of Radon space and the Radon transform in the two dimensional case gives this approach to CT image reconstruction a paramount position in tomographic image reconstruction.
[0010] The Radon space and Radon transformation reconstruction methodology is more problematic when applied to three-dimensional image reconstruction. Three-dimensional CT, or volume CT, employs an x-ray source that projects a cone beam on a two-dimensional array of detector elements as shown in FIG. 5 . Each view is thus a 2D array of x-ray attenuation measurements and a complete scan produced by acquiring multiple views as the x-ray source and detector array are revolved around the subject results in a 3D array of attenuation measurements. The reason for this difficulty is that the simple relation between the Radon transform and the x-ray projection transform for the 2D case in not valid in the 3D cone beam case. In the three-dimensional case, the Radon transform is defined as an integral over a plane, not an integral along a straight line. Consequently, we have difficulty generalizing the success of the Radon transform as applied to the 2D fan beam reconstruction to the 3D cone beam reconstruction. In other words, we have not managed to derive a shift-invariant FBP method by directly rebinning the measured cone beam data into Radon space. Numerous solutions to this problem have been proposed as exemplified in U.S. Pat. Nos. 5,270,926; 6,104,775; 5,257,183; 5,625,660; 6,097,784; 6,219,441; and 5,400,255.
SUMMARY OF THE INVENTION
[0011] The present invention is a method for reconstructing an image from fan beam attenuation measurements that does not rely on the Radon transformation method. A general method for reconstructing an image from fan beam projection views includes: calculating the derivative of each projection along the trajectory of the x-ray source; convolving the derivative data with a kernel function; back projecting the convolved data with a weight function; and add the back projected data to the image. A more specific application of this method to a third generation scanner having a circular x-ray source trajectory and either a flat or actuate detector array includes: filtering each acquired projection view by a first filter factor; backprojecting each resulting filtered view Q 1 (θ) with a first weight; adding the backprojected data to the image; filtering each acquired projection view by a second filter factor; backprojecting each resulting filtered view Q 2 (θ) with a second weight; and adding the backprojected data to this image. The image evolves as projection views are acquired and processed from a blurry and unrecognizable subject to a finished image.
[0012] A general object of this invention is to accurately reconstruct an image from a scan using a fan beam source and a detector array. Accurate images may be reconstructed when the source travels in a circular path around the object to be imaged or when the path is not circular.
[0013] Another object of the invention is to provide an image reconstruction method in which each acquired view is processed and added to an image. Rather than acquiring the entire raw data set and then reconstructing an image therefrom, the present invention enables each view to be processed as the scan is conducted. The image thus evolves as the scan is conducted.
[0014] Another object of the invention is to reduce the number of views needed to satisfy data sufficiency conditions. To meet this condition it is only necessary that the x-ray source travel around the object being imaged such that any straight line through the object in the plane of the x-ray source motion will intersect the x-ray source path. This means that when smaller objects are being imaged, views over a smaller range of view angles need be acquired to satisfy this sufficiency condition. This translates to less radiation exposure and is particularly advantageous for pediatric imaging.
[0015] The foregoing and other objects and advantages of the invention will appear from the following description. In the description, reference is made to the accompanying drawings which form a part hereof, and in which there is shown by way of illustration a preferred embodiment of the invention. Such embodiment. does not necessarily represent the full scope of the invention, however, and reference is made therefore to the claims and herein for interpreting the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIGS. 1-4 are schematic representations of different CT system geometries;
[0017] FIG. 5 is a pictorial representation of a 3D, or volume, CT system;
[0018] FIG. 6 is a schematic representation of a third generation CT system with a coordinate system used to generally describe the invention;
[0019] FIG. 7 is a schematic representation of a third generation CT system with coordinate system used to describe the application of the invention to one preferred embodiment;
[0020] FIG. 8 is a schematic representation of the CT system of FIG. 7 with additional variables shown;
[0021] FIG. 9 is a schematic representation of another third generation CT system with coordinate system used to describe the application of the invention to another preferred embodiment;
[0022] FIG. 10 is a schematic representation of a CT system region of interest with coordinates and variables used to explain the minimum gantry movement required during a scan;
[0023] FIG. 11 is a pictorial view of a CT system which employs the present invention;
[0024] FIG. 12 is a block diagram of the CT system of FIG. 11 ;
[0025] FIG. 13 is a flow chart of the steps performed by the CT system of FIGS. 11 and 12 to practice a preferred embodiment of the invention;
[0026] FIG. 14 is a pictorial representation of the FOV of the CT system of FIG. 7 used to explain weighting; and
[0027] FIG. 15 is a graphic representation of the weighting used in the method of FIG. 13 .
GENERAL DESCRIPTION OF THE INVENTION
[0028] The present invention is a new method for reconstructing images from acquired divergent beam projections. This method will be described with respect to 2D fan-beam projections, but the approach is also applicable to 3D cone beam projections.
[0029] We first define fan-beam projections {overscore (g)}({circumflex over (r)},{right arrow over (y)}) produced by an x-ray source 10 and a one-dimensional detector array 12 by a focal point vector {right arrow over (y)} and a unit ray vector {circumflex over (r)} as shown in FIG. 6
g → [ r ^ , y → ( t ) ] = ∫ 0 ∞ ⅆ s f [ y → ( t ) + s r ^ ] , ( 1 )
where the focal point vector {right arrow over (y)}(t) is parameterized by a single scalar parameter t which corresponds to view angle and s is the distance from the x-ray source along direction {circumflex over (r)}. A reconstructed image function f({right arrow over (x)}) of a finite object 14 is assumed to have a compact support Ω. After we measure the data {overscore (g)}({circumflex over (r)}, {right arrow over (y)}), we backproject the data along the ray with a weight 1/r, where r is the distance from the backprojected point to the x-ray source position. Namely, we have:
g ( r ^ , y → ) = 1 r g → ( r ^ , y → ) = ∫ 0 ∞ ⅆ s f [ y → ( t ) + s r → ] ( 2 )
where we decompose a vector into its magnitude and a unit vector which is denoted by a hat, e.g., {right arrow over (r)}=r{right arrow over (r)}. This backprojection procedure provides a two-dimensional array of the backprojected data.
[0032] Rather than invoke the two-dimensional Radon inversion formula, we are going to use the Fourier transform and the inverse Fourier transform of image function f({right arrow over (x)}). However, for the divergent beam problem, we lose the translational symmetry of the parallel beam problem. Therefore, we need an intermediate function to connect the projections g({right arrow over (r)}, {right arrow over (y)}) defined in the Eq. (1) with the Fourier transform of the image function f({right arrow over (x)}). To accomplish this goal, we now define an intermediate function G 2 ({right arrow over (k)},{right arrow over (y)}) by taking a local Fourier transform for the vector {right arrow over (r)} in fan beam projections g({right arrow over (r)}, {right arrow over (y)}).
G 2 ( k → , y → ) = ∫ ⅆ 2 r → g ( r → , y → ) ⅇ - ⅈ 2 π k → · r → , = ∫ 0 ∞ ⅆ s ∫ ⅆ 2 r → f ( y → + s r → ) ⅇ - ⅈ2 π k → · r → , = ∫ 0 ∞ ⅆ s s 2 ⅇ - ⅈ2 π k → · y → / s ∫ ⅆ 2 z → f ( z → ) ⅇ - ⅈ2 π k → · z → / s , = ∫ 0 ∞ ⅆ s s 2 ⅇ - ⅈ2 π k → · y → / s f ~ ( k → s ) . ( 3 )
In the last two lines, we introduced a new variable {right arrow over (z)} and Fourier transform for object function f({right arrow over (x)}) as
z → = y → + s r → , ( 4 ) f ( k → ) = ∫ ⅆ 2 x → f ( x → ) ⅇ ⅈ2 π k → · x → . ( 5 )
The scaling property set forth in Eq. (2) of fan beam projections is nicely preserved in this intermediate function G 2 ({right arrow over (k)}, {right arrow over (y)}). That is
G 2 ( k → , y → ) = 1 k G 2 ( k ^ , y → ) . ( 6 )
To further simplify Eq. (3), we change variables from s to τ through τ=k/s. One obtains
G 2 ( k → , y → ) = 1 k ∫ 0 ∞ ⅆ τ f ~ ( τ k ^ ) ⅇ - ⅈ2 π k ^ · y → , = 1 k ∫ 0 ∞ ⅆ τ f ~ ( τ → ) ⅇ - ⅈ2 π τ → · y → , ( 7 )
where {right arrow over (τ)}τ{circumflex over (k)} has been introduced. A comparison of Eq. (7) with Eq. (6) gives
G 2 ( k ^ , y → ) = ∫ 0 ∞ ⅆ τ f ~ ( τ → ) ⅇ ⅈ2 π τ → · y → . ( 8 )
This form of the intermediate function G 2 is very suggestive. It is reminiscent of an inverse Fourier transform of object function f({right arrow over (x)}) in a polar coordinate system. To make this more apparent, we take the partial derivative with respect to the source trajectory parameter t for both sides of Eq. (8).
1 ⅈ2 π k ^ · y → ′ ( t ) ∂ ∂ t G 2 [ k ^ , y → ( t ) ] = ∫ 0 ∞ ⅆ ττ f ~ ( τ → ) ⅇ ⅈ2 π τ → · y → . ( 9 )
We now can see that the right hand side of the equation is exactly the radial part of an inverse Fourier transform of the image function. The next step is to integrate the above equation over the polar angle φ k of unit vector {circumflex over (k)}, that is
∫ 0 2 π ⅆ ϕ k ∫ 0 ∞ ⅆ ττ f ~ ( τ → ) ⅇ ⅈ2 π τ → · y → = ∫ 0 2 π ⅆ ϕ k 1 ⅈ2 π k ^ · y → ′ ( t ) ∂ ∂ t G 2 [ k ^ , y → ( t ) ] . ( 10 )
If we impose the following condition,
{circumflex over (k)}·{right arrow over (x)}={circumflex over (k)}·{right arrow over (y)} ( t ), (11)
on source trajectory for each point {right arrow over (x)} within the region of interest (“ROI”) and an arbitrary unit vector {circumflex over (k)}, we can now safely replace the exponential factor in the right hand side (RHS) of equation (10) by exp(i2π{right arrow over (τ)}·{right arrow over (x)}). Thus, the RHS of equation (10) is the inverse Fourier transform. Therefore, we obtain the following general inversion formula for the fan beam projections,
f ( x → ) = ∫ 0 2 π ⅆ ϕ k 1 ⅈ2 π k ^ · y → ′ ( t ) ∂ ∂ t G 2 [ k ^ , y → ( t ) ] ❘ k ^ · [ x → - y → ( t ) ] = 0 . ( 12 )
This inversion formula is the first of our main results. It tells us that we can generally reconstruct the image f({right arrow over (x)}) from fan beam projections by three steps: first, calculating the intermediate function G 2 ; secondly, calculating the derivative of the intermediate function with respect to trajectory parameter t; finally, backprojecting the data with a weight 1/[2πi{circumflex over (k)}·{right arrow over (y)}′(t)].
[0042] The general inversion formula in Eq. (12) can be reformatted into a form in which the filtered back projection step is more apparent. First we look at the intermediate function G 2 ({circumflex over (k)},{right arrow over (y)}). The main goal is to reduce the two-fold integral in Eq. (3) to a single integral. To do so, we choose to work in a polar coordinate system in which vector {right arrow over (r)} is decomposed into {right arrow over (r)}=(r,φ r )=r{circumflex over (r)}. Thus the function G 2 ({circumflex over (k)},{right arrow over (y)}) can be calculated in the following way:
G 2 ( k ^ , y ⇀ ) = ∫ ⅆ 2 r ⇀ g ( r ⇀ , y ⇀ ) ⅇ - ⅈ2 n k ^ · r ^ , = ∫ 0 2 π ⅆ ϕ r ∫ 0 ∞ ⅆ rrg ( r r ^ , y ⇀ ) ⅇ - ⅈ2π r k ^ · r ^ , = ∫ 0 2 π ⅆ ϕ r g _ ( r ^ , y ⇀ ) ∫ 0 ∞ ⅆ rⅇ - ⅈ2π r k ^ · r ^ , = ∫ 0 2 π ⅆ ϕ r g _ ( r ^ , y ⇀ ) ∫ - ∞ + ∞ ⅆ ru ( r ) ⅇ - ⅈ2π r k ^ · r ^ , ( 13 )
where u(r) is the step function. From the second line to the third line we used the scaling property in Eq. (2). The inner integral in the last line of Eq. (13) is the Fourier transform of the step function. That is
∫ - ∞ + ∞ ⅆ ru ( r ) ⅇ - ⅈ2π k · ^ r ^ = 1 2 δ ( k ^ · r ^ ) + 1 i2 π k ^ · r ^ . ( 14 )
Note that both δ({circumflex over (k)}·{right arrow over (r)}) and 1/{circumflex over (k)}·{circumflex over (r)} are the degree −1 homogeneous functions and thus consistent with the scaling symmetry of G 2 ({circumflex over (k)},{right arrow over (y)}) in Eq. (6). A further simplification lies in the following observation: the first term is even under the transformation {circumflex over (k)}→−{circumflex over (k)}, but the second term is odd. We should also recognize that the factor {circumflex over (k)}·{right arrow over (y)}′(t) in the inversion formula Eq. (12) is odd under the above parity transformation on {right arrow over (k)}. Since the integration over {circumflex over (k)} is on a unit circle, we conclude that the contribution of the delta function term in the inversion formula Eq. (12) vanishes due to this parity symmetry on {circumflex over (k)}. Therefore, we only need to keep the second term in Eq. (14) for the inversion formula Eq. (12). That is,
G 2 ( k ^ , y ⇀ ) = 1 2 π i ∫ 0 2 π ⅆ ϕ r g _ ( r ^ , y ⇀ ) k ^ · r ^ . ( 15 )
We emphasize again that the above equation is valid up to non-vanishing contribution in the inversion formula (12).
[0046] An examination of the general inversion formula Eq. (12) reveals that for a specific point {right arrow over (x)} in the ROI and a specific unit vector {circumflex over (k)}, it is possible that there are several points t i (i=1, 2, . . . ) along the source trajectory satisfying Eq. (11). In other words, redundant data is acquired during the scan. In principle, any t i could be used in Eq. (12). Namely we can use only one projection and discard all the redundant others. However, such weighting scheme is not the optimal solution in practice. Here we keep a most general functional form with all the possible parameters for the weighting function. Since the possible solutions of Eq. (11) strongly depend on {right arrow over (x)} and {circumflex over (k)}, a most general form of the weighting function is w({right arrow over (x)},{circumflex over (k)};t i ). This general form of the weighting function provides the opportunity to design new weighting methods. Two such methods will be described below. Physically, we impose the following normalization condition on w({right arrow over (x)},{circumflex over (k)};t i ):
∑ i = 1 n ( x ⇀ , k ^ ) w ( x ⇀ , k ^ ; t i ) = 1. ( 16 )
where n({right arrow over (x)},{circumflex over (k)}) is the total number of redundant projections for Eq. (11). After taking this data redundancy into account, the general inversion formula (12) is modified into the following:
f ( x ⇀ ) = ∫ 0 2 π ⅆ ϕ k ∑ j = 1 n ( x ⇀ , k ^ ) w ( x ⇀ , k ^ ; t i ) i2 π k ^ · y ⇀ ′ ( t j ) ∂ ∂ q G 2 [ k ^ , y ⇀ ( q ) ] ❘ q = t j , ( 17 )
This modified general inversion formula takes the average of all redundant projections that satisfy Eq. (11).
[0049] Equation (17) is not very convenient in practice because of the summation procedure it requires. We can eliminate the summation by using a trick widely used in physics and signal processing. The idea is to change a summation over discrete points into an integral over a continuous variable. To be more specific, we use the well-known identity of Dirac delta function:
∫ - ∞ + ∞ ⅆ tf ( t ) δ [ g ( t ) ] = ∑ i f ( t i ) g ′ ( t i ) , g ′ ( t i ) ≠ 0 ( 18 )
where t i (i=1, 2, . . . ) are the roots of equation g(t)=0. We now set function f(t) and g(t) as
f ( t ) = sgn [ k ^ · y ⇀ ′ ( t ) ] w ( x ⇀ , k ^ ; t ) ∂ ∂ q G 2 ( k ^ , y ⇀ ( q ) ) q = t , ( 19 ) g ( t ) = k ^ · [ x ⇀ - y ⇀ ( t ) ] . ( 20 )
Using Eq. (18), the summation in Eq. (17) can be written into an integral over the parameter t of the source trajectory. That is,
f ( x ⇀ ) = 1 2 π i ∫ 0 2 π ⅆ ϕ k ∫ ⅆ tw ( x ⇀ , k ^ ; t ) x sgn [ k ^ · y ⇀ ′ ( t ) ] ∂ ∂ q G 2 ( k ^ , y ⇀ ( q ) ❘ q = t δ [ k ^ · ( x ⇀ - y ⇀ ( t ) ) ] , ( 21 ) = 1 2 π i ∫ ⅆ t ∫ 0 2 π ⅆ ϕ k w ( x ⇀ , k ^ ; t ) x ⇀ - y ⇀ ( t ) sgn [ k ^ · y ⇀ ′ ( t ) ] ∂ ∂ q G 2 ( k ^ , y ⇀ ( q ) ) ❘ q = t δ ( k ^ · β ^ ) ,
where we used a simple relation |x|=sgn(x)x. The unit vector {circumflex over (β)} in Eq. (21) is defined as
β ^ = x ⇀ - y ⇀ ( t ) x ⇀ - y ⇀ ( t ) . ( 22 )
From the first line to the second line in Eq. (21), we used the scaling property of Dirac delta function δ(ax)=δ(x)/|a|. Due to the Dirac delta function δ({circumflex over (k)}·{circumflex over (β)}, the integral over unit vector {circumflex over (k)} can now be easily performed. The result is
f ( x ⇀ ) = 1 2 π i ∫ ⅆ t w ( x ⇀ , β ^ 1 _ ; t ) x ⇀ - y ⇀ ( t ) sgn [ β ^ 1 _ · y ⇀ ′ ( t ) ] ∂ ∂ q G 2 [ β ^ 1 _ , y ⇀ ( q ) ] ❘ q = t , ( 23 )
where {circumflex over (β)} ⊥ is a unit vector perpendicular to {circumflex over (β)},
[0055] With Eq. (23) and Eq. (15) in hand, we obtain the following fan beam reconstruction formula.
f ( x ⇀ ) = - 1 4 π 2 ∫ ⅆ t w ( β ^ ⊥ x ⇀ ; t ) x ⇀ - y ⇀ ( t ) sgn [ β ^ ⊥ · y ⇀ ′ ( t ) ] ∫ 0 2 π ⅆ ϕ r 1 β ^ ] · r ^ ∂ ∂ q g [ r ^ , y ⇀ ( q ) ] ❘ q = t . ( 24 )
Therefore, after we replace the summation over the redundant data by the integral along the source trajectory, we end up with the reconstruction formula (24). This reconstruction formula is general because we did not specify any x-ray source trajectory nor any detector configuration. As soon as the trajectory of the x-ray source about the subject satisfies the data sufficiency condition, inversion formula (24) produces an accurate reconstruction of the acquired attenuation measurements.
[0057] To see the FBP structure in formula (24), we note that, in an arbitrary polar coordinate system, we have
{circumflex over (β)} ⊥ {circumflex over (r)} =cos(φ β ⊥ −φ r ) (25)
where φ β ⊥ and φ r are the polar angle of the corresponding unit vectors {circumflex over (β)} ⊥ , {circumflex over (r)} respectively. Therefore, the implementation of Eq. (24) requires the following steps:
1. Calculate the derivative of each projection along the trajectory of the x-ray source; 2. Convolve the derivative data with the kernel function 1/{circumflex over (β)} ⊥ ·{circumflex over (r)}; 3. Backproject the convolved data with weight w({circumflex over (β)} ⊥ ,{right arrow over (x)}; t)sgn[{circumflex over (β)} ⊥ ·{right arrow over (y)}′(t)/|{right arrow over (x)}−{right arrow over (y)}(t)|; and 4. Add the backprojected data to an image.
[0063] As views are acquired, processed and added to the image, the image evolves from a blurry, unrecognizable subject to a finished image.
[0064] We now apply this reconstruction method to a specific scanning configuration. As shown in FIG. 7 a third generation scanner having an x-ray source 10 at a radius R emits a fan beam over angle γ m which is received by an arc detector 12 . In the Cartesian coordinate system shown in FIG. 7 , a point {right arrow over (x)} in the image of the ROI and focal point {right arrow over (y)}(t) can be written as:
{right arrow over (x)}= ( x,y ), y ({right arrow over ( t )})= R (cos t , sin t ), (26)
Similarly, the variable {right arrow over (β)} and {circumflex over (β)} ⊥ in Eq. (24) are as follows:
β ⇀ = x ⇀ -> y ⇀ ( t ) = ( x - R cos t , y - R sin t ) , ( 27 ) β ^ ] = sgn ( x - R cos t ) β ⇀ ( R sin t - y , x - R cos t ) = ( cos β ⊥ , sin β ⊥ ) . ( 28 )
Here we specify one direction from two possible orientations for {circumflex over (β)} ⊥ as shown in FIG. 8 . For a specific point {right arrow over (x)} in the ROI and a specific angular x-ray focal point location t on the circular source trajectory 16 , the polar angle β ⊥ is determined by the following equation:
tan β ⊥ = x - R cos t R sin t - y . ( 29 )
The ROI is completely inside the gantry and thus, for any point {right arrow over (x)} in the ROI, we have
x cos t+y sin t<R, sgn ( x cos t+y sin t−R )≡−1, (30)
for any value of t. Therefore, a straightforward calculation gives
sgn [({circumflex over (β)} ⊥ ·{right arrow over (y)}′ ( t )]=− sgn ( x−R cos t ). (31)
Therefore, Eq. (24) can be expressed as follows for the third generation scanner of FIG. 7 :
f ( x ⇀ ) = 1 4 π 2 ∫ ⅆ t w ( x ⇀ , t ) sgn ( x - R cos t ) x ⇀ - y ⇀ ( t ) ∫ 0 2 π ⅆ ϕ r 1 cos ( β ≡ _ - ϕ r ) ∂ ∂ q g ( ϕ r , q ) ❘ q = t . ( 32 )
The weighting function is denoted as w({right arrow over (x)},t)=w({right arrow over (x)},{circumflex over (β)} ⊥ ;t).
[0071] It is more convenient to define the location of each attenuation measurement by the location of the detector and the source at the moment the data is acquired. We denote the measured data as g m (γ, t) with γ labeling the position of the detector and t labeling the location of the source as shown in FIG. 7 . A data rebinning equation connects g m (γ, t) with g m (φ r , t). This relation can be easily established by observing the geometry in FIG. 7 .
ϕ r = π - γ m 2 + t + γ , ( 33 ) g [ ϕ r ( γ , t ) , t ] = g m ( γ , t ) , ( 34 )
where γ m is the total fan beam angle.
[0073] Using this relation, we immediately have an analytical understanding of taking the derivative with respect to the “source trajectory”. To facilitate the discussion, we use simplest central difference to approximate the derivative. That is
∂ ∂ q g ( ϕ r , q ) ❘ q = t = g m ( γ - Δ t , t + Δ t ) - g m ( γ + Δ t , t - Δ t ) 2 Δ , ( 35 )
where Δt is the angular distance between two successive view acquisitions. In the numerical implementation, the values of g m (γ−Δt, t+Δt) and g m (γ+Δt, t−Δt) are obtained by linear interpolation of the acquired measurements.
[0075] The reconstruction equations discussed above require that the derivative of the acquired attenuation data be calculated with respect to the x-ray source trajectory parameters φ r and t. This is not desirable in practice because the numerical derivative of measured data which is also discrete can cause significant numerical errors. We can avoid this practical problem by doing two things: change the variables of integration in Eq. (32) from independent variables φ r and t to the independent variables γ and t; and move the differentiation operation on the acquired data somewhere else.
[0076] We accomplish these goals by using rebinning equations (33) and (34) again. In terms of variables φ r and t, Eqs. (33) and (34) can be rewritten as
γ=φ r −π+γ m /2− t; (36)
g m (γ, t )= g m [γ(φ r ), t]=g (φ r ,t ). (37)
Using the chain rule of differentiation, we obtain:
∂ ∂ q g ( ϕ r , q ) ❘ g = t = ∂ ∂ t g m [ γ ( ϕ r , t ) ] , = ∂ ∂ q g m [ γ ( ϕ r , t ) , q ] q = t + ∂ γ ∂ t ∂ ∂ γ g m [ γ ( ϕ r , t ) , t ] , = ∂ ∂ q g m ( γ , t ) - ∂ ∂ γ g m ( γ , t ) . ( 38 )
Two factors allow us to determine the integral interval for the new variable γ to be [0,γ m ]. The data is non-truncated and the image function f({right arrow over (x)}) has a compact support. After taking into account the unit Jacobian for the variable changing from (φ r ,t) to (γ,t), we rewrite Eq. (32) as:
f ( x ⇀ ) = - 1 4 π 2 ∫ ⅆ t w ( x ⇀ , t ) sgn ( x - R cos t ) x ⇀ - y ⇀ ( t ) ×
∫ 0 γ m ⅆ γ 1 cos ( β ⊥ - t - γ + γ m / 2 ( ∂ ∂ t - ∂ ∂ γ ) g m ( γ , t ) . ( 39 )
Using the property derived in the Appendix B, we can write the above formula in a way to show the FBP structure transparently. That is:
f ( x ⇀ ) = - 1 4 π 2 ∫ ⅆ t w ( x ⇀ , t ) x ⇀ - y ⇀ ( t ) ∫ 0 γ m ⅆ γ 1 sin ( θ - γ + γ m / 2 ) ( ∂ ∂ t - ∂ ∂ γ ) g m ( γ , t ) . ( 40 )
Here variable θ depends on the parameter t. As shown in the Appendix A, it is defined by the following equation:
tan θ = y cos t - x sin t x cos t + y sin t - R . ( 41 )
To avoid the differentiation of the measured data in the above equation, a standard practice is to perform integration by parts so that we can trade the derivatives to the prefactors which can be calculated analytically before we digitally implement the method. This analytical operation leads us to a new reconstruction method. As shown in Appendix A, the integration by parts yields the following reconstruction formula:
f ( x -> ) = - 1 4 π 2 w ( x -> , t ) x -> - y -> ( t ) ∫ 0 γ m ⅆ γ g m ( γ , t ) sin ( θ - γ + γ m / 2 ) ❘ t = t i t = t f + 1 4 π 2 ∫ ⅆ t w ′ ( x -> , t ) x -> - y -> ( t ) ∫ 0 γ m ⅆ γ g m ( γ , t ) sin ( θ - γ + γ m / 2 ) + 1 4 π 2 ∫ ⅆ t R w ( x -> , t ) x -> - y -> ( t ) 2 ∫ 0 γ m ⅆ γ g m ( γ , t ) cos ( γ - γ m / 2 ) [ sin ( θ - γ + γ m / 2 ) ] 2 . ( 42 )
Equations (42) and (41) are the optimal formulas for an accurate reconstruction of the ROI from the fan beam projections produced by the third generation scanner of FIG. 7 , provided the x-ray source trajectory revolves around the ROI to satisfy the data sufficiency condition Eq. (11). In Eq. (42), the integral over tεA is implied. Compared with Eq. (39), this new formula allows us to reconstruct the image sequentially. The formula (42) suggests the following steps to reconstruct the image:
[0083] STEP 1: For each view, multiply the measured data by a factor cos(γ−γ m /2), after this step, we obtain modified projections:
{tilde over ( g )}(γ, t )= g (γ, t )cos(γ−γ m /2).
[0084] STEP 2: For each view, filter the measured data by a filter
1 sin ( γ - γ m / 2 )
(the result is called Q 1 (θ)) and filter the modified projections by the other filter
1 sin 2 ( γ - γ m / 2 )
(the result is called Q 2 (θ)).
[0087] STEP 3: For each view, backproject the filtered data Q 1 (θ) with a weight
w ′ ( x -> , t ) x -> - y -> ( t )
and backproject the filtered data Q 2 (θ) with a weight
R w ( x -> , t ) x -> - y -> ( t ) 2 .
[0089] STEP 4: Add up all the contributions from all the different view angles t.
[heading-0090] In this manner an image is produced immediately by the above filtered backprojection.
[0091] In the preceding section an optimal reconstruction formula for an equiangular third generation arc detector was described. Now we describe an optimal reconstruction formula for fan beam projections acquired with a circular trajectory, third generation scanner having an equally-spaced, collinear detector as shown in FIG. 9 .
[0092] From the geometry depicted in FIG. 9 , we have the following coordinate transformation:
γ = γ m 2 + arctan s 2 R . ( 43 )
Using this relation, as shown in Appendix B, Eq. (42) can be changed into:
f ( x -> ) = - 1 4 π 2 w ( x -> , t ) R - x cos t - y sin t ∫ - d m d m ⅆ sh H ( s ~ - s ) g ~ ( s , t ) ❘ t = t i t = t f + 1 4 π 2 ∫ ⅆ t w ′ ( x -> , t ) R - x cos t - y sin t ∫ - d m d m ⅆ sh H ( s ~ - s ) g ~ ( s , t ) + 1 4 π 2 ∫ ⅆ t R w ( x -> , t ) ( R - x cos t - y sin t ) 2 ∫ - d m d m ⅆ sh R ( s ~ - s ) g ~ ( s , t ) , ( 44 )
where h H (s) and h R (x) are a Hilbert filter and a Ramp filter defined as follows:
h H ( n Δ x ) = 2 n Δ x , n = odd , ( 45 ) h R ( x ) = ∫ - ∞ + ∞ ⅆ ω ω ⅇ ⅈ2π ω x . ( 46 )
We also introduced a new variable {tilde over (s)} which is defined by:
s ~ = 2 R tan θ = 2 R x sin t - y cos t x cos + y sin t - R . ( 47 )
In addition, the {tilde over (g)}(s, t) is rescaled projection data given by the following equation:
g ~ ( s , t ) = 2 R s 2 + 4 R 2 g m ( s , t ) . ( 48 )
[0097] Therefore, the implementation of Eq. (44) requires the following steps:
1. Filter each acquired view with 1/sin(γ−γ m /2); 2. Backproject each resulting filtered view Q 1 (θ) with weight W′({right arrow over (x)},t)/|{right arrow over (x)}−{right arrow over (y)}(t)|; 3. Add the backprojected view to an image; 4. Filter each acquired view with cos(γ−γ m /2)/[sin(γ−γ m /2)*sin(γ−γ m /2)]; 5. Backproject each resulting filtered view Q 2 (θ) with weight RW({right arrow over (x)},t)/|{right arrow over (x)}−{right arrow over (y)}(t)|; and 6. Add backprojected view to the image.
[0104] The image evolves as successive views g(γ,t) are acquired and processed to change from a blurry, unrecognizable subject to a finished image.
[0105] Using the image reconstruction method indicated above in Eq. (24) one ends up with a general filtered backprojection scheme. It is general in the sense that it yields a mathematically exact image reconstruction for any differentiable planar x-ray source trajectory and any detector configuration. The image reconstruction methods indicated by Eqs. (42) and (44) produce mathematically exact images for the clinically useful scanner geometries having a circular x-ray source trajectory with a third generation arc detector and collinear detector respectively. The method expressed by Eqs. (42) and (44) are valid for a wide range of weighting functions, they do not require taking the derivative of acquired attenuation data, and the image reconstruction can be performed sequentially in real time. That is, each view can be processed after it is acquired to form an image and the image is continuously improved as more views are acquired and processed. As will now be discussed, two extra terms in these reconstruction equations also enable the scan path to be shortened without truncating the data set needed to produce an artifact free image.
[0106] We now analyze the data sufficiency condition dictated by inversion formula (12) with reference to FIG. 10 . We first specify a region of interest (ROI) 18 for the object to be imaged. The ROI may be the whole function support region Q of the scanner, or it may be a smaller part of the function support region Ω.
[0107] To define an intermediate function G 2 [{right arrow over (k)},{right arrow over (y)}(t)] for a specific point {right arrow over (y)}(t) on the source trajectory, as shown in the Eq. (3), we need to know all the projections g[{right arrow over (r)},{right arrow over (y)}(t)]. The acquired data is not allowed to be truncated and we therefore need to know all the line integrals in a fan containing the whole object.
[0108] The question is how long the x-ray source scan path must be to acquire the necessary projections. For a specific point {right arrow over (x)} within the ROI, we can use Eq. (12) to calculate f({right arrow over (x)}) provided the following mathematical condition is satisfied:
[0109] Condition: For every point {right arrow over (x)} within the ROI 18 and an arbitrary direction {circumflex over (k)}, we need at least one focal position {right arrow over (y)}(t) to satisfy Eq. (11).
[0110] This mathematical condition can be summarized into the following statement for the fan beam data sufficient condition. To accurately reconstruct an image for a given ROI, we require that any straight line passing through the ROI should intersect the x-ray source trajectory at least once. We call such a source trajectory a complete trajectory Λ.
[0111] Referring to FIG. 10 , if we consider a circular source trajectory with radius R, the ROI 18 consists of a concentric disc region with radius r<R, then the data sufficiency condition Eq. (11) requires that the x-ray source trajectory is the bigger arc (AMB) of the circle. It is easy to see that the corresponding angle for this arc is π+2 arcsin (r/R).
[0112] As indicated above, a number of possibilities are available for the choice of the weighting function w({right arrow over (x)},t). Two prescriptions for the weighting function are preferred. It is important to understand that this invention is the first method to explicitly introduce image pixel {right arrow over (x)} into a weighting function. In the first method, a ray-driven weighting function is used in which the weighting function does not depend on the image pixels. In other words, there is no {right arrow over (x)} dependence. In the second method, a pixel-driven weighting function is used in which the choice of the weighting function strongly depends on the pixels.
[0113] Ray-Driven Weighting Function
[0114] Arbitrarily pick one smooth (e.g., can take the derivative) and positive-definite (i.e., non-negative everywhere) function C(t), where t is defined on the complete trajectory Λ, and outside this range, C(t)≡0. Then the weighting function can be given by:
w ( x → , t ) = W ( t ) = C ( t ) C ( t ) + C ( t + π + 2 γ ) ,
where γ is the index of the detector counted from the central line (i.e., the line between the source position and the system isocenter).
[0116] Pixel-Driven Weighting Function
[0117] Referring particularly to FIG. 14 , for each specific pixel {right arrow over (x)} 0 , draw two straight lines between {right arrow over (x)} 0 and two end points labeled t i and t f on the source trajectory 16 . These two lines will intersect the source trajectory at two other points labeled t 1 and t 2 . Noting that points t 1 and t 2 are strongly pixel dependent. Points t i , t 1 , t 2 ,t f cut the complete trajectory 16 into three pieces: (t i , t 1 )∪(t 1 , t 2 )∪(t 2 , t f ). The weighting scheme is to assign weight ½ for the first and last pieces of the orbit and assign weight 1 for the second piece as shown in FIG. 15 . Using this method, the second terms in equations (42) and (44) do not play any role and thus the computational load can be reduced by just calculating the first and the last terms.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0118] With initial reference to FIGS. 11 and 12 , a computed tomography (CT) imaging system 10 includes a gantry 12 representative of a “third generation” CT scanner. Gantry 12 has an x-ray source 13 that projects a fan beam of x-rays 14 toward a detector array 16 on the opposite side of the gantry. The detector array 16 is formed by a number of detector elements 18 which together sense the projected x-rays that pass through a medical patient 15 . Each detector element 18 produces an electrical signal that represents the intensity of an impinging x-ray beam and hence the attenuation of the beam as it passes through the patient. During a scan to acquire x-ray projection data, the gantry 12 and the components mounted thereon rotate about a center of rotation 19 located within the patient 15 .
[0119] The rotation of the gantry and the operation of the x-ray source 13 are governed by a control mechanism 20 of the CT system. The control mechanism 20 includes an x-ray controller 22 that provides power and timing signals to the x-ray source 13 and a gantry motor controller 23 that controls the rotational speed and position of the gantry 12 . A data acquisition system (DAS) 24 in the control mechanism 20 samples analog data from detector elements 18 and converts the data to digital signals for subsequent processing. An image reconstructor 25 , receives sampled and digitized x-ray data from the DAS 24 and performs high speed image reconstruction according to the method of the present invention. The reconstructed image is applied as an input to a computer 26 which stores the image in a mass storage device 29 .
[0120] The computer 26 also receives commands and scanning parameters from an operator via console 30 that has a keyboard. An associated cathode ray tube display 32 allows the operator to observe the reconstructed image and other data from the computer 26 . The operator supplied commands and parameters are used by the computer 26 to provide control signals and information to the DAS 24 , the x-ray controller 22 and the gantry motor controller 23 . In addition, computer 26 operates a table motor controller 34 which controls a motorized table 36 to position the patient 15 in the gantry 12 .
[0121] The CT imaging system is operated to acquire views of attenuation data g(γ, t) at a series of gantry angles γ as the x-ray source 13 is moved to a series of locations t on a circular path. In the preferred embodiment an arcuate shaped detector array 16 is employed and the reconstruction method according to the above equation (44) is employed. As will now be described, each acquired view g(γ, t) is processed in near real time and the resulting backprojecting image data is added to an image data set which can be displayed even as the scan is being performed.
[0122] Referring particularly to FIG. 13 , each view is acquired as indicated at process block 100 and processed in two parallel paths. In the first path the attenuation data g(γ, t) is filtered by multiplying by a first filter 1/sin(γ−γ m /2) as indicated by process block 102 . The resulting filtered data set Q 1 (θ) is then backprojected as indicated at process block 104 with a weighting factor of w′({right arrow over (x)},{right arrow over (y)})/|{right arrow over (x)}−{right arrow over (y)}(t)|.
[0123] The same attenuation data g(γ, t) is processed in a second path in which it is first filtered as indicated by process block 106 with cos(γ−γ m /2)/[sin(γ−γ m /2)*sin(γ−γ m /2)]. The resulting filtered data set is then backprojected as indicated at process block 108 with a weight RW({right arrow over (x)},t)/|{right arrow over (x)}−{right arrow over (y)}(t)|.
[0124] The resulting image data from the two, parallel backprojections 104 and 108 are added to an image data set as indicated at process block 110 . As the scan progresses more image data is added to the image data set and the displayed image progressively improves in clarity and becomes devoid of image artifacts. The system loops back at decision block 112 until sufficient views have been acquired to satisfy the data sufficiency condition of Eq. (11).
[0125] It should be apparent that a very similar process is employed to reconstruct an image from a third generation CT scanner having a collinear detection array such as that shown in FIG. 9 . The filter factors and weighting function are different, but the process is otherwise the same as that illustrated in FIG. 13 .
[0126] The generalized form of the reconstruction method as expressed in Eq. (24) may be employed when the x-ray source travels a non-circular path. It is contemplated that this reconstruction method may be used when the x-ray source does not follow a perfect circular path due to manufacturing tolerances or wear. In such case, the exact path is measured during a calibration procedure and Equation (24) is implemented in the reconstruction process using the exact, measured source path.
[heading-0127] Appendix A
[0128] In this appendix, we derive reconstruction formula Eq. (42). Using Eqs. (27), (28) and (31), we obtain
sgn ( x - R cos t ) x → - y → ( t ) cos ( β ⊥ - ϕ r ) = 1 x sin ϕ r = y cos ϕ r - R sin ( ϕ r - t ) = P ( x → ; γ , t ) . ( 55 )
Using φ r =π+t+γ=γ m /2, we obtain
x sin ϕ r - y cos ϕ r - R sin ( ϕ r - t )
= ( - x sin t - y cos t ) cos ( γ - γ m 2 ) + ( R - x cos t - y sin t ) sin ( γ - γ m 2 )
= 1 [ sin θ cos ( γ γ m 2 ) - cos θ sin ( γ - γ m 2 ) ] ,
= 1 sin ( θ - γ + γ m 2 ) , ( 56 )
where we introduced length l and angler theta as follows:
tan θ = x sin t - y cos t x cos t + y sin t - R , ( 57 ) 1 = ( x sin t - y cos t ) 2 + ( x cos t + y sin t - R ) 2 , ( 58 ) = ( x - R cos t ) 2 + ( y - R sin t ) 2 ( 59 ) = x → - y → ( t ) .
Therefore, we obtain
P ( x → ; γ , t ) = 1 x → - y → ( t ) sin ( θ - γ + γ m / 2 ) . ( 60 )
In addition, using Eq. (55) and φ r =π+t+γ−γ m /2, we can calculate its derivatives as following:
( ∂ ∂ t - ∂ ∂ γ ) P ( x → ; γ , t ) = P 2 ( x → ; γ , t ) R cos ( γ - γ m 2 ) ( 61 )
[0133] Substituting the above equation into Eq. (39), we obtain
f ( x → ) = - 1 4 π 2 ∫ ⅆ t ∫ 0 γ m w ( x → , t ) P ( x → ; γ , t ) ( ∂ ∂ t - ∂ ∂ γ ) g m ( γ , t ) , = - 1 4 π 2 ∫ ⅆ t ∫ 0 γ m ( ∂ ∂ t - ∂ ∂ γ ) [ w ( x → , t ) P ( x → ; γ , t ) g m ( γ , t ) ] + 1 4 π 2 ∫ ⅆ t ∫ 0 γ m g m ( γ , t ) ( ∂ ∂ t - ∂ ∂ γ ) [ w ( x → , t ) P ( x → ; γ , t ) ] , = - 1 4 π 2 ∫ 0 γ m w ( x → , t ) P ( x → ; γ , t ) g m ( γ , t ) ❘ t = t f t = t i + 1 4 π 2 ∫ ⅆ t w ( x → , t ) P ( x → ; γ , t ) g m ( γ , t ) ❘ γ = γ m γ = 0 + 1 4 π 2 ∫ ⅆ t ∫ 0 γ m g m ( γ , t ) ( ∂ ∂ t - ∂ ∂ γ ) [ w ( x → , t ) P ( x → ; γ , t ) ] . ( 62 )
Since we have assumed that the data is non-truncated, we have
g m (γ=0 ,t )=0 =g m (γ=γ m ,t ). (63)
Thus the second term in the above equation vanishes. Thus we obtain
f ( x → ) = - 1 4 π 2 ∫ 0 γ m w ( x → , t ) P ( x → ; γ , t ) g m ( γ , t ) ❘ t = t f t = t i + 1 4 π 2 ∫ ⅆ t ∫ 0 γ m g m ( γ , t ) ( ∂ ∂ t - ∂ ∂ γ ) [ w ( x → , t ) P ( x → ; γ , t ) ] . ( 64 )
Using Eq. (61), we can calculate the derivatives in Eq. (64). The result is
( ∂ ∂ t - ∂ ∂ γ ) [ w ( x → , t ) P ( x → ; γ , t ) ] = BP 1 ( x → ; γ , t ) + BP 2 ( x → ; γ , t ) , ( 65 )
where we have introduced two backprojection kernels BP 1 ({right arrow over (x)};γ,t) and BP 2 ({right arrow over (x)};γ,t) as follows
BP 1 ( x → ; γ , t ) = P ( x → ; γ , t ) ⅆ w ( x → , t ) ⅆ t = P ( x → ; γ , t ) w ′ ( x → , t ) ; ( 66 ) BP 2 ( x → ; γ , t ) = Rw ( x → , t ) cos ( γ - γ m 2 ) [ P ( x → ; γ , t ) ] 2 . ( 67 )
Substituting Eqs. (60), (66), and (67) into Eq. (64), we obtain Eq. (42).
Appendix B
[0140] In this appendix, we show how to derive the Eq. (52). Using the Eq. (51), we have
d γ = 2 R s 2 + 4 R 2 d s , ( 68 ) cos ( γ - γ m 2 ) = 2 R s 2 + 4 R 2 , ( 69 ) sin ( γ - γ m 2 ) = s s 2 + 4 R 2 . ( 70 )
On the other hand, we have
x -> - y -> ( t ) sin ( θ - γ + γ m 2 ) ( 71 ) = x -> - y -> ( t ) sin θcos ( γ - γ m 2 ) - cos θ sin ( γ - γ m 2 ) ]
= ( - x sin t + y cos t ) 2 R s 2 4 R 2 - ( R - x cos t - y sin t ) s s 2 + 4 R 2 ,
= R - x cos t - y sin t s 2 + 4 R 2 ( 2 R tan θ - s ) , ( 72 )
where we used Eq. (56) amd Eq. (57). After we plug Eqs. (68), (69) and (71) into Eq. (42), we obtain Eq. (52). | A new image reconstruction method is described for CT systems. Reconstruction formulas for general application to any CT system geometry are derived and more specific formulas for two third generation CT system geometries are described. A preferred embodiment of a CT system which employs one of the specific formulas is described. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a system for verifying the authenticity of documents such as checks wherein a field of photoactive microcapsules containing a radiation sensitive internal phase is provided in a localized area on one or more faces of the document and image-wise exposed to produce a latent image which is developed upon presenting the document and used to verify its authenticity.
Various systems have been developed for authenticating documents but none are particularly convenient for use in authenticating checks and the like which are negotiated by signatures which often cannot be immediately verified. For example, U.S. Pat. No. 3,001,887 to Ahlem, Jr. et al (1961) discloses a system for authenticating documents such as raffle tickets wherein fine colloidal silica is presented on the document in the form of an invisible latent image and the document is authenticated by applying to the surface of the document a colorless reactant such as a color former which reacts with the silica and produces a colored image which can be used to check the validity of the ticket.
U.S. Pat. No. 4,037,007 to Wood (1977) discloses a paper for security documents such as bank checks which contain planchettes which contain one or more color formers wherein the documents are authenticated by the addition of reactants which cause the planchettes to change color.
U.S. Pat. No. 4,360,543 to Skees et al (1982) discloses a method for producing a hidden image by applying to a document surface a colorless ink in the configuration of an image. This ink is overcoated with an encapsulated reactant which is capable of reacting with the ink to form color. The document is authenticated by applying pressure to the encapsulated reactant which causes it to be released from the microcapsules and react with the ink whereupon the hidden image is revealed.
SUMMARY OF THE INVENTION
In accordance with the present invention a field of photoactive microcapsules capable of carrying a latent verification image is provided on at least one surface of a document and the latent image is developed prior to honoring the document by simply rupturing the microcapsules such as by passing the document through a pair of pressure rollers.
In accordance with the invention, the photoactive microcapsules contain a radiation sensitive internal phase which under goes a change in viscosity upon exposure to actinic radiation. This viscosity change controls whether the microcapules can rupture and release the internal phase when pressure or some other means of rupturing the microcapsules is applied. Typically, the internal phase includes an image forming agent which renders the latent image visible when the microcapsules are ruptured. Thus, documents (including the signatures they carry) can be authenticated by image-wise exposing the field of microcapsules to actinic radiation in the configuration of a verification image such as an authorized signature, an identification number or the like to produce a latent image, and developing this image by rupturing the microcapsules. From the developed image the cashier, teller or the like can determine whether the document or the signatures thereon are authentic.
In the most typical case a subtantially colorless electron donating color former is associated with the microcapsules. The color former reacts with an electron accepting color developer to produce a color image. The color developer may be present in the field of microcapsules (e.g., in an underlying layer), on a separate developer sheet, or less preferably, applied externally following microcapsule rupture. In each case, the color former can only react with the developer in the areas in which the internal phase is released from the microcapsules. Hence, if the microcapsules contain a photohardenable material, by exposing the field to a line image of the authorized signature, the microcapsules in the exposed areas harden and do not release the color former whereas the microcapsules in the unexposed areas corresponding to the signature release the color former which reacts with the developer to produce an image of a signature which should match the signature on the document.
Since documents in accordance with the present invention will be handled in room and/or sunlight prior to developing the latent image, it is important that the radiation sensitive composition in the microcapsules be sensitive to "non-ambient" radiation and be shielded from ambient radiation if it exhibits substantial sensitivity to room or sunlight. This can be accomplished by selecting appropriate photoinitiators and/or incorporating light-shielding agents in the microcapsule wall former. In accordance with a preferred embodiment of the invention, the radiation sensitive composition is only sensitive to intense ultraviolet exposure in the far ultraviolet range (e.g. less than about 360 nm).
The document security system of the present invention is particularly advantageous because the latent image can be applied to the document by photographic techniques without the need to form the latent image mechanically by applying a reactant selectively to the face of the document in the configuration of the latent image as taught in the prior art. As a result, the security system of the present invention can be adapted to apply the verification means at the same time that the documents are cut or drafted. For example, payroll checks provided with a field of microcapsules on the backside could be exposed to provide a latent image of the employee's signature at the same time the checks are completed. Furthermore, in accordance with the preferred embodiments of the invention, the development process is an entirely dry process which can be carried out quickly and easily by cashiers or tellers without the need to apply external developers or processing solutions.
The present invention is not limited to reproducing signatures and identification numbers. Because it relies upon photographic techniques it can also be used to reproduce images of other identification means such as fingerprints or an actual photograph of the person who is entitled to performance upon presentation of the document.
Thus, in accordance with one embodiment of the invention a document is provided having a field of microcapsules on at least one surface thereof in a localized area. The microcapsules contain an internal phase including a radiation sensitive composition which undergoes a change in viscosity upon exposure to actinic radiation and are capable of carrying a latent image in the form of microcapsules which image-wise release the internal phase upon rupturing. A latent image useful in verifying the authenticity of the document or the signatures thereon is produced in the field of microcapsules by image-wise exposing the field to actinic radiation and, in the preferred case, the latent image is developed by rupturing the microcapsules to reveal an image from which the authenticity of the document can be verified.
Another embodiment of the present invention is a process which comprises image-wise exposing the aforesaid field of microcapsules to actinic radiation so as to produce a latent image useful in verifying the authenticity of the document and/or the signatures thereon, and rupturing the microcapsules and developing the latent image to produce a visible image from which the authenticity of the document can be determined.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overhead perspective view of the front face of a negotiable instrument in accordance with the present invention.
FIG. 2 is an overhead perspective view of the back side of another negotiable instrument in accordance with the present invention.
FIG. 3 is an overhead perspective view showing another embodiment of the invention.
FIG. 4 is a cross-sectional view of a field of microcapsules bearing a latent image in accordance with one embodiment of the present invention.
DEFINITIONS
The term "document" includes negotiable instruments such as checks, travelers cheques, postal orders, lottery tickets, trading checks, bearer bonds and the like as well as documents such a passports, admission tickets, travel tickets and bank notes.
The term "microcapsule" is used herein to refer to both microcapsules having a discrete wall and microcapsules formed in an open phase system wherein discrete droplets of photoactive internal phase are dispersed in a binder. Thus, whenever reference is made to "microcapsules" or "encapsulation" in the specification and appended claims, without reference to a discrete microcapsule wall, both types of microcapsules are intended.
The term "image areas" as used herein means the areas in which the internal phase is released from the microcapsules, regardless of whether the image formed is a positive or negative image.
The term "actinic radiation" is open to the entire electromagnetic spectrum and includes ultraviolet, infrared, visible, X-ray and other radiation sources such as ion beam.
The term "ambient radiation" means radiation which is encountered in substantial intensities in the normal course of daily activity and includes room and sunlight.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a negotiable instrument 10 in accordance with the present invention having a field of microcapsules 12 on the face thereof below the authorized signature of the drawer 14. The field of microcapsules 12 is shown as containing a latent image of the drawer's signature as indicated by phantom line 16.
FIGS. 2 and 3 illustrate the back side of two instruments 18 and 20 carrying microcapsule fields 22 and 24 respectively. In accordance with the embodiment illustrated in FIG. 2, the microcapsules carry a latent image of an identification number of the authorized payee 26 whereas, in FIG. 3, the field 24 contains an actual image of the authorized payee 28.
The photoactive microcapsules used in the present invention are described in detail in commonly assigned applications Ser. Nos. 320,356 and 320,643 filed Nov. 12, 1981 which are incorporated herein by reference.
FIG. 4 is a cross-sectional view through a latent image bearing field of microcapules in accordance with the present invention. Therein the document 10 has on the surface thereof a layer of developer material 30 which is overcoated with a field of microcapsules 12 having discrete microcapsule walls 32. For purposes of this illustration, the microcapsules are considered to contain a photohardenable internal phase which includes a color former and which undergoes an increase in viscosity upon exposure to actinic radiation. Thus, upon exposing the field 12 to an image in the form of an authorized signature, the microcapsules 34 in the areas corresponding to the dark line image of the signature are not exposed and the internal phase 36 remains liquid. In the areas not corresponding to the signature, however, the microcapsules 38 are exposed and the internal phase increases in viscosity. This is shown as actually hardening the internal phase 40 in microcapsules 38, however, in reality the internal phase in the exposed microcapsules may simply be converted to a more viscous, gelatinous or semisolid form. Thus, the field of microcapsules 12 bears a latent image 16 in the form of microcapsules 34 which, following exposure, contain a still liquid internal phase 36.
When pressure is applied to microcapsules 38 in the exposed areas, they do not release the internal phase. In the unexposed area, however, microcapsules 34 rupture and release the internal phase whereupon the color former migrates into the developer layer 30 where a color image (phantom lines) 42 is produced.
Various image-forming agents and radiation sensitive compositions can be used in conjunction with the present invention to produce verification images by a number of different mechanisms. For example, positive working photohardenable or negative working photosoftenable radiation sensitive compositions can be used. Photohardenable compositions such as photopolyermizable and photocrosslinkable materials increase in viscosity or solidify upon exposure and yield positive images. Photosoftenable materials, such as some photodecomposable or photodepolymerizable materials, decrease in viscosity and result in negative images. Either type can be used to produce an image suitable for document verification in accordance with the present invention.
Ethylenically unsaturated organic compounds are useful radiation curable materials. These compounds contain at least one terminal ethene group per molecule. Typically, they are liquid. Polyethylenically unsaturated compounds having two or more terminal ethylene groups per molecule are preferred. An example of this preferred subgroup are ethylenically unsaturated acid esters of polyhydric alcohols, such as ethylene diacrylate, 1,5 pentanediol dimethacrylate, 1,3 propanediol dimethacyrlate, trimethylol propane triacrylate (TMPTA), etc.
Another suitable radiation sensitive composition is an acrylate prepolymer derived from the partial reaction of pentaerythritol with acrylic acid or acrylic acid esters. Photosensitive compositions based on these prepolymers having an acrylate functionality of between approximately two and three are available commercially in two-package systems from The Richardson Company, Melrose Park, Illinois, such as RL-1482 and RL-1483. These are recommended to be mixed together to form a radiation curable clear varnish in a ratio of 4.4 parts of RL-1482 to one part RL-1483.
Another group of substances useful as radiation sensitive compositions include isocyanate modified acrylic, methacrylic and itaconic acid esters of polyhydric alcohols as disclosed in U.S. Pat. Nos. 3,783,151; 3,759,809 and 3,825,479, all to Carlick et al. Radiation curable compositions including these isocyanate modified esters and reactive diluents such as tetraethylene glycol diacrylate as well as photoinitiators such as chlorinated resins, chlorinated paraffins and amine photoinitiation synergists are commercially available as over print varnishes from Sun Chemical Corp., Carlstat, N.J., under the tradename of Sun Cure resins.
The radiation sensitive component of several radiation curable inks is also suitable for use in this invention. An example of this type of material is a mixture of pentaerythritol acrylate and a halogenated aromatic, alicyclic or aliphatic photoinitiator, as disclosed in U.S. Pat. No. 3,661,614 to Bessemir et al.
An example of radiation depolymerizable materials that may be useful in other embodiments of the invention are 3-oximino-2-butanone methacrylate which undergoes main chain scission upon U.V. exposure and poly 4'-alkyl acylophenones. See Reichmanis, E.; Am. Chem. Soc. Div. Org. Coat. Plast. Chem. Prepr. 1980. 43, 243-251 and Lukac, I.; Chmela S., Int. Conf. on Modif. Polym. 5th. Bratislave, Czech. July 3-6, 1979, I.U.P.A.C. Oxford, England 1979, 1, 176-182.
The radiation sensitive composition must make up a large enough proportion of the internal phase to effectively control the flow of the internal phase upon development. This generally means that the radiation sensitive material must constitute approximately 40 to 99% by weight of the internal phase of the microcapsules.
In most cases, the radiation sensitive composition includes a photoinitiator. It is possible to use either photoinitiators which are converted to an active species by homolytic cleavage upon absorption of radiation or those which generate a radical by abstracting a hydrogen from a hydrogen donor. There may also be used photoinitiators which complex with the sensitizer to produce a free radical generating species or photoinitiators which otherwise generate radicals in the presence of a sensitizer. If the system relies upon ionic polymerization, the photoinitiator may be the anion or cation generating type, depending on the nature of the polymerization.
Examples of photoinitiators useful in the present invention include diaryl ketone derivatives, quinones and benzoin alkyl ethers. Where ultraviolet sensitivity is desired, suitable photoinitiators include alkoxy phenyl ketones, O-acylated oximinoketones, polycyclic quinones, phenanthrenequinone, naphthoquine, diisopropylphenanthrenequinone, benzophenones and substituted benzophenones, xanthones, thioxanthones, halogenated compounds such as chlorosulfonyl and chloromethyl polynuclear aromatic compounds, chlorosulfonyl and chloromethyl heterocyclic compounds, chlorosulfonyl and chloromethyl benzophenones and fluorenones, and haloalkanes.
Since the documents in accordance with the present invention are handled in ambient light, it is essential that the radiation sensitive composition within the microcapsules be sensitive to non-ambient radiation and not be sensitive to ambient radiation or that the microcapsule walls sufficiently shield the radiation sensitive composition to prevent its exposure by ambient light. The radiation sensitive composition can be shielded by incorporating ambient radiation absorbers in the microcapsule walls. Preferably, radiation sensitive compositions are used which are sensitive to high intensity ultraviolet radiation preferably in the wavelength range of about 360 nm or less. For ultraviolet sensitivity desirable photoinitiators include Michler's ketone, thioxanthone, and benzophenone. These initiators are sufficiently insensitive to ambient radiation to provide the desired handleability but can be imaged with ultraviolet sources such as a high intensity U.V. lamp or laser.
Various image-forming agents can be used in the present invention. For example, images can be formed by the interaction of color formers and color developers of the type conventionally used in the carbonless paper art. Images can also be formed by the color producing interaction of a chelating agent and a metal salt or by the reaction of certain oxidation-reduction reaction pairs, many of which have been investigated for use in pressure-sensitive carbonless papers. An example of an image-forming salt-chelate pair is nickel nitrate and N,N'bis (2-octanoylox-ethyl)-dithiooxamide. It is preferable to encapsulate the chelating agent and use the salt in a developer layer.
Alternatively, a pigment or an oil soluble dye can be used and images can be formed by transferring the dye or pigment to plain or treated paper to develop the verification image. Substantially any benign colored dye can be used as an image-forming agent. A few examples are Sudan Blue and Rhodamine B dyes. The dyes are preferably oil soluble since the most easily employed encapsulation techniques are conducted using an aqueous continuous phase. The internal phase itself has its own image-forming capability. For example, it is known that the toner used in xerographic recording processes selectively adheres to the image areas of an imaging sheet exposed and developed as in the present invention.
The image-forming agent can be provided inside the microcapsules, in the microcapsule wall, or outside the microcapsules in the same layer as the microcapsules or in a different layer. In the latter cases, the internal phase picks up the image-forming agent (e.g., by dissolution) upon being released from the microcapsules and carries it to the developer layer or an associated developer sheet.
Typical color precursors useful in the aforesaid embodiments include colorless electron donating type compounds. Representative examples of such color formers include substantially colorless compounds having in their partial skeleton a lactone, a lactam, a sultone, a spiropyran, an ester or an amido structure such as triarylmethane compounds, bisphenylmethane compounds, xanthene compounds, fluorans, thiazine compounds, spiropyran compounds and the like. Crystal Violet Lactone and Copikem X, IV and XI are often used alone or in combination as color precursors in the present invention.
Illustrative examples of color developers useful in conjunction with the aforesaid color precursors are clay minerals such as acid clay, active clay, attapulgite, etc.; organic acids such as tannic acid, gallic acid, propyl gallate, etc.; acid polymers such as phenol-formaldehyde resins, phenol acetylene condensation resins, condensates between an organic carboxylic acid having at least one hydroxy group and formaldehyde, etc.; metal salts or aromatic carboxylic acids such as zinc salicylate, tin salicylate, zinc 2-hydroxy naphthoate, zinc 3,5 di-tert butyl salicylate, oil soluble metal salts or phenol-formaldehyde novolak resins (e.g., see U.S. Pat. Nos. 3,672,935; 3,732,120 and 3,737,410) such as zinc modified oil soluble phenol-formaldehyde resin as disclosed in U.S. Pat. No. 3,732,120, zinc carbonate etc. and mixtures thereof.
Preferably, the developer is carried on the document in the field of microcapsules since this simplifies development. If, for example, color precursors are carried in the microcapsules with the radiation sensitive composition, a color developer can be provided in an underlying layer and the visible verification image can be developed by simply rupturing the microcapsules whereupon the color former migrates to the developer layer and reacts. Otherwise, the developer can be provided on a separate sheet in which case the verification image is developed by a transfer process in which the document is assembled with the developer sheet and the microcapsules are ruptured. Other arrangements are also possible. The aforementioned color formers and color developers can be used interchangably, that is the color former can be encapsulated and the developer can be provided in a layer or vice versa.
Depending on the nature of the radiation sensitive composition and whether an image-forming agent is present in the interal phase, a diluent oil may be included in the internal phase. Suitable diluent oils are known in the carbonless paper art and can be used in the present invention as long as they are photographically compatible with the radiation sensitive composition. Alkylated biphenyls, castor oil, mineral oil, and deodorized kerosene are a few examples.
The discrete walled microcapsules used in the present invention can be produced using known encapsulation techniques including coacervation, interfacial polymerization, polymerization of one or more monomers in an oil, etc. Representative examples of suitable wall-formers are gelatin materials (see U.S. Pat. Nos. 2,730,456 and 2,800,457 to Green et al) including gum arabic, polyvinyl alcohol, carboxy-methyl-cellulose; resorcinol-formaldehyde wall formers (see U.S. Pat. No. 3,755,190 to Hart et al); isocyanate wall-formers (see U.S. Pat. No. 3,914,511 to Vassiliades); isocyanate-polyol wall-formers (see U.S. Pat. No. 3,796,669 to Kirintani et al); urea formaldehyde wall-formers, particularly urea-resorcinol-formaldehyde in which oleophilicity is enhanced by the addition of resorcinol (see U.S. Pat. Nos. 4,001,140; 4,087,376 and 4,089,802 to Foris et al); and melamine-formaldehyde resin and hydroxypropyl cellulose (see commonly assigned U.S. Pat. No. 4,025,455 to Shackle).
The material used to form the microcapsule walls must be selected for the radiation sensitive composition that is to be encapsulated such that it is substantially transparent to the exposure radiation. For the systems described above, urea-resorcinol-formaldehyde and gelatin microcapsules are generally preferred.
The mean microcapsule size used in the present invention generally ranges from about 1 to 25 microns.
An open phase system may be used instead of discrete microcapsules. This can be done by dispersing what would otherwise be the internal phase throughout a binder as discrete droplets and coating the composition on the substrate. Suitable coatings for this embodiment include polymer binders whose viscosity has been adjusted to match the dispersion required in the coating. Suitable binders are gelatin, polyvinyl alcohol, polyacrylamide, and acrylic lattices.
Documents embodying the invention can be exposed using a fairly simple exposure apparatus to produce a latent image in the microcapsule field. In its simplest form for reflection imaging, the apparatus requires only a radiation source and means of focusing the exposure radiation from the original onto the imaging sheet. Transmission imaging could also be used. Depending upon the exposure source used and the nature of the exposing radiation, the exposure alone may cause a sufficient change in the viscosity of the internal phase to control imaging. Otherwise, exposure can be used to initiate or advance the photochemistry in the exposed areas and a subsequent uniform exposure or heat treatment can be used to enhance the image.
The latent image can be developed using various means for rupturing the microcapsules, but the application of pressure, generally using pressure rollers, is preferred for its simplicity. In some cases it is possible to rupture the microcapsules by applying a pressure-sensitive adhesive backed sheet to the field and stripping it away.
The present invention is illustrated more specifically by the following non-limiting proposed example.
EXAMPLE
A document may be prepared by coating the following compositions, in order, on a sheet of 80 pound Black and White Enamel Stock (a product of The Mead Corporation) preprinted in a check form or the like:
DEVELOPER COATING COMPOSITION
A mixture of 240 g 25% Tamol 731 (Rohm & Haas Co.), 75 g dry HT clay, 1000 g SD-74 Resin (a synthetic developer manufactured by Fuji Photo Film Co., Ltd.), 15 g Calgon T (Calgon, Inc.) and 30 g Dequest 20006 (Monsanto Co.) is ground to a particle size of less than 5 microns. 65 parts by weight of the ground mixture is added to 25 parts HT clay and 10 parts Dow 501 Latex (Dow Chemical Co.). This mixture is coated on the aforementioned enamel stock using a No. 10 Meyer rod in a coat weight of 5 pounds per 3300 sq. ft.
MICROCAPSULE COATING
A solution of 50 g TMPTA, 12 g Irgacure 651 (Ciba Giegy), 1 g Quantacure ITX (Blenkinsop & Co., Ltd.) and 6 g of 50% Copikem X in dibutyl succinate (Hilton Davis Co.) is prepared as the photoactive internal phase. This solution is microencapsulated as follows:
A mixture of 22.6 g 20.4% Isobam, 54.5 g water and 30.8 g gum arabic is heated with stirring to 60° C. and the pH is adjusted to 4.0 with the addition of 20% sulfuric acid. Thereafter 8.3 g urea and 0.8 g resorcinol are added and the solution is maintained at 60° C. to prepare a continuous phase. The continuous phase is placed in a Waring blender and the photoactive internal phase at 60° C. is added with blending at 90 V for 90 seconds. Thereafter the speed of the blender is reduced to 40 V and 21.4 ml of 37% formaldehyde is added. Blending is continued at that speed for 2 hours at 60° C. The emulsion is then transferred to a metal beaker and 0.6 g of ammonium sulfate in 12.2 g water is added. This emulsion is stirred with an overhead mixer at 60° C. for another hour and the pH is adjusted to 9.0 using a 10% solution of sodium hydroxide. Finally, 2.8 g sodium bisulfite is dissolved in the mixture with stirring.
The microcapsule preparation is diluted 1:1 with water containing 1% Triton-X 100 (Rohm & Hass Co.) and coated on the developer layer to provide a coat weight of about 6 g/m 2 .
A document prepared as above can be exposed to low intensity ultraviolet light and handled in room light without deteriorating the latent image.
Having described the invention in detail and with respect to specific embodiments thereof, it will be apparent that numerous variations and modifications are possible without departing from the scope of the following claims: | A system for verifying the authenticity of documents such as negotiable instruments wherein a field of photoactive microcapsules is provided in a localized area on the document. By image-wise exposing the document, a latent image of a verification meand such as a signature, fingerprint, or the like can be produced on the document which can be instantly developed upon rupturing the microcapsules to verify the authenticity of the document when it is presented. | 1 |
[0001] This application is a divisional application of U.S. application Ser. No. 10/814,552, filed Mar. 30, 2004; the content of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to the field of packet processing, and more specifically, packet classification or modification.
RELATED ART
[0003] Current packet processing architectures are under increasing pressure to handle higher and higher data throughputs of, e.g., 10 GB/s or more, and more complex and diverse data packet formats, e.g., embedded packet formats. However, these architectures are subject to various bottlenecks and constraints which limit the data throughput which is achievable and the packet formats which can be handled with these architectures. Hence, there is a need for a packet processing architecture which overcomes the problems of the prior art.
SUMMARY OF THE INVENTION
[0004] A first aspect of the invention involves providing a plurality of quality of service indicators for a packet, each with an assigned priority, and utilizing a configurable priority resolution scheme to select one of the plurality of quality of service indicators for assigning to the packet. The plurality of quality of service indicators, and associated priorities, may each originate from different sources. In one embodiment, a mapping process is employed to map one or more fields of the packet into one or more quality of service indicators and associated priorities. In a second embodiment, a searching process is employed to locate one or more quality of service indicators and associated priorities. In a third embodiment, a combination of the foregoing approaches is employed. The priorities associated with the quality of service indicators may vary based on user or traffic type.
[0005] A second aspect of the invention involves the utilization of a wide data path in one or more selected areas of the packet processing system where the resultant high throughput is needed, while avoiding universal utilization of the wide data path and the associated high cost.
[0006] In one embodiment, a packet classification system comprises a slicer for slicing all or some of a packet into portions and providing the portions in parallel over a first data path having a first width to a classification engine. The classification engine is configured to classify the packet responsive to the packet portions provided over the first data path. The packet classification system is configured to associate data representative of the packet classification with the packet to form an associated packet, and provide the same over a second data path having a second width less than the first width.
[0007] In a second embodiment, a packet modification system comprises a buffer for providing all or some of a packet as portions and providing the portions in parallel over a first data path having a first width to a modification engine. The modification engine is configured to modify the packet, or one or more packet portions, to form a modified packet. The packet modification system is configured to provide the modified packet over a second data path having a second width less than the first width.
[0008] A third aspect of the invention involves the utilization of one or more stacks to control packet processing. In one embodiment, a packet classification system is configured to maintain a first stack which identifies packets which are waiting to be classified by the packet classification system, and a second stack which identifies packets which are in the process of being classified by the packet classification system. When a packet is received by the packet classification system, an identifier of the packet is placed on the first stack. When the packet classification system begins the process of classifying the packet, the packet identifier is popped off the first stack and placed on the second stack. When the packet classification system has completed the process of classifying the packet, the packet identifier is popped off the second stack. The packet classification system is thereafter free to output the packet. Until then, the packet classification system is prevented from outputting the packet.
[0009] A fourth aspect of the invention involves allocating a packet size determiner to a packet from a pool of packet size determiners. The packet size determiner is configured to determine the size of the packet. Once the packet size determiner has determined the size of the packet, the packet size determiner may be returned to the pool, and the determined size of the packet used to update one or more packet statistics maintained by the system. In one embodiment, cumulative size statistics are maintained, indicating the cumulative size of those packets which fulfill certain processing conditions or hits. In this embodiment, once the size of a packet has been determined, the cumulative size statistic for a particular processing condition or hit is incremented by the size of the packet if that packet satisfies the specified processing condition or hit. In one implementation, the packet size determiners are counters.
[0010] A fifth aspect of the invention involves buffering a packet upon ingress thereof to the system, processing the packet, and forming a packet for egress from the system by combining one or more unmodified portions of the packet as retrieved directly from the buffer with modified or new packet data.
[0011] In one embodiment, a packet is buffered in a buffer upon or after entry thereof into a packet classification system. The packet is classified and data representative of the packet classification provided. Some or all of the packet, as retrieved directly from the buffer, is associated with the packet classification data to form an associated packet that is placed on an egress data path of the system.
[0012] In a second embodiment, a packet is buffered in a buffer upon or after entry thereof into the packet modification system. The packet, or one or more portions thereof, is modified. One or more unmodified portions of the packet, as retrieved directly from the buffer, are associated with one or more modified portions of the packet to form an associated packet that is placed on an egress data path of the system.
[0013] A sixth aspect of the invention involves a system for preventing re-ordering of packets in a packet processing system. In one embodiment, a packet is assigned a sequence number upon or after ingress thereof to the system. The packet is processed and data representative of the packet placed in a buffer. An expected sequence number for the next packet to be output by the system is maintained, and the buffer checked for this expected sequence number. If a match is found, the packet corresponding to the match is output from the system. Otherwise, the system waits until a match is found.
[0014] A seventh aspect of the invention involves any combination of two or more of the foregoing.
[0015] Related methods are also provided. Other systems, methods, features and advantages of the invention or combinations of the foregoing will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, advantages and combinations be included within this description, be within the scope of the invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0017] FIG. 1 is a block diagram of an embodiment of a packet processing system which comprises a receive-side packet classification system and a transmit-side packet modification system.
[0018] FIG. 2 illustrates an example of the format of a packet header as produced by an embodiment of a packet classification system in a packet processing system.
[0019] FIG. 3 is a block diagram of an embodiment of a receive-side packet classification system.
[0020] FIGS. 4A-4B is a block diagram of an embodiment of a transmit-side packet modification system.
[0021] FIG. 5 is a block diagram of an embodiment of a cascade of multiple packet processing systems.
[0022] FIG. 6 is a flowchart of an embodiment of method of processing a packet which comprises multiple parsing steps.
[0023] FIG. 7 is a flowchart of an embodiment of a method of performing egress mirroring of a packet.
[0024] FIG. 8 is a flowchart of an embodiment of a method of performing egress marking of a packet.
[0025] FIG. 9 is a flowchart of an embodiment of a method of resolving a plurality of quality of service (QoS) indicators for a packet utilizing a configurable priority resolution scheme.
[0026] FIG. 10 is a flowchart of an embodiment of a method of classifying a packet in which sliced packet data is provided to a packet classification engine over a wide data path.
[0027] FIG. 11 is a flowchart of an embodiment of a method of modifying a packet in which sliced packet data is provided to a packet modification engine over a wide data path.
[0028] FIG. 12 is a flowchart of an embodiment of a method of controlling packet classification processing of a packet through first and second stacks.
[0029] FIG. 13 is a flowchart of an embodiment of a method of maintaining packet statistics which involves allocating a packet size determiner to a packet from a pool of packet size determiners.
[0030] FIG. 14 is a flowchart of an embodiment of a method of classifying a packet which involves buffering the packet in a buffer upon or after ingress thereof, and associating packet classification data with the packet as retrieved directly from the buffer to form a classified packet on an egress data path.
[0031] FIG. 15 is a flowchart of an embodiment of a method of modifying a packet which involves buffering the packet in a buffer upon or after ingress thereof, and assembling a packet on an egress data path from one or more modified portions of the packet, and one or more unmodified portions as retrieved directly from the buffer.
[0032] FIG. 16 is a flowchart of an embodiment of a method of performing classification processing of a packet in a cascaded combination of multiple, replicated packet classification systems.
[0033] FIG. 17 is a flowchart of an embodiment of a method of preventing re-ordering of packets in a packet processing system.
RELATED APPLICATIONS
[0034] The following applications are commonly owned by the assignee hereof, are being filed on even date herewith, and are each incorporated by reference herein as though set forth in full:
Howrey Dkt. No. Extreme Dkt. No. Title 02453.0025.NPUS00 P111 PACKET PROCESSING SYSTEM ARCHITECTURE AND METHOD 02453.0026.NPUS00 P122 PACKET DATA MODIFICATION PROCESSOR 02453.0027.NPUS00 P124 SYSTEM AND METHOD FOR PACKET PROCESSOR STATUS MONITORING 02453.0028.NPUS00 P126 METHOD AND SYSTEM FOR INCREMENTALLY UPDATING A CHECKSUM IN A NETWORK DATA PACKET 02453.0029.NPUS00 P127 SYSTEM AND METHOD FOR EGRESS PACKET MARKING 02453.0030.NPUS00 P128 SYSTEM AND METHOD FOR ASSEMBLING A DATA PACKET 02453.0032.NPUS00 P125 PACKET DATA MODIFICATION PROCESSOR COMMAND INSTRUCTION SET 02453.0033.NPUS00 P123 DATA STRUCTURES FOR SUPPORTING PACKET DATA MODIFICATION OPERATIONS 02453.0043.PZUS00 P156 RECEIVE-SIDE PACKET PROCESSING SYSTEM
DETAILED DESCRIPTION
[0035] As utilized herein, terms such as “about” and “substantially” and “near” are intended to allow some leeway in mathematical exactness to account for tolerances that are acceptable in the trade. Accordingly, any deviations upward or downward from the value modified by the terms “about” or “substantially” or “near” in the range of 1% to 20% or less should be considered to be explicitly within the scope of the stated value.
[0036] As used herein, the terms “software” or “instructions” or “commands” include source code, assembly language code, binary code, firmware, macro-instructions, micro-instructions, or the like, or any combination of two or more of the foregoing.
[0037] The term “memory” refers to any processor-readable physical or logical medium, including but not limited to RAM, ROM, EPROM, PROM, EEPROM, disk, floppy disk, hard disk, CD-ROM, DVD, queue, FIFO or the like, or any combination of two or more of the foregoing, on which may be stored one or more instructions or commands executable by a processor, data, or packets in whole or in part.
[0038] The terms “processor” or “CPU” or “engine” refer to any device capable of executing one or more commands or instructions and includes, without limitation, a general- or special-purpose microprocessor, finite state machine, controller, computer, digital signal processor (DSP), or the like.
[0039] The term “logic” refers to implementations in hardware, software, or combinations of hardware and software.
[0040] The term “stack” may be implemented through a first-in-first-out memory such as a FIFO.
[0041] The term “packet” means (1) a group of binary digits including data and control elements which is switched and transmitted as a composite whole, wherein the data and control elements and possibly error control information are arranged in a specified format; (2) a block of information that is transmitted within a single transfer operation; (3) a collection of symbols that contains addressing information and possibly error detection or correction information; (4) a sequence of characters with a specific order and format, such as destination followed by a payload; (5) a grouping of data of some finite size that is transmitted as a unit; (6) a frame; (7) the logical organization of control and data fields defined for any of the layers or sub-layers of an applicable reference model, including the OSI or TCP/IP reference models, e.g., MAC sub-layer; or (8) a unit of transmission for any of the layers or sub-layers of an applicable reference model, including the OSI or TCP/IP reference models.
[0042] The term “layer two of the OSI reference model” includes the MAC sub-layer.
[0043] The term “port” or “channel” refers to any point of ingress or egress to or from a switch or other entity, including any port channel or sub-channel, or any channel or sub-channel of a bus coupled to the port.
[0044] FIG. 1 illustrates an embodiment 100 of a packet processing system comprising a packet classification system 102 and a packet modification system 104 . The packet classification system 102 has an ingress portion 106 and an egress portion 108 . Similarly, the packet modification system 104 has an ingress portion 110 and an egress portion 112 . The ingress portion 106 of the packet classification system 102 is coupled, through interface 118 , to one or more network-side devices 114 , and the egress portion 108 of the packet classification system 102 is coupled, through interface 120 , to one or more switch-side devices 116 . The ingress portion 110 of the packet modification system 104 is coupled, through interface 122 , to the one or more switch-side devices 116 , and the egress portion 124 of the packet modification system 104 is coupled, through interface 112 , to the one or more network-side devices 114 .
[0045] The packet classification system 102 comprises an ingress portion 106 , a first packet parser 126 for parsing a packet and providing first data representative thereof, and a packet classification engine 128 for classifying the packet responsive to the first data. The packet modification system 104 comprises a second packet parser 130 for parsing the classified packet (after a round trip through the one or more switch-side devices 116 ) or a packet derived there-from and providing second data representative thereof, a packet modification engine 132 for modifying some or all of the packet responsive to the second data, a third packet parser 134 for parsing the modified packet and providing third data representative thereof, and a packet post-processor 136 for post- processing the modified packet responsive to the third data.
[0046] In one embodiment, the packet undergoing processing by the system has a plurality of encapsulated layers, and each of the first, second and third parsers 126 , 130 , 134 is configured to parse the packet by providing context pointers pointing to the start of one or more of the encapsulated layers. In a second embodiment, the packet undergoing processing by the system comprises a first packet forming the payload portion of a second packet, each of the first and second packets having a plurality of encapsulated layers, and each of the first, second and third parsers 126 , 130 , 134 is configured to parse the packet by providing context pointers pointing to the start of one or more of the encapsulated layers of the first packet and one or more of the encapsulated layers of the second packet.
[0047] In one implementation, the packet post-processor 136 is configured to compute a checksum for a modified packet responsive to the third data provided by parser 134 . In one embodiment, the packet post-processor 136 is configured to independently calculate a layer three (IP) and layer four (TCP/UDP) checksum.
[0048] In one embodiment, packet post-processor 136 comprises Egress Access Control List (ACL) logic 136 a and Packet Marking logic 136 b. The Egress ACL logic 136 a is configured to arrive at an ACL decision with respect to a packet. In one implementation, four ACL decisions can be independently performed: 1) default ACL action; 2) CPU copy; 3) mirror copy; and 4) kill. The default ACL action may be set to kill or allow. The CPU copy action forwards a copy of the packet to a host 138 coupled to the system. The mirror copy action implements an egress mirroring function (to be discussed in more detail later), in which a copy of the packet is forwarded to mirror FIFO 140 and then on to the egress portion 108 of the packet classification system 102 . The kill action either kills the packet or marks it for killing by a downstream Medium Access Control (MAC) processor.
[0049] The Packet Marking logic 136 b is configured to implement a packet egress marking function in which certain packet marking control information for a packet generated by the packet classification system 102 is used to selectively modify one or more quality of service (QoS) fields in the packet.
[0050] In one embodiment, Content Addressable Memory (CAM) 142 is used by the packet classification system 102 to perform packet searches to arrive at a classification decision for a packet. In one implementation, the CAM searches are ternary in that all entries of the CAM have a data and mask field allowing don't care setting of any bit position in the data field. In another implementation, the CAM searches are binary, or combinations of binary and ternary.
[0051] The associated RAM (ARAM) 144 provides associated data for each entry in the CAM 142 . The ARAM 144 is accessed using the match address returned by the CAM 142 as a result of a search operation. The ARAM 144 entry data is used to supply intermediate classification information for the packet that is used by the classification engine 128 in making a final classification decision for the packet.
[0052] The statistics RAM 146 is used to maintain various packet statistics, including, for each CAM entry, the cumulative number and size of packets which hit or matched that entry.
[0053] The modification RAM 148 provides data and control structures for packet modification operations performed by the modification engine 132 .
[0054] In one implementation, the interfaces 150 , 152 , 154 , and 156 with any of the RAMs or CAMs may be a QDR- or DDR-type interface as described in U.S. patent application Ser. No. 10/655,742, filed Sep. 4, 2003, which is hereby fully incorporated by reference herein as though set forth in full.
[0055] FIG. 2 illustrates the format of classification data 200 for a packet as produced by one embodiment of packet classification system 102 . The classification data 200 in this embodiment has first and second portions, identified respectively with numerals 202 and 204 . The first portion 202 is a 64 bit Address Filtering Header (AFH) which is pre-pended to the packet. The second portion 204 is a 20 bit grouping of flags which are encoded as control bits maintained by the system 100 .
[0056] In one embodiment, the Port Tag Index (PTI) field is an identifier of the port or list of ports within interface 118 over which the packet will be sent by the packet modification engine. (The assumption in this embodiment is that the interface 118 is a multi-port interface).
[0057] The Egress Quality of Service (EQOS) field may be used to perform an egress queue selection function in a device encountering the packet. In one embodiment, this field also encodes one of the following functions: nothing, pre-emptive kill, normal kill, thermonuclear kill, egress mirror copy, pre-emptive intercept to host, and normal intercept to host.
[0058] The Link Aggregation Index (LAI) field may be used to implement physical link selection, ingress alias, echo kill alias, or equal cost multi-path functions in a device encountering the packet.
[0059] The JUMBO flag, if asserted, directs a device encountering the packet to perform a JUMBO-allowed check. In one embodiment, the flag is used to implement the policy that the only valid JUMBO packets are IP packets. Therefore, if the packet is a non-IP JUMBO packet, the device either sends it to a host, fragments it, or kills it.
[0060] The DON'T FRAG flag, if asserted, directs a device encountering the packet not to fragment it in the course of implementing a JUMBO-allowed check.
[0061] The IF TYPE flag indicates whether the ingress interface over which the packet was received is an Ethernet or Packet Over Sonet (POS) interface.
[0062] The ROUTE flag, if asserted, indicates that the packet is being bridged not routed, and may be used by devices encountering the packet to implement an echo kill suppress function.
[0063] The RANDOM EARLY DROP (RED) flag may be used to implement a random early drop function in devices encountering the packet.
[0064] The CTL flag indicates the format of the AFH. FIG. 2 illustrates the format of the header for packets exiting the packet classification system 102 and destined for the one or more switch-side devices 116 . Another format applies for packets exiting the one or more switch-side devices 116 and destined for the packet modification system 104 . The CTL flag indicates which of these two formats is applicable.
[0065] The Transmit Modification Index (TXMI) field is used by the modification engine 132 to retrieve control and data structures from Modification RAM 148 for use in performing any necessary modifications to the packet.
[0066] The CPU Quality of Service (CQoS) field may be used to perform an ingress queue select function in a host coupled to the packet processing system.
[0067] In one embodiment, the CPU Copy flag, if asserted, directs one or more of the switch-side devices 116 to forward a copy of the packet to a host coupled to the packet processing system. In another embodiment, the CPU Copy flag, if asserted, directs a copy of a packet to be forwarded to the host through a host bus or another PBUS.
[0068] The Redirect flag, if asserted, directs one or more of the switch-side devices 116 to forward a copy of the packet to the host for redirect processing. In redirect processing, the host receives the packet copy and redirects it to the sender, with an indication that the sender should switch the packet, not route it.
[0069] The Statistical Sample (SSAMPLE) flag, if asserted, indicates to one or more of the switch-side devices 116 that the packet is a candidate for statistical sampling. If the packet is ultimately selected for statistical sampling, a copy of the packet is directed to the host, which performs a statistical analysis of the packet for the purpose of accurately characterizing the network traffic of which the packet is a part.
[0070] The LEARN flag, if asserted, directs one or more of the switch-side devices 116 to forward a copy of the packet to the host so the host can perform learn processing. In learn processing, the host analyzes the packet to “learn” the sender's MAC address for future packet switching of packets to that address.
[0071] The Egress Mirror (EMIRROR) flag, if asserted, implements egress mirroring by directing one or more of the switch-side devices 116 to send a copy of the packet to mirror FIFO 140 . From mirror FIFO 140 , the packet passes through the egress portion 108 of the packet classification system 102 en route to the one or more switch-side devices 116 .
[0072] The Ingress Quality of Service (IQoS) field may be used to perform an ingress queue selection function in a device encountering the packet.
[0073] The Egress Mark Select (EMRK SEL) field selects one of several possible egress mark functions. The Egress Mask (EMRK MASK) field selects one of several possible egress masks. Together, the EMRK SEL and EMRK MASK fields forms an embodiment of packet egress marking control information which may be used by packet marking logic 136 b to mark the packet, i.e., selectively modify one or more QoS fields within the packet.
[0074] The Ingress Mirror (IMIRROR) flag, if asserted, directs one or more of the switch-side devices 116 to forward a copy of the packet to the designated ingress mirror port on the switch.
[0075] The Parity Error Kill (PERR KILL) flag, if asserted, directs the interface 120 to kill the packet due to detection of an ARAM parity error.
[0076] In one embodiment, the EMIRROR bit is normally in an unasserted state. If the packet classification system 102 , after analyzing the packet, determines that egress mirroring of the packet is appropriate, the packet classification system 102 changes the state of the EMIRROR bit to place it in the asserted state.
[0077] The packet, along with a pre-pended AFH containing the EMIRROR bit, is then forwarded to the one or more switch-side devices 116 . After processing the packet, the one or more devices transmit the packet, with the EMIRROR bit preserved in a pre-pended packet header, back to the packet modification system 104 over interface 122 . In response, the packet modification system 104 is configured to detect the state of the EMIRROR bit to determine if egress mirroring of the modified packet is activated, and if so, provide a copy of the modified packet to the egress portion 108 of the packet classification system 102 through the mirror FIFO 140 .
[0078] In one embodiment, the EQOS, CQOS, IQoS, EMRK SEL and EMRK MASK fields define a multi-dimensional quality of service indicator for the packet. In this embodiment, the EMRK SEL and EMRK MASK fields form packet egress marking control information which is utilized by packet modification system 104 to selectively modify one or more quality of service fields within the packet, or a packet derived there-from.
[0079] The quality of service indicator for a packet may be derived from a plurality of candidate quality of service indicators derived from diverse sources. In one embodiment, a plurality of candidate quality of service indicators are derived for a packet, each with an assigned priority, and a configurable priority resolution scheme is utilized to select one of the plurality of quality of service indicators for assigning to the packet. In one embodiment, one or more of the candidate quality of service indicators, and associated priorities, are derived by mapping one or more fields of the packet into one or more candidate quality of service indicators for the packet and associated priorities. In a second embodiment, one or more searches are conducted to obtain one or more candidate quality of service indicators for the packet and associated priorities. In a third embodiment, a combination of these two approaches is utilized.
[0080] In one example, candidate quality of service indicators, and associated priorities, are derived from three sources. The first is a VLAN mapping scheme in which a VLAN from the packet is mapped into a candidate quality of service indicator and associated priority using a VLAN state table (VST). The VLAN from the packet may represent a subnet or traffic type, and the associated priority may vary based on the subnet or traffic type. The second is a CAM-based search which yields an associated ARAM entry which in turn yields a candidate quality of service indicator. A field of an entry in a Sequence Control Table (SCT) RAM, which provides the sequence of commands controlling the operation of one embodiment of the packet classification engine 102 , provides the associated priority. The third is a QoS mapping scheme, which operates in one of three modes, as determined by a field in a SCT RAM entry.
[0081] In the first mode, the .lp mapping mode, the VST provides the four QSEGment bits. The QSEG and the .lp bits are mapped into a candidate quality of service indicator, and the VLAN itself is mapped into an associated priority using the VST. In the second mode, the MPLS mapping mode, the EXP/QOS fields from the packet are mapped into a candidate quality of service indicator, and a VLAN from the packet is mapped into the associated priority using the VST. In the third mode, the ToS mapping mode, the IPv4ToS, IPv6 Traffic Class, or Ipv6 Flow Label based QoS fields are mapped into a candidate quality of service indicator, and a VLAN from the packet is mapped into an associated priority using the VST.
[0082] In this example, the candidate quality of service indicator with the highest priority is assigned to the packet. Moreover, a candidate from one of the sources can be established as the default, which may be overridden by a candidate obtained from one of the other sources, at least a candidate which has a higher priority than the default selection. For example, the candidate quality of service indicator resulting from the .1p mapping mode can be established as the default selection, and this default overridden only by a candidate quality of service indicator resulting from an ARAM entry in turn resulting from a CAM-based search.
[0083] FIG. 3 illustrates an embodiment 300 of a packet classification system. In this embodiment, the packet classification system is coupled to one or more network-side devices through a multi-port packet bus (PBUS) 302 , as described in U.S. patent application Ser. Nos. 10/405,960 and 10/405,961, filed Apr. 1, 2003, which are both hereby fully incorporated herein by reference. PBUS ingress logic 304 is configured to detect a start of packet (SOP) condition for packets arriving at the packet classification system over the PBUS.
[0084] Upon or after detection of the SOP condition, the packet, or a portion thereof, is stored in slicer 306 . Slicer 306 is configured to slice some or all of a packet into portions and provide the portions in parallel over first data path 308 having a first width to classification engine 310 . In one embodiment, the slicer 306 is a FIFO which stores the first 128 bytes of a packet (or the entirety of the packet if less than 128 bytes), and provides the 1024 bits thereof in parallel to the packet classification engine 310 over the first data path 308 .
[0085] Upon or after detection of the SOP condition, parser 312 parses the packet in the manner described previously, and stores the resultant context pointers (and other flags resulting from the parsing process) in parser result RAM 314 . Concurrently with this parsing process, the packet is stored in buffer 318 , which in one embodiment, is a FIFO buffer.
[0086] The packet classification engine 310 is configured to classify the packet responsive to the packet portions received over the first data path 308 and the parser results as stored in the parser result RAM 314 , and store data representative of the packet classification in classification RAM 316 . In one embodiment, the classification data is the AF header illustrated in FIG. 2 .
[0087] An associator 320 is configured to associate the data representative of the packet classification with some or all of the packet, and provide the associated packet over a second data path 322 having a second width less than the first width.
[0088] The packet classification system is coupled to one or more switch-side devices over a multi-port PBUS 326 , and PBUS egress logic 324 is configured to transmit the associated packet over the PBUS 326 .
[0089] In one embodiment, slicer 306 comprises a plurality of memories configured to store some or all of the packet, and provide the portions thereof in parallel over the first data path 308 to the classification engine 310 . In one example, the slicer 306 is configured as eight (8) memories configured to provide the first 1024 bits of the bits of the packet (or less if the packet is less than 128 bytes) in parallel over the first data path 308 to classification engine 310 .
[0090] In one embodiment, the associator 320 comprises a multiplexor configured to multiplex onto the second data path 322 the data representative of the packet classification as stored in classification RAM 316 and some or all of the packet as stored in buffer 318 . In one implementation, the multiplexor multiplexes the first 8 byte portion 202 of the AF data illustrated in FIG. 2 (which may be referred to as the AF header) onto the second data path followed by the packet as stored in buffer 318 , thereby effectively pre-pending the AF header to the packet. In this implementation, control logic 328 controls the operation of the multiplexor through one or more signals provided over control data path 334 .
[0091] More specifically, the multiplexor in this implementation is configured to select one of three inputs and output the selected input to the second data path 322 under the control of the control logic 328 . The first input is the classification data as stored in classification RAM 316 . The second input is the packet as stored in buffer 318 . The third input is the output of the mirror FIFO 140 . This third input is selected when the egress mirroring function, discussed previously, is activated.
[0092] In one embodiment, the control logic 328 is also configured to maintain first and second FIFO buffers, identified respectively with numerals 330 and 332 , the first FIFO buffer 330 for identifying those packets which are awaiting classification by the packet classification system, and the second FIFO buffer 332 for identifying those packets which are undergoing classification by the classification system.
[0093] In this embodiment, the control logic 328 is configured to place an identifier of a packet on the first FIFO buffer 330 upon or after receipt of the packet by the packet classification system, pop the identifier off the first FIFO buffer 330 and place it on the second FIFO buffer 332 upon or after initiation of classification processing of the packet by the packet classification system, and pop the identifier off the second FIFO buffer 332 upon or after completion of classification processing of the packet by the packet classification system.
[0094] The control logic 328 is configured to prevent the packet classification system from outputting a packet onto PBUS 326 while an identifier of the same is placed on either the first or second FIFO buffers 330 , 332 , and allows the packet classification system to output the packet onto PBUS 326 upon or after the identifier of the packet has been popped off the second FIFO buffer 332 . In one implementation, the control logic 328 prevents the associator 320 from outputting data on the second data path 322 through one or more signals provided over control data path 334 . In one implementation, the control logic 328 is a state machine.
[0095] In one embodiment, the control logic 328 forms the basis of a packet statistics maintaining system within the packet classification system. In this embodiment, the control logic 328 is configured to maintain a pool of packet size determiners, and allocate a packet size determiner to a packet from the pool upon or after receipt thereof by the packet classification system.
[0096] In one implementation, the control logic 328 allocates a packet size determiner to a packet upon or after the PBUS ingress logic 304 signals a SOP condition for the packet. The packet size determiner is configured to determine the size of the packet, and the control logic 328 is configured to return the packet size determiner to the pool upon or after the same has determined the size of the packet. In one implementation example, the packet size determiners are counters.
[0097] Statistics RAM 330 in this embodiment maintains packet statistics, and statistics update logic 336 is configured to update the packet statistics responsive to the determined size of the packet. In one implementation, the statistics update logic 336 includes a queue for queuing statistics update requests issued by the control logic 328 .
[0098] In one configuration, the packet statistics maintaining system is configured to maintain packet statistics indicating the cumulative size of packets which have met specified processing conditions or hits, and the statistics update logic 336 , upon or after a packet size determiner has determined the size of a packet, is configured to increment a cumulative size statistic for a particular processing condition or hit by the determined size of the packet if the packet satisfies that particular processing condition or hit. In one example, the system maintains statistics indicating the cumulative size and number of packets which have resulted in each of a plurality of ternary CAM 142 hits.
[0099] FIGS. 4A-4B illustrate an embodiment 400 of a packet modification system having PBUS ingress logic 404 which is coupled to one or more switch-side devices through PBUS 402 . In this embodiment, the packets are received over the PBUS channels in bursts. The PBUS ingress logic 404 is configured to monitor the PBUS channels in a round robin fashion. When the PBUS ingress logic 404 detects a SOP condition on one of the channels, the Transmit Modification Index (TXMI) is extracted from the AF header of the packet, and it, along with the length of the initial packet burst, and an end of packet (EOP) marker if the packet length is less than or equal to the burst length, is placed on Transmit In Control FIFO 406 . The packet or packet burst is stored in Transmit In Data FIFO 428 , and a pointer to the start of the packet or packet burst (SOP pointer) is stored in Transmit Engine FIFO 408 , along with an identifier of the PBUS channel over which the packet or packet burst was received. In one implementation, the packet bursts are 128 bytes in length.
[0100] Transmit In Data FIFO 428 stores the packet data such that portions of the packet can be passed in parallel over a first data path 402 having a first width to a modification engine 422 . In one implementation, the Transmit In Data FIFO 428 comprises a plurality of FIFOs, with the outputs of the FIFOs coupled in parallel to the modification engine 422 and collectively forming the first data path 402 . Incoming packet or packet bursts are copied into each of the plurality of FIFOs, thereby providing the modification engine with sliced portions of the packets or packet bursts in parallel.
[0101] The incoming packets or packet bursts are also input to the second packet parser 424 , which parses the packets or packet bursts in the manner described previously. The context pointers and status bits resulting from the parsing process are stored in parser result RAM 426 .
[0102] The Transmit Command Sequencer 410 is configured to read a SOP pointer and channel from the Transmit Engine FIFO 408 , and utilize this information to locate the packet or packet bursts in the Transmit In Control FIFO 406 . The Transmit Modification Index (TXMI) within the AF header of this packet or packet burst is then located and used to access a TXMI link in External Transmit SRAM 412 , an SRAM located off-chip in relation to modification engine 422 . The TXMI link may either be 1) an internal recipe link to a recipe of modification commands stored in Internal Recipe RAM 414 , an on-chip RAM in relation to modification engine 422 , and related data structures stored in External Transmit SRAM 412 , or 2) an external recipe link to a recipe of modification commands stored in External Transmit SRAM 412 and related data structures also stored in External Transmit SRAM 412 .
[0103] The sequencer 410 also assigns a sequence number to the packet to prevent packet re-ordering. It then directs the Transmit RAM arbiter 416 to read the recipe of modification commands stored in the External Transmit SRAM 412 (assuming the TXMI link is an external recipe link) or Internal Recipe RAM 414 (assuming the TXMI link is an internal recipe link) and store the same in Recipe RAM 418 , an on-chip RAM in relation to modification engine 422 . It further directs the arbiter 416 to read the data structures associated with the specified internal or external recipe command sequence, and store the same in Data RAM 420 , another on-chip RAM in relation to modification engine 422 .
[0104] The sequencer 410 then awaits an available slot in the pipeline of the modification engine 422 . When such is available, the sequencer 410 passes to the engine 422 for placement in the slot a pointer to the recipe as stored in Recipe RAM 418 and other related information.
[0105] The sequencer 410 assigns a fragment buffer to the packet. The fragment buffer is a buffer within a plurality of fragment buffers which collectively may be referred to as TX work buffer 436 . The modification engine then executes the recipe for the packet or packet burst, through one or more passes through the modification engine pipeline. In one embodiment, the recipe comprises one or more entries, and one or more passes through the pipeline are performed to execute each entry of the recipe.
[0106] In the process of executing the recipe, the modification engine 422 stores the modified fragments of the packet in the fragment buffer allocated to the packet in TX work buffer 436 . At the same time, the modification engine 422 stores, in ascending order in fragment format RAM 438 , pointers to the modified fragments of the packet as stored in the fragment buffer and pointers to the unmodified fragments of the packet as stored in Transmit In Data FIFO 428 .
[0107] When all the recipe entries have been executed, the modification engine 422 writes an entry to the fragment CAM 440 , the entry comprising the PBUS channel over which the packet was received, the sequence number for the packet, the SOP pointer to the packet (as stored in the Transmit In Data FIFO 428 ), a packet to be killed flag, a packet offset in the Transmit In Data FIFO 428 , and the total length of the list of fragments as stored in the fragment format RAM 438 . This completes the processing of the packet by the modification engine 422 .
[0108] Fragment/burst processor 442 assembles the packets for ultimate egress from the system. To prevent packet re-ordering, the fragment/burst processor 442 processes, for each PBUS channel, the packets in the order in which they were received by the modification system 400 . More specifically, the fragment/burst processor 442 maintains an expected next sequence number for each PBUS channel, and then performs, in round robin fashion, CAM searches in fragment CAM 440 for an entry bearing the expected next sequence number for the channel. If an entry is found with that sequence number, the fragment/burst processor 442 processes it. If such an entry is not found, the fragment/burst processor 442 takes no action with respect to the channel at that time, and proceeds to process the next channel.
[0109] When a fragment CAM entry with the expected next sequence number is located, the fragment/burst processor 442 directs assembler 446 to assemble the packet responsive to the fragment list for the packet as stored in the fragment format RAM 438 . In one embodiment, the assembler 446 is a multiplexor, which is directed to multiplex between outputting on second data path 444 , responsive to the fragment list, the modified packet fragments as stored in the TX work buffer 436 and the unmodified packet fragments as stored in the Transmit In Data FIFO 428 (as provided to the multiplexor 446 over data path 434 ). Through this process, the packet is assembled in ascending order on second data path 444 . In one embodiment, the second data path 444 has a width less than the width of the first data path 402 . In one implementation, the fragment/burst processor 442 outputs the packets over data path 444 in the form of bursts.
[0110] The assembled packet is parsed by the third packet parser 448 in the manner described previously. The resultant context pointers and status flags are then passed, along with the packet, for concurrent processing by Transmit Processor Block 452 and Transmit ACL Logic 454 .
[0111] The Transmit Processor Block 452 performs two main functions. First, it performs egress mark processing by selectively modifying one or more QoS fields in the packet responsive to the egress mark control information from the packet stored by the modification engine in Transmit Post Processor RAM 456 . In one example, any of the VLAN VPRI, MPLS EXP, and IPv4/IPv6 TOS fields may be modified through this process utilizing the VPRI/EXP/IPToS RAMs 458 as appropriate. The egress mark control information may be derived from one or more egress mark commands specified by an AFH pre-pended to the packet, or from one or more egress mark commands within a recipe for the packet. Second, it performs OSI Layer 3 /Layer 4 checksum calculation or modification.
[0112] The Transmit ACL logic 454 conducts a CAM search for the packet in Egress ACL CAM 460 to determine if the packet should be killed, a copy sent to the host, or mirrored to the egress mirror FIFO 140 . The packet then exits the packet modification system 400 through the egress portion 462 of the system 400 , and is output onto PBUS 464 .
[0113] FIG. 5 illustrates a cascaded combination 500 of multiple, replicated packet systems, each of which is either a packet classification system or a packet modification system. In one embodiment, the cascaded combination comprises a first one 502 of the replicated packet systems having ingress and egress portions, identified respectively with numerals 504 and 506 , and a second one 508 of the replicated packet systems having ingress and egress portions, identified respectively with numerals 510 and 512 .
[0114] In this embodiment, the egress portion 506 of the first packet system 502 is coupled to the ingress portion 510 of the second packet system 508 . Moreover, the first one 502 of the replicated packet systems is configured to perform partial processing of a packet, either classification or modification processing as the case may be, and the second one 508 of the replicated packet systems is configured to complete processing of the packet.
[0115] In one configuration, packet system 508 forms the last one of a plurality of systems in the cascaded combination, and packet system 502 forms either the first or the next to last one of the systems in the cascaded combination.
[0116] In one example, each of the replicated systems performs a limited number of processing cycles, and the number of replicated systems is chosen to increase the number of processing cycles to a desired level beyond that achievable with a single system.
[0117] In a second example, a complete set of processing functions or tasks is allocated amongst the replicated systems. In one configuration, a first replicated system is allocated ACL and QoS classification processing tasks, and a second replicated system is allocated PTI/TXMI classification processing tasks.
[0118] FIG. 6 is a flowchart of one embodiment 600 of a method of processing a packet. In this embodiment, the method comprises step 602 , parsing a packet and providing first data representative thereof, and step 604 , classifying the packet responsive to the first data.
[0119] In step 606 , the packet is forwarded to and received from switching fabric, which may perform additional processing of the packet. Step 608 comprises parsing the packet received from the switching fabric (which may be the packet forwarded to the switching fabric, or a packet derived there-from), and providing second data representative thereof.
[0120] Step 610 comprises modifying the packet responsive to the second data, and step 612 comprises parsing the modified packet and providing third data representative thereof. Step 614 comprises post-processing the modified packet responsive to the third data.
[0121] In one embodiment, the packet undergoing processing has a plurality of encapsulation layers, and each of the first, second and third parsing steps 602 , 608 , 612 comprising providing context pointers pointing to the start of one or more of the encapsulated layers of the packet.
[0122] In a second embodiment, the packet undergoing processing comprises a first packet forming the payload portion of a second packet, each of the first and second packets having a plurality of encapsulation layers, and each of the first, second and third parsing steps 602 , 608 , 612 comprises providing context pointers pointing to the start of one or more of the encapsulated layers of the first packet and one or more of the encapsulated layers of the second packet.
[0123] In one implementation, the post-processing step comprises computing a checksum for the modified packet. In a second implementation, the post-processing step comprises egress marking of the packet. In a third implementation, the post-processing step comprises the combination of the foregoing two implementations.
[0124] FIG. 7 is a flowchart of a second embodiment 700 of a method of processing a packet. In this embodiment, step 702 comprises analyzing a packet in a packet classification system and, responsive thereto, selectively changing the state of a control bit from a first state to a second state. Step 704 comprises forwarding the packet to and from switching fabric. Step 706 comprises modifying, in a packet modification system, the packet received from the switching fabric (either the packet forwarded to the switching fabric, or a packet derived there-from), detecting the control bit to determine if egress mirroring of the modified packet is activated, and if so, providing a copy of the modified packet to the packet classification system.
[0125] In one implementation, the control bit is associated with the packet received from the switching fabric. In one example, the control bit is in a packet header pre-pended to the packet received from the switching fabric.
[0126] FIG. 8 is a flowchart of a third embodiment 800 of a method of processing a packet. Step 802 comprises providing a multi-dimensional quality of service (QoS) indicator for a packet. Step 804 comprises forwarding the packet to and from switching fabric. Step 806 comprises egress marking of the packet received from the switching fabric (either the packet forwarded to the switching fabric, or a packet derived there-from), responsive to at least a portion of the multi-dimensional QoS indicator.
[0127] In one implementation, step 806 comprises selectively modifying one or more quality of service fields within the packet received from the switching fabric responsive to at least a portion of the multi-dimensional quality of service indicator.
[0128] In one configuration, the multi-dimensional quality of service indicator comprises an ingress quality of service indicator, an egress quality of service indicator, and packet marking control information, and step 806 comprises selectively modifying one or more quality of service fields within the packet received from the switching fabric responsive to the packet marking control information. In one example, the multi-dimensional quality of service indicator further comprises a host quality of service indicator.
[0129] In one embodiment, the method further comprises utilizing the ingress quality of service indicator as an ingress queue select. In a second embodiment, the method further comprises utilizing the egress quality of service indicator as an egress queue select. In a third embodiment, the method further comprises utilizing the host quality of service indicator as an ingress queue select for a host.
[0130] FIG. 9 is a flowchart of an embodiment 900 of assigning a quality of service indicator to a packet. In this embodiment, step 902 comprises providing a plurality of quality of service indicators for a packet, each with an assigned priority, and step 904 comprises utilizing a configurable priority resolution scheme to select one of the plurality of quality of service indicators for assigning to the packet.
[0131] In one implementation, step 902 comprises mapping one or more fields of the packet into a quality of service indicator for the packet and an associated priority. In a second implementation, step 902 comprises performing a search to obtain a quality of service indicator for the packet and an associated priority. A third implementation comprises a combination of the foregoing two implementations.
[0132] FIG. 10 is a flowchart of an embodiment 1000 of a method of classifying a packet. In this embodiment, step 1002 comprises slicing some or all of a packet into portions and providing the portions in parallel over a first data path having a first width to a classification engine. Step 1004 comprises classifying, in the packet classification engine, the packet responsive to the packet portions received over the first data path and providing data representative of the packet classification. Step 1006 comprises associating the data representative of the packet classification with the packet to form an associated packet, and providing the associated packet over a second data path having a second width less than the first width.
[0133] In one implementation, the step of providing the packet portions over the first data path comprises providing each of the bits of some or all of the packet in parallel over the first data path to the classification engine.
[0134] In a second implementation, the associating step comprises multiplexing the data representative of the packet classification and some or all of the packet onto the second data path.
[0135] FIG. 11 is a flowchart of an embodiment 1100 of a method of modifying a packet. Step 1102 comprises providing some or all of a packet as packet portions and providing the portions in parallel over a first data path having a first width to a modification engine. Step 1104 comprises modifying, in the modification engine, one or more of the packet portions. Step 1106 comprises assembling a packet from the one or more modified and one or more unmodified packet portions, and providing the assembled packet over a second data path having a second width less than the first width.
[0136] FIG. 12 is a flowchart 1200 of an embodiment of a method of classifying a packet. Step 1202 comprises placing an identifier of a packet on a first FIFO buffer. Step 1204 comprises popping the identifier off the first FIFO buffer and placing it on a second FIFO buffer upon or after initiation of classification processing of the packet. Step 1206 comprises avoiding outputting the packet while an identifier of the same is placed on either the first or second FIFO buffers. Step 1208 comprises outputting the packet upon or after the identifier of the packet has been popped off the second FIFO buffer.
[0137] FIG. 13 is a flowchart illustrating an embodiment 1300 of a method of maintaining packet statistics. Step 1302 comprises allocating a packet size determiner to a packet from a pool of packet size determiners. Step 1304 comprises using the packet size determiner to determine the size of the packet. Step 1306 comprises updating one or more packet statistics responsive to the determined size of the packet. Step 1308 comprises returning the packet size determiner to the pool upon or after the same has determined the size of the packet.
[0138] In one implementation, the packet size determiner is a counter which counts the size of the packet. In a second implementation, the method further comprises queuing one or more statistics update requests.
[0139] In one implementation example, the one or more packet statistics indicate the cumulative size of packets which have met specified processing conditions or hits, and step 1306 comprises incrementing a cumulative size statistic for a particular processing condition or hit by the determined size of the packet if the packet meets that particular processing condition or hit.
[0140] FIG. 14 illustrates an embodiment 1400 of a method of classifying a packet. Step 1402 comprises buffering a packet in a buffer upon or after ingress thereof. Step 1404 comprises classifying the packet and providing data representative of the packet classification. Step 1406 comprises associating the data representative of the packet classification with some or all of the packet as directly retrieved from the buffer to form a packet on an egress data path.
[0141] In one implementation, step 1406 comprises multiplexing the data representative of the packet classification onto a data path followed by some or all of the packet as directly retrieved from the buffer.
[0142] FIG. 15 illustrates an embodiment 1500 of a method of modifying a packet. Step 1502 comprises buffering the packet in a buffer upon ingress thereof. Step 1504 comprises modifying one or more portions of the packet. Step 1506 comprises assembling the one or more modified portions of the packet with one or more unmodified portions of the packet as retrieved directly from the buffer to form an assembled packet on an egress data path.
[0143] In one implementation, the method comprises providing a list indicating which portions of the assembled packet are to comprise modified portions of an ingress packet, and which portions are to comprise unmodified portions of the ingress packet, and step 1506 comprises assembling the assembled packet responsive to the list.
[0144] FIG. 16 illustrates an embodiment 1600 of a method of processing a packet in a cascaded combination of multiple, replicated packet processing systems. In one implementation, each of systems is either a packet classification system or a packet modification system, and the processing which is performed by each system is either classification processing or modification processing as the case may be. Step 1602 comprises performing partial processing of a packet in a first of the replicated packet processing systems, and step 1604 comprises completing processing of the packet in a second of the replicated packet processing systems.
[0145] In one implementation, the second packet processing system is the last of a plurality of replicated packet processing systems, and the first packet processing system is either the first or next to last packet processing system in the plurality of packet processing systems, wherein partial processing of a packet is performed in the first replicated packet processing system, and processing is completed in the second replicated packet processing system.
[0146] FIG. 17 illustrates an embodiment 1700 of a method of preventing re-ordering of packets in a packet processing system. Step 1702 comprises assigning a sequence number to a packet upon or after ingress thereof to the system. Step 1704 comprises processing the packet. Step 1706 comprises storing data representative of the packet in a buffer. Step 1708 comprises checking the buffer for an entry matching an expected next sequence number. Inquiry step 1710 comprises determining if a match is present. If so, steps 1712 and 1714 are performed. Step 1712 comprises outputting the corresponding packet, and step 1714 comprises updating the expected next sequence number to reflect the outputting of the packet. If not, the method loops back to step 1708 , thus deferring outputting a packet if a match is not present.
[0147] In one implementation, steps 1708 - 1714 comprise maintaining an expected next sequence number for each of a plurality of output channels, checking the buffer for a match for each of the channels, outputting the corresponding packet on a channel if a match for that channel is present and updating the expected next sequence number for that channel, and deferring outputting a packet on a channel if a match for that channel is not present.
[0148] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of this invention. | A packet processing system architecture and method are provided. According to a first aspect of the invention, a plurality of quality of service indicators are provided for a packet, each with an assigned priority, and a configurable priority resolution scheme is utilized to select one of the quality of service indicators for assigning to the packet. According to a second aspect of the invention, wide data paths are utilized in selected areas of the system, while avoiding universal utilization of the wide data paths in the system. According to a third aspect of the invention, one or more stacks are utilized to facilitate packet processing. According to a fourth aspect of the invention, a packet size determiner is allocated to a packet from a pool of packet size determiners, and is returned to the pool upon or after determining the size of the packet. According to a fifth aspect of the invention, a packet is buffered upon or after ingress thereof to the system, and a packet for egress from the system assembled from new or modified packet data and unmodified packet data as retrieved directly from the buffer. According to a sixth aspect of the invention, a system for preventing re-ordering of packets in a packet processing system is provided. A seventh aspect of the invention involves any combination of one or more of the foregoing. | 7 |
OTHER REFERENCES
[0001] Chem. Abst., 66, 76542m (1967). Fluorine-containing compositions for treating substrates to render them oil-, water- and soil-repellant, comprising A fluorine-containing acrylic copolymer and a fluorine-free poly (meth) acryl ate.
[0002] This application is a divisional of U.S. patent application Ser. No. 10/611,746 filed Jun. 30, 2003. Titled “Chemical formulations and methods utilizing NPB (n-propyl bromide) as non-aqueous carrier mediums to apply fluorocarbons and other organic chemicals to substrates” which is incorporated by reference in its entirety herein.
BACKGROUND OF THE INVENTION
[0003] NPB (n-propyl bromide) has been used in the metal parts degreasing industry, particularly in vapor degreasers for years. Now according to the invention it has been discovered to have a very useful and desired purpose in other industries. Many substrates, for example, home textiles, carpets, upholstery acquire oil-, water- and soil-repellant properties by treatment with fluorocarbons.
[0004] These chemicals are now applied to substrates with water based (aqueous) carriers requiring other auxiliary chemicals i.e.: emulsifiers and dispersing agents to keep organics in suspension. These auxiliary chemicals needed for aqueous application often lesson the intended benefit of the applied chemical to the substrate. These aqueous carriers require high temperatures and expensive drying systems to evaporate the water. Chlorinated hydrocarbons have been used in the past as carrier mediums to apply organic chemicals to substrates when an aqueous carrier could not be used. Chlorinated hydrocarbons are being phased out by mandate of the Environmental Protection Agency (EPA).
BRIEF SUMMERY OF THE INVENTION
[0005] By this invention, NPB has shown an excellent alternative to current aqueous and chlorinated hydrocarbons as a carrier medium for application of organics to substrates. NPB is non-regulated, non-toxic and has no ozone pollution properties. NPB is economical and environmentally friendly.
[0006] The invention relates to compositions for providing one or more fire retardant properties to, or for enhancing one or more fire retardant properties of, substrates containing at least 5 weight percent of non-thermoplastic material, such as non-thermoplastic filaments, microfibers, fibers, fibrous compositions, threads, yarns, fabrics, textiles, materials, items of apparel, paper or tissue, or blends or products produced using any of the foregoing materials, and to substrates treated in accordance with the processes, systems or compositions of the invention.
[0007] After extensive study, it has been found that the use of NPB as a carrier dramatically improves the performances and durability of benefits achieved by application of organics to substrate and that this invention is superior to current methods and chemistry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0008] The invention relates to methods and formulations to provide substrates with treatment to include fire retardant treatment, for example; the treatment of home textiles and apparel, which achieve desired effects with significantly smaller amounts of expensive fire retardant compounds as compared to available current technology, as illustrated in Example 2 compared to Example 4.
[0009] The following description, taken in conjunction with the referenced examples, is presented to enable one of ordinary skill in the art to make and use the invention. Various modifications will be readily apparent to those Skilled in the art, and the general principles defined herein may be applied to a wide range of aspects. Thus, the present invention is not intended to be limited to the aspects presented, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. Furthermore, the compositions according to the invention should furthermore impart to the substrates, in particular the home textiles, water-repellant actions that meet increased requirements.
[0010] Another object comprises providing treatment compositions with which the heat treatment or curing can be carried out at the lowest temperature or, preferably, no heat treatment is necessary (Example 3).
[0011] In one aspect, invention relates to substrates from the group consisting of naturally occurring and synthetic textiles and their mixtures, leather, mineral substances, thermoplastic and thermosetting polymers and paper, which are treated with fluorine-containing compositions of the type mentioned below in an amount of 10 to 10,000 ppm, preferably 50 to 5,000 ppm, particularly preferably 100 to 2,000 ppm, calculated based on the total weight of substrates provided wit treatment.
[0012] In another aspect, other textile auxiliary chemicals can be added during preparation of the treatment formula as according to the invention, or subsequently. Such additives are crease-proofing and soft handle agents, melamine, water and oil repellent, oleophobizing agents, hydrophobizing agents, Urethane, finishing agents, extenders for textile auxiliaries and others.
[0013] Substrates which are suitable for treatment according to the invention are: linen, cotton, wool, silk, jute, polyamide, polyester, polyacrylonitrile and mixtures thereof, leather, stone slabs, floor tiles, glazed tiles, roof tiles, glass, ground surfaces of silicon, foils and films and compact work pieces of polyolefin's, polyesters, polyamides, polycarbonates, polyurethane, polyacetals, polyethers, polysulphides, polysulphones, polyamides and other thermoplastics, as well as of phenol/formaldehyde resins, urea/formaldehyde resins, melamine/formaldehyde resins and other thermosetting resins, paper and paper-like materials, such as paperboard. Preferred base substrates are home textiles based on naturally occurring and synthetic textiles and their mixtures, which are employed, for example, as carpets, curtains, decorative materials or coverings for upholstered furniture.
[0014] Processes for the treatment of such base substrates and therefore for application of the compositions according to the invention are known to the expert and are, for example, foaming, dipping or spraying of the base substrates; the compositions according to the invention furthermore can be employed during the production of the base substrates, for example the pulp.
[0015] Textiles as base substrates, preferably home textiles and apparel can be treated, for example, in the padding, spraying or foaming process. The padder consists of a liquor trough (chassis) and at least one pair of rubber rolls (Example 2). The textiles to be treated are impregnated with the treatment liquor in the chassis and squeezed off between the rolls; the liquor runs back into the chassis. It is very important that a uniform liquor pick-up is achieved over the entire width of the goods during squeezing-off.
[0016] In the padding process, the liquor pick-up is stated in percentage of the weight of goods, and for normal textile constructions can be between 30 and 300%, depending on the quality of the goods and the padder pressure used.
[0017] In the spraying process, (Example 3) the textile is sprayed with the treatment liquor. The treatment liquor is finely divided by nozzles and applied uniformly. An amount of treatment liquor precisely defined beforehand is applied to one square meter of textile goods.
[0018] In the foaming process, the treatment liquor is continuously foamed mechanically in a commercially available mixer with out the addition of a foaming agent. The foam is produced in the mixing head by mixing the liquor with air. The foam, which emerges, is conveyed via a foam line to a discharge slot in the applicator. The goods are pressed against the slot and taken off via a separate unit, for example a stenter frame. In example 1, a concentration of 92% NPB and 6% retardant treatments with 2% foaming aid were carried out on the Gaston Systems, Inc. Foam Generation and Application system, Stanly, N.C.
[0019] By the invention, it has been discovered surprisingly that a mixture of NPB Fire retardant and Perfluoroalkyl polyacrylate as foaming aid can be foamed without the aid of a foaming agent (Example 1). Not using foaming agents greatly improves the benefit of the applied composition to the substrate and reduces the amount of compound added to fabric to achieve properties.
[0020] In prior art, fire retardants are used in the textile industry. However, they generally applied by dip and squeeze and produce limited results, because they are used in suspension form. According to the invention, the non-aqueous solution of fire retardants are in solution with NPB, optionally with complementary components, is applied to textile materials and penetrates into the fibers, and then polymerization is effected by heating at temperatures above 230.degree. F., thus polymerizing and binding the resulting polymers and retardants to the fibers.
[0021] According to the invention retardants can be applied with (meth) acrylate derivatives, such as butyl acrylate, methyl methacrylate or other monomers, to produce transparent plastics bonding retardants to the fiber.
[0022] In another aspect, this invention involves the surprising discovery that the use of NPB with retardants via dipping and squeezing with pressure rollers (Padding) and the NPB being evaporated away imparts a much improved softness and luster to treated textile substrates, especially home furnishing, apparel fabrics and upholstery fabrics.
[0023] After the treatment, the textiles, preferably home textiles, are dried, it being possible to use temperatures of 120.degree. To 170.degree. C. to achieve the desired treatment effect according to the known procedure. However, good treatments can also be obtained with the new compositions according to the invention at significantly lower drying temperatures, for example at 25.degree. C. (Example 3).
[0024] Samples of the materials thus pretreated were taken for testing of the following effects:
[0025] Oil-repellency (according to AATCC 118-1972): The test sample is placed on a horizontal, smooth surface, a small drop (drop diameter about 5 mm) of he test liquids is applied to the test sample with the aid of a dropping pipette, In addition, the sample is evaluated as specified.
[0026] The AATCC oil-repellency level of a test fabric is the highest number of that test liquid which does not wet or penetrate into the test material within a time span of 30 seconds. The test liquids and mixtures for the test method are: No. 1: Nujol or paraffin oil DAB 8; No. 2: 65% by volume of Nujol and 35% by volume of n-hexadecane; No. 3: n-hexadecane; No. 4: n-tetradecane; No. 5: n-dodecane; No. 6: n-decane; No. 7: n-octane; No. 8: n-heptane.
[0027] Repellency towards a water/alcohol mixture (hydrophobicity): Drops of water/isopropanol mixtures (ratio 90/10 to 10/90) are applied to the test sample. The test result corresponds to the mixture with the highest isopropanol content which remains on the test sample in unchanged form for at least 20 seconds (the value 80/20, for example, is better than 20/80).
EXAMPLES
[0028] Compositions which are not according to the invention (Example 4) and which represent the prior art are the following: Nuva HPU (Clariant Corporation). Scotchgard.RTM. FC 396 (3M Comp.) according to DE-A 2 149 292 Baygard.RTM. SF-A. (Bayer AG) according to DE-A 3 307 420 and Zonyl (E.I. Dupont)
[0029] The compositions according to the invention (Example 1) is a non-aqueous solution, contents of which comprise a mixture of NPB (component A) and one or more fire retardants (component B) and optionally (component C) one or more poly (meth) acrylates with cross linker.
Use of the Compositions According to the Invention:
Example 1
[0030] 91.8% NPB, 6% alkyl phosphate, 2% tribromoneopentyl alcohol and .2% perfluoroalkyl polyacrylate. Solution foamed at 20:1 blow ratio until a stable foam was achieve ( Approximately 3 minutes).
[0031] Fabric without flame retardants was placed into a pin frame and completely covered with a foamed non-aqueous solution according to the invention described in EXAMPLE 1 at 50% wet pick-up and dried at 230 deg F. for 2 minutes.
[0032] The dried fabric was then flame tested using the NFPA 701 test. The char length of the dried flame retarded fabric was determined to be less than 3 inches. Thus, this treated substrate also passed the NFPA 701 test. Additionally, there was no after flame, indicating that the substrate had good fire resistance, and that the induced flame was self extinguishing.
Example 2
[0033] A solution of 99.6% NPB and .4% Perfluoroalkyl polyacrylate were mixed and applied to the substrates listed below via a pad applicator at 3.5 bars pressure. The solution was applied at noted wet pickup. Again, the substrates were dried at 170 deg C. with a 1-minute dwell.
Initial After 10 Home Laundries Example 2 Oil IPA Spray Fluoride Oil IPA Spray Fluoride Cotton 6 100 100 2480 ppm 3 90 80 2200 ppm Polyester 8 90 100 1270 ppm 6 90 90 1100 ppm Pes/Rayon 8 80 100 6 80 80
Example 3
[0034] A solution of 99.6% NPB and 2% Perfluoroalkyl polyacrylate were mixed and applied to the substrates listed below via a Spray at 1.5 bars pressure. The solution was applied at noted wet pickup. Again, the substrates were dried at 170 deg C. with a 1-minute dwell.
Initial After 10 Home Laundries Example 3 Oil IPA Spray Fluoride Oil IPA Spray Fluoride Cotton 6 85 100 2260 ppm 2 60 70 1690 ppm Polyester 6 90 100 1170 ppm 5 90 90 1080 ppm Pes/Rayon 6 80 100 5 60 70
Use of the Compositions not According to the Invention
Example 4
[0035] An aqueous Perfluoroalkyl polyacrylate dispersion using Nuva HPU at 2% concentration was prepared and applied via a padding applicator at 3.5 bars pressure. The solution was applied at noted wet pickup. Again, the substrates were dried at 170 deg C. with a 1-minute dwell.
Initial After 10 Home Laundries Example 4 Oil IPA Spray Fluoride Oil IPA Spray Fluoride Cotton 7 100 100 2460 7 90 80 2210 ppm ppm Polyester 6 60 100 1270 4-5 45-50 90 1100 ppm ppm Pes/ 5 60 100 2 35-40 70 Rayon
[0036] In all examples, the substrates used were (1) White Polyester 8oz/sq yd (PES), (2) 100% Cotton interlock and (3) 60/40 PES and Rayon Blend. | The present invention relates to methods and chemical compositions utilizing NPB (n-propyl bromide) also called 1-bromopropane or propyl bromide or 1-BP or N-Bromopropane as non-aqueous carrier mediums to apply fire retardants, fluorocarbons and other chemicals to substrates, whereby the NPB is evaporated away leaving the remaining chemicals on the substrate. The present invention offers compositions and method for applying organic chemicals to substrates that perform superior to current water based technology. Additional, the invention offers a more economical and environmental friendly alternative to current chlorinated hydrocarbons carriers that are being phased out by mandate of the Environmental Protection Agency (EPA). | 3 |
OBJECT OF THE PATENT
[0001] The object of the patent is to furnish a lightning conduction system for current wind turbine blades. The new lightning system is achieved by adding a device that reduces the current fraction of the lightning transmitted through the carbon fiber laminates.
BACKGROUND OF THE INVENTION
[0002] Given the height of the wind turbines and their erection in elevated regions lacking other elements having similar heights, there is a high risk of being struck by lightning, especially in the blades. With this in mind, blades must be equipped with a lightning protection system, and any other additional system installed in the blade containing conductor elements (metal parts, sensors, beacon systems, etc.) must be protected against direct impacts of lightning bolts and indirect effects of the electromagnetic field induced by the bolt current.
[0003] The primary components of the lightning protection system for wind turbine blades are a series of metal receptors mounted on the surface of the blade and a cable conductor to transit the bolt from the receptors to the blade root.
[0004] The evolution of wind turbines together with the growth in their provided power have led to new generations of wind turbines having ever-increasing dimensions insofar as tower height and rotor diameter. Blade lengthening necessitates an increase in rigidity. The use of a larger quantity of carbon fiber-based laminates in blade production is common to achieve this rigidity. However, carbon fiber laminates are conductors and must therefore be connected in parallel with the lightning protection system conductor cable to prevent internal arcing between the cable and the laminates and direct lightning bolt strikes on the carbon laminate.
[0005] In this regard, international patent WO2006051147, which presents a “lightning conductor system for wind generator blades comprising carbon fibre laminates”, can be cited since the use of carbon fiber in blade beam construction requires that this material be equipotentialized with the lightning conductor system. To do so, the primary cable of the lightning conductor system is furnished with bypasses for connections directly with the carbon fiber laminates. These auxiliary cables are connected with a bolted joint to a metal plate in direct contact with the carbon fiber layers. The electrical connection can be improved with the use of additional conductor resins in the joint area.
[0006] Notwithstanding this solution, the distribution of current transmitted across the cable and carbon laminates are not controlled, which could make the transfer of current across the carbon without damaging it even more difficult, thus necessitating a device to connect the carbon fiber laminates in parallel with the cable conductor of the system and to control the current circulating through the carbon fiber as in the proposal for the present invention.
DESCRIPTION
[0007] The longer lengths of blades currently in use call for suitable reinforcement of the internal blade beam (structural element withstanding the largest stresses). The beam is thus manufactured with an increasing number of carbon fiber layers which could result in a problem (since thicker and wider laminates offer less resistance to the passage of current) in conducting strong currents through the cable coming down from the lightning conductor system instead of the beam laminate.
[0008] An object of this invention is to improve the current lightning conductor system for blades of a lesser length and with a smaller amount of carbon fiber in the laminates on the blade beam.
[0009] Another object of this invention is to include a device in at least one of the existing connections between the laminates of the carbon fiber and the conductor cable of the lightning conductor system to control the current fraction of the bolt transmitted through the carbon fiber laminates.
[0010] Another object of the invention is the current control device formed by a highly conductive element, thus reducing the current fraction of the bolt transmitted through the fiber carbon laminates.
[0011] The foregoing is attained by connecting the carbon fiber laminate with the conductor cable. Thus, the lightning protection system is converted into a two-branched circuit in parallel: one branch formed by the cable conductor, of low resistance and high inductance, and the other branch formed by the carbon laminate, having high resistance and low inductance. When lightning strikes one of the receptors on the blade, the lightning protection system must evacuate bolt current, whose waveform is characterized by having a first phase in which the current rises steeply, followed by a second phase where the current drops slowly. When this current is injected into the circuit formed by the carbon laminate connect in parallel to the cable, the current is distributed as follows:
During the steep rise phase, most of the current is transmitted by the conductor with less inductance (carbon laminate) During the gradual drop phase, most of the current is transmitted by the conductor with less resistance (conductor cable)
[0014] With the current distribution described above, the carbon laminate undergoes a large current peak at the beginning of the discharge, whereas, based on the increased size of the blades, the inductance of the carbon laminates (wider and thicker) decreases. This provokes the fraction of the current conducted by the carbon to increase. The transmission of a lightning bolt discharge is simple to carry out in metal elements, yet complicated in carbon laminates, which contain resins that degenerate at temperatures between 100° C. and 200° C.).
[0015] The main advantage of using the high-inductance device placed in the connection between the carbon laminates and the conductor cable is that it reduces the passage of current through the carbon laminate and favors conduction through the metal cable.
[0016] Another advantage is that it is unnecessary to utilize a device in the two connections between the carbon and the conductor cable (at the beginning and end of the laminate); a mere device used at one of the two connections will suffice.
DESCRIPTION OF THE FIGURES
[0017] FIG. 1 represents the relative position between the carbon flanges and the cable that runs through the core in a section of the blade.
[0018] FIG. 2 shows the plate making the connection with the carbon fiber, as well as the bypasses with auxiliary cables.
[0019] FIG. 3 shows the detail of the connection between the plate and the carbon fiber, and the bypasses of the auxiliary cable to the primary cable with the inclusion of the high-inductance device.
DESCRIPTION OF THE PREFERENTIAL EMBODIMENT
[0020] As shown in FIG. 1 , the lightning conduction system in the blade ( 1 ) with carbon fiber laminates ( 2 ), object of the invention, employs a lightning conduction system based on a primary cable ( 6 ) to which, additionally, some bypasses are fitted in order to connect it directly with the carbon fiber laminates ( 2 ) thereby ensuring the equipotentiality of both systems.
[0021] As shown in FIG. 2 , the bypasses are made with two connections to each one of the two carbon fiber laminates ( 2 ), the one corresponding to the upper part of the beam ( 10 ) and the one corresponding to the lower part of the beam, represented in the previous figure. These laminates are located on the two sides that are affixed to the shells of the blade known as the flanges ( 4 ). One connection is made in the beam root area and the other at the tip area so that the flanges ( 4 ) of the beam become alternative paths for the bolt. The differentiating characteristic of the system lies in the form that connections are made between the primary cable ( 6 ) and the carbon laminates ( 2 ), this is achieved by bypasses from the primary cable ( 6 ) due to small pieces of auxiliary cable ( 5 ) connected with a bolted joint to a metal plate ( 3 ). This metal plate ( 3 ) is designed to make the direct connection with the carbon ( 2 ). The plates ( 3 ) are mounted during the beam lamination process onto the beam's layers of carbon fiber and are subsequently covered with glass or carbon fiber layers employed in the later lamination of the beam. The plates ( 3 ) adhere to the laminates in the normal curing of the beam thus achieving a mechanically robust union with the beam and electrically well connected with the carbon fiber ( 2 ).
[0022] As shown in FIG. 3 , according to the practical embodiment of the invention, this is a typical blade beam comprising two cores ( 8 ) and two flanges ( 4 ). The carbon laminates ( 2 ) used to stiffen the beam are employed in the flanges ( 4 ) of the beam ( 10 ). For this purpose, these laminates ( 2 ) are connected to the drop cable or primary cable ( 6 ) through an auxiliary conductor element ( 5 ) and connects using a bolted joint to the metal plate ( 3 ) and to the device ( 12 ) capable of reducing the passage of current across the carbon laminate ( 2 ) and thus favoring the conduction across the primary cable ( 6 ). The device ( 12 ) redistributes the current within the blade and not outside of it, hence protecting the carbon fiber ( 2 ) used in the beam of the blade ( 1 ).
[0023] The lightning conduction system device, object of this invention, is applicable to already existing lightning conduction systems. This would merely imply including the new device by cutting the existing cable and connecting it between the carbon laminate ( 2 ) and the primary cable ( 6 ). The device ( 12 ) is an inductive element whose inductance varies between 5 mH and 50 mH based on the length of the blade (which could vary between 20 and 70 meters) and is preferentially formed by coil with two terminals for ease of connection. | Lightning rod system for wind turbine blades formed by various connections set up on carbon fiber laminates ( 2 ) on the blade ( 1 ), equipotentializing the surface of the flanges ( 4 ) of the beam ( 10 ) through the deviations of a primary cable ( 6 ) with the respective auxiliary cables ( 5 ), carried out with the use of a device ( 12 ) whose terminals are connected between the ends of the cited auxiliary cable ( 5 ).
The use, given the elevated inductance of device ( 12 ) mounted on the connection between the carbon laminates ( 2 ) and the conductor cable or primary cable ( 6 ), is to reduce the passage of current across the carbon laminate and favor the conduction through the metal cable. | 5 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Serial No. 60/137,989 filed on Jun. 7, 1999 and which is incorporated herein by reference.
FIELD OF THE INVENTION
The present invention is generally directed towards a display cabinet and particularly a commercial display cabinet having an internal lighting system and assembly.
BACKGROUND OF THE INVENTION
A wide variety of commercial display cabinets exists. One common type of a refrigerated display cabinet includes a cabinet frame which extends generally about the periphery of the front of the display cabinet. The frame includes an upper frame member, a lower frame member, two laterally spaced side frame members extending vertically between the upper and the lower frame members, and a center mullion which extends vertically between the upper frame member and the lower frame member and connected thereto. The mullion provides support for the cabinet frame, associated doors, and also provides a sealing surface against which portions of the door assemblies engage and seal for effective sealing of the refrigerated cabinet. Typically, mullions are also equipped with electrical conduits for delivering electrical power to anti-condensation devices for the door assemblies and for a fluorescent lighting fixture associated with the mullion.
One popular design for a refrigerator or freezer cabinet frame assembly provides for one central mullion, a door stop for a pair of doors, each door pair member being mounted to a respective front edge of the display cabinet. Thus, the doors open from the front center of the cabinet with the left opening door pair member having hinge pins on the left side of the door and the right opening door pair member having hinge pins on the right side of the door. The central mullion provides a gasket covered surface and support for engaging and securing the doors in a closed position.
A fluorescent light is typically mounted on the rear surface of the center mullion so as to illuminate the interior of the display cabinet. Proper illumination of the merchandise present within the display cabinet is important so as to maintain an attractive product appearance and to allow a customer to visually locate merchandise within the cabinets prior to opening the cabinet door. Various louvered reflectors have been disposed inside the cabinet to redirect the light within the cabinet. As such, it is desirable to provide a refrigerated display cabinet having a lighting assembly which improves the illumination of the cabinet merchandise.
The construction and components used in an illuminated refrigeration or freezer display cabinet are well known in the art. For instance, U.S. Pat. Nos. 5,471,372 to Mamelson et al. and 5,879,070 to Severloh, are directed to the construction of lighted refrigerated display cases, these references being incorporated herein by this reference.
SUMMARY OF THE INVENTION
In accordance with the present invention, an improved refrigerated display case having a central vertical mullion spaced opposite the handle portion of adjacent side pivoted doors is provided. The central mullion is secured at its top and its bottom to the cabinet frame, and a pair of rectangular doors are mounted to opposite sides of the frame on vertical hinge axes for swinging movement between open positions and closed positions. In the closed position, the central mullion defines a front surface adapted to seal with the rectangular door inner surface. The central mullion is generally rectangular and hollow and has a front surface facing outwardly of the cabinet assembly, a back surface facing inwardly of the cabinet assembly, the two sides of the mullion being open and adapted for receiving a fluorescent lighting assembly. The lighting assembly positions a fluorescent bulb within each side of the center mullion whereby the bulb may be easily accessed and replaced. This placement also allows a significant portion of the bulbs' illumination to be directed towards and reflect from the interior glass door surface and thereby increase the effective illumination within the cabinet's interior. An outer protective lens is removable to access the light assembly components. In one embodiment of the invention, the leading edge of each door is canted outwardly forming an approximate 77.5 degree angle relative to an axis perpendicular to a plane defined by a rear cabinet wall.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front perspective view of a display case in accordance with the present invention;
FIG. 2 is a perspective view in partial section of a central support mullion and associated doors as seen from an interior of the case;
FIG. 3 is a sectional view taken along line 3 — 3 of FIG. 2;
FIG. 4 is a perspective view of an embodiment of a central mullion with details of the light assembly components;
FIG. 5 is a sectional view taken along line 5 — 5 of FIG. 4; and
FIG. 6 is a sectional view similar to FIG. 5 showing an alternative embodiment of a lens construction.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the existing construction.
In describing the various figures herein, the same reference numbers are used throughout to describe the same apparatus. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus is labeled with the same reference numbers.
In reference to FIG. 1, a refrigerated display case 10 is provided having a cabinet which defines an enclosure having an interior space accessible via a front opening. A pair of doors 12 and 14 is supported by the cabinet and may be selectively positioned to close the cabinet's front opening or allow access to the interior space of the cabinet's enclosure via the front opening. Each door 12 , 14 , includes a panel 16 that is transparent or translucent to permit viewing of the product within the enclosure and is movable to provide access to the product. As illustrated in the figures, doors 12 and 14 are mounted to opposite sides of case 10 in a conventional manner for swinging movement between an open position and a closed position. However, the hinge portions of the doors could be installed along the center mullion so that the doors open from opposite ends of the display case. Handles 13 are used to engage and pivot the doors 12 and 14 . If desired, the movable doors could be provided by one or more sliding glass doors.
An inner perimeter of each door defines a conventional seal and gasket arrangement to provide a substantially air tight thermal barrier for case 10 when the respective doors are closed. As seen in reference to FIG. 3, a portion of door gasket 40 carries a magnet 42 which helps maintain the pivoting doors 12 and 14 in a closed position.
As seen in reference to FIG. 2, a central mullion is designated generally by the numeral 20 and extends the height of the enclosure and is positioned opposite a leading edge of door 12 and door 14 when oriented to close the front opening of the cabinet. The mullion 20 extends the height of the enclosure and is positioned opposite a leading edge of each of the individual doors 12 and 14 . The mullion has a front surface 24 , a back surface 28 opposite the front, and a pair of opposed sides extending between the front and the back, each side defining a lateral opening 26 .
As explained more fully below and shown in FIG. 5 for example, mullion 20 defines a front face 24 which is formed of a magnetic material that will attract the magnet 42 of the door gaskets. As shown in FIGS. 4 and 5 (chain-dashed line), mullion 20 further defines a pair of integral upper flanges 21 which are used to secure the mullion to the cabinet front, each flange 21 defining an aperture 23 for attaching the mullion to the cabinet. Each side edge 27 of front face 24 engages a respective support member 22 , which is desirably fabricated as a plastic extrusion. Support member 22 defines a front surface 25 and a rear surface which defines mullion back surface 28 . A resistive wire 29 provides a heating element disposed against the inner surface of the mullion face to reduce condensation on the portion of the mullion's face 24 , which is exposed to the external environment when the doors are opened. Alternatively, insulation (not illustrated) may be installed for this same purpose as is conventional within the art.
As best seen in reference to FIGS. 3 and 4, a light fixture 30 is supported within each lateral opening 26 defined by support member 22 along either side of the mullion. Each light fixture 30 is configured and disposed for receiving and supporting an illumination source such as a fluorescent bulb 34 . As shown in FIG. 3, a mounting clip 37 receives the electrical end prongs 38 of each bulb 34 . A light diffuser such as a diffusing lens 32 is positioned within the lateral openings 26 and opposite the light fixture 30 and bulb 34 so as to diffuse the direction and intensity of light emanating from the illumination source. Lens 32 covers the lateral openings 26 .
As seen in reference to FIG. 4, the front face 24 of center mullion 20 engages the support member 22 along either edge 27 of front face 24 . A pair of mounting flanges 21 extend normally with respect to the main body of front face 24 and over a portion of the mullion's interior and define a hole 23 for attaching the mullion to the display case's cabinet. Each extruded support member 22 provides a U-shaped housing, the interior of which is adapted for receiving the light fixture 30 . In reference to the orientation seen in FIGS. 3 and 5, the lateral opening 26 along each side of the mullion 20 , is defined by support member 22 is configured to and allow each bulb 34 to emit light through the respective lateral opening 26 , passing through diffusion lens 32 . As seen in FIGS. 3 and 5, the diffusing effect of lens 32 is indicated schematically as a single directional ray of light, designated as “L”, which is diverged into multiple rays (“LL”) upon passing through the lens 32 . For clarity of illustration, only a single ray “L” is shown diverging into multiple rays “LL”.
Lens 32 may be provided by a flexible curved piece of translucent plastic which is removably held in a tensioned fashion by support member 22 . As best seen in reference to FIG. 5, it has been found useful to provide a first ridge 50 and a second ridge 52 as part of support member 22 . Ridges 50 , 52 generally define therebetween lateral opening 26 . Ridges 50 and 52 are used to engage respective correspondingly shaped first notch 54 and second notch 56 formed near opposite edges of the embodiment of lens 32 shown in FIG. 5 . Preferably, lens 32 has sufficient flexibility that a simple lens 32 may be easily inserted and removed by providing a slight compressive action to the terminal ends of the lens 32 .
In an alternative configuration of lens 32 and support member 22 shown in FIG. 3 for example, recessions 31 and 33 are formed in the opposite side edges of support member 22 and configured to receive the respective side edges of lens 32 . A boss 35 is provided along the exterior surface of lens 32 to provide a means of gripping lens 32 to pry it from engagement with support member 22 .
Yet another alternative configuration of lens 32 is shown in FIG. 6 . An inner surface of lens 32 defines a plurality of inwardly directed projections 60 . Each projection 60 extends along the length of the lens 32 and may be integrally formed with lens 32 . Collectively, projections 60 define a baffle or series of blind-like slats which alter the direction and intensity of emitted light in comparison to a lens 32 without the projections.
As seen in FIG. 6, projections may be substantially perpendicular to reference line A so as to achieve a substantially uniform distribution of light horizontally across the front edges of the display shelves. However, depending upon the desired illumination effect, the spacing between the projections, the number of projections, the relative angles of one or more of the projections, the size, thickness, and length of the projections may be modified. As further seen in reference to FIG. 6, the projections 60 may extend inwardly different lengths, depending upon location, so as to affect the amount and direction of transmitted light.
The projections 60 do not alter the pathway of light rays (L) which pass between the opposite projections. However, rays (L) which strike a single projection 60 will partially block and alter the resulting scatter light “LL”. As a consequence, projections 60 serve to soften and lower the intensity of emitted light rays which pass through or impact an internal projection 60 . Further, there is a corresponding increase in the relative amount and intensity of the light fractions which are transmitted between the projections. The improved gradient of transmitted light prevents over-illumination of product immediately adjacent the light source and improves the illumination quality of product which is more distant from the light source.
In accordance with this invention, it has been found that the glass door will reflect a significant portion of the light emitted from a lateral opening 26 , redirecting the reflected light towards the interior of the cabinet. The reflected light from the door's interior surface provides an even, front illumination source of reflective light for merchandise displayed within the cabinet. Additional lighting is provided directly from light passing through the diffuser lens. This combination of lighting provides for an even product illumination.
If desired, support member 22 can be provided from a transparent or translucent material such as polycarbonate or other clear or translucent plastic. The light transmitting support member will allow a broader distribution pattern of light from the mullion, the distribution pattern not being limited to the physical dimensions of the lateral opening. Alternatively, support member 22 may be coated with a reflective or non-absorbing paint so as to increase the efficiency of the light source.
In the illustrated embodiment shown in FIG. 3 for example, a reference line “A” is defined to extend perpendicular to a rear plane defined by the rear wall (not shown) of the cabinet. Line “P” is used as a reference point, reference line “P” being parallel to the rear wall plane. Reference line “A” bisects the front cabinet face along a midpoint of a mullion. In the illustrated embodiment, this midpoint of the mullion also defines a point along the front edge of the cabinet mullion which extends outwardly and forwardly the greatest distance from the interior of the cabinet.
As seen in reference to FIG. 3, an angle α is formed between the intersection of reference line “A” and planes “D 1 ” and “D 2 ” defined respectively by the interior perimeter surfaces 15 and 17 of doors 12 and 14 . Angle α is desirably between about 75 degrees to about 90 degrees, preferably between about 75 to 85 degrees, still more preferably between 76 to 79 degrees and still more preferably between 77 to 78 degrees. In the illustrated embodiment, angle α is about 77.5 degrees. When angle α is 90 degrees, surfaces 15 and 17 are parallel to plane P.
For the purposes of this invention, when angle α is about 90 degrees, a parallel arrangement exists between the plane of the inner door frame and the plane P defined by the rear wall of the cabinet. In other words, in this parallel arrangement, bulb(s) 34 provide(s) a substantial amount of illumination that is desirably reflected from the interior door surface 15 and/or 17 towards the display area of the shelves inside the case 10 . The diffusing lens 32 directs a portion of the light from the side of the mullion to the door surface at a sufficient angle to create a reflected light component which is directed towards the interior of the cabinet. However, by reducing the value of angle α, it has been further found that a greater proportion of the illumination striking the interior door surface may be reflected towards the cabinet display area.
It is also envisioned that the interior door surface may be provided by a piece of angled or curved glass or other transparent or translucent material. For instance, as viewed from the interior of the cabinet, a slight, generally concave curvature may be provided to the reflecting portion of the door. Such a curvature may provide a more efficient reflective surface in the sense that it increases the amount of light reflected to the interior of the display case. Further, the curved door surface could be used to favorably direct or concentrate the reflected light to a desired region of the cabinet. A similar effect may be achieved by having one or more angled facets defined by the interior reflective face of the door.
The present invention provides a useful process for improving the illumination of a cabinet. By directing discharged light toward the interior surface of the door, the door may provide a reflective surface which redirects the light towards the interior space of the cabinet. The position of the reflective door surface, relative to the illumination source, may be varied to increase the amount of light which is reflected.
The interior door surface may further define a curved or multifaceted reflective surface to increase the amount of reflected light and/or the direction of the reflected light. Further, a coating layer may also be applied to the interior door surface to increase the surface's reflective properties. Such coatings, as known in the art, still allow the interior of the display case to be viewed through the transparent door.
Prior art lighting systems for similar cabinets, make use of a single light fixture positioned upon the rear mullion surface that faces the interior of the cabinet. The resulting lighting is uneven and has prompted the use of various louvers and reflectors as mentioned in the background section above.
The present invention, using a standard size mullion, provides for a dual bulb lighting, effectively doubling the amount of available light. Further, by directing the light through a diffuser, harsh illumination is avoided. The lighting is enhanced further by positioning a reflective surface of the door relative to the light fixture to reflect additional light towards the display areas of the cabinet. Projections defined along the interior surface of the diffuser provide yet an additional light distributing mechanism to increase illumination along the entire front display region while minimizing harsh glare or uneven illumination patterns. The resulting light provides a balance to the illumination, minimizing shadows and harshness associated with unidirectional lighting systems.
While the illustrated embodiments discussed above are in reference to a single center mullion cabinet construction, the advantages of the improved lighting of the present invention may be used with different styles of cabinets. For instance, wide refrigeration or freezer units may have multiple mullions, each mullion simultaneously engaging the support hinge of one door along one side of the mullion while the opposite mullion side engages the handled door edge of an adjacent door. The multiple mullions can provide the side emitting light features and construction as described above to enhance the illumination and light qualities of the display cases.
Additionally, the display case need not be refrigerated to take advantage of the center mullion side lighting assembly of the present invention. Although desired embodiments of the invention have been described using specific terms, materials, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit and scope of the present invention which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole or in part. | A refrigerated display case and process of illuminating the case is provided. The display case has a support mullion ( 22 ) positioned in proximity to a glass door. A fluorescent lamp ( 34 ) is located within a lateral opening along either side of the support mullion ( 22 ). A diffusing lens ( 32 ) is positioned within the lateral opening, opposite the lamps, scattering the light as it passes through from the side of the mullion and through the diffusing lens ( 32 ). The glass door provides a reflective surface which reflects a substantial portion of the scattered light towards the interior space of the display case. | 5 |
TECHNICAL FIELD
[0001] The present relation relates to a door hinge, and more particularly to a disassemblable hinging device with a latching function.
BACKGROUND
[0002] In the field of cabinet doors and hatches, there is usually a closing device like a latch. The latch may be of various complexities, from a swivel latch or a hasp to more complex latches. Regular doors on cabinets are generally mounted in conventional ways, having a hinged side and a latch and handle on the other side. However, in many industrial applications, there may be a need to be able to open the door from either side. This may be due to space limitations or the need for ability to reach the content of the cabinet from different angles, or alternatively removing the door completely for a maintenance action. An example of usage areas for such hatches may be electrical enclosures, or hatches in ventilation ducts for use by maintenance staff and engineers.
[0003] A known way of solving the above problem is to use a disassemblable hinge as disclosed in WO2006/136939. A pair of disassemblable hinges may be mounted on two or more sides of the cabinet door at the same time, and function as both a hinge and a latch. It may contain a fixed part to be mounted on a door frame, and a movable part to be mounted on the door. The fixed part has a hinge pin, and the movable part has a handle that operates a pair of claws that closes around the hinge pin and is fixed in that state when the handle is closed, allowing the hinge to swing when the claws are closed, and open as a hatch when the claws are released. When assembled on both sides, the door is shut, but when releasing the hinge on one side, the other hinge may enable the door to swing in the opposite direction.
[0004] The problem with such a solution is that it may only be safe to use on certain types of doors and hatches. For instance, if the hatch would be mounted in a ceiling, there would be a risk that the hatch abruptly swings down on the person opening it. Another example may be that the hatch to be open may contain any pressurized media behind it. If to be used on a pressurized hatch, the hatch may, when releasing the hinge, swing open with a large force from the pressure, risking injuring the person opening the hatch.
[0005] It is therefore a need to provide a more secure disassemblable hinge.
SUMMARY
[0006] It is an object of the present invention to provide an improved solution that alleviates the mentioned drawbacks with present devices. Furthermore, it is an object to provide a disassemblable hinge having a latching member, adapted to be associated with an openable door, and a hinge member, adapted to be associated with a corresponding door frame. The latching member comprises a main body and a catch, and the main body has a hinge slot adapted to receive the hinge member, wherein the catch is rotatably engageable with the hinge member around a first axis. The catch is movable between a closed state and an open state. The catch is further movable into a disengaged state, wherein the catch and the hinge slot, defines a space for housing the hinge member. The catch, in its closed state, locks the hinge member in the space, wherein the space is expanded when the catch is moved from the closed state into the disengaged state, wherein the catch is moved from the disengaged state to the open state by rotating the catch around the second axis, thereby releasing the hinge member from the space.
[0007] With a hinge that can be disassembled by having a catch that may be disengaged and removed from the hinge member in more than one step, a safer opening of the hinge may be provided. For instance, for a disassemblable hinge that may be used on a pressurized hatch, the hinge may be opened with a two-step-manoeuvre, where the hinge may provide an air tight closure for the hatch when closed. For example, the catch may apply pressure onto the hinge member that ensures a tight compression of the hatch when the catch is in its dosed state. The hinge member may be located in a hinge slot, incorporated in the latching member, adapted to enable a rotational movement for the hinge member. The hinge slot and the catch may limit the hinge member in a space, so the hinge member does not escape from its location, and thereby may be locked in its location. When opening the pressurized hatch, maintenance staff may have the liberty to decide from which side to open the hatch, since the disassemblable hinge may be provided at two or more sides of the hatch. During the opening operation, maintenance staff may operate the catch to move into a disengaged state, wherein the space is slightly expanded, but still trapping the hinge member in a limited space. The hinge member may thus still be locked by the catch with a slightly loser grip, allowing the hatch to open slightly and the pressure behind the hatch to escape without risking the hatch to fling open on the maintenance staff, and let the pressure equalize before the hinge may be completely loosened and the catch, by being rotated, releases the hinge member, allowing the hatch to open. The hinge may thus provide a choice of whether to open the hatch on one side, or even remove the hatch completely during maintenance, since the hinge on either side may be removable. The hatch may be closed again by first placing the hinge slot over the hinge member, perform a reverse two-step-operation by turning the catch back into its disengaged state when the hatch is slightly open, and subsequently cause the catch to compress against the hinge member, narrowing the space, to its closed state in order to fully close the hatch.
[0008] According to one embodiment, the catch may be moved from the closed state to the disengaged state by moving the catch away from the hinge member axially along a second axis.
[0009] The catch may be movable in order to expand the space and thus disengage the hinge member. The direction of the movement of the catch may stretch along an axis which may be perpendicular to the hinge slot, in order to increase the space volume between the hinge member and the catch. The space may be expanded enough in order to disengage the hinge member, but still be narrow enough for the hinge member to be locked by the catch in the space.
[0010] According to one embodiment, the second axis may be perpendicular to the first axis. The second axis of movement may be perpendicular to the first rotational axis which may coincide with the hinge member, since it may provide a more even and symmetric effect from any forces that may arise from the disengaged, partially open hatch.
[0011] According to one embodiment, the catch may comprise a shaft and a pawl, wherein the shaft extends axially along the second axis, wherein the pawl may be perpendicular to the shaft. In order to facilitate any operation of the pawl, it may further comprise a shaft. Also, the catch may comprise a pawl that may be arranged so that the extremity of the pawl extends perpendicularly relative to the shaft. The shaft may be arranged so that the pawl may be operated in a simple manner. The shaft may be operated manually via a handle or possibly automatically via a motor.
[0012] According to another embodiment, the hinge member may comprise a hinge pin, adapted to be received in the hinge slot. The hinge member may be adapted to facilitate any hinging effect by being provided with a hinge pin. The hinge pin may be arranged between two symmetric holders. By having a hinge pin that is placed between two holders, the middle section may be arranged to be placed in the hinge slot, when the hinge is to be closed. The hinge member may further be provided with a number of mounting holes in order to enable attachment to for instance a door frame. The hinge pin may alternatively be arranged to be supported by another holder arrangement. For example, the hinge pin may be arranged with only one holder at a suitable place along the hinge pin.
[0013] According to another embodiment, the latching member further comprises a handle which may be pivotal relative to the main body, wherein the catch may be connected to the handle. By providing a handle, the catch may be operated more sufficiently and accurately. The handle may be directly or indirectly connected to the catch, and may provide a torque to allow the catch to rotate. It is possible that the handle may be incorporated in the catch or act as an extension of the catch. The handle may be an elongated shaft, a circular handle or a T-handle or another type of handle, such as a knob. The handle may be pivotal in relation to the main body in order to provide motion in several required directions. This may be achieved by allowing rotation by the handle around more than one axis, for instance two intersecting axes. Since the handle may operate the catch for any of its movements, the handle may need to be able to perform corresponding movements.
[0014] According to yet another embodiment, the handle may be rotatably connected to the catch via a third axis. The catch may be operated by the handle, and in order to allow for the catch's movement in an axial direction along the second axis, this movement may be enabled by a rotation of the handle. The connection between the handle and the catch may thus be via a third rotation axis. The second axis may intersect the third axis to provide a pivot effect to allow the handle to rotate around several axes.
[0015] According to another embodiment, the handle may be adapted to produce a momentum around a momentum axis when the handle is moved between a folded down position and a raised position, which causes the catch to move axially along the second axis.
[0016] The handle may be adapted to be able to provide axial movement of the pawl. In order to transfer any movement by the handle, that may be rotational, to the catch, which movement is axial, the handle may transfer an eccentric movement. The handle that may be connected to the catch via a hinged joint may thus by its folding down movement cause the catch to move in an axial direction opposite to the handle's direction of movement. This may be enabled by allowing the handle to produce a momentum, and allowing the counter force to act upon the catch. The momentum may be produced by letting the handle, as it is folded down towards the main body, rest on a support and thereby cause leverage on the catch. The location of the support may define the momentum axis. The support may be incorporated in the handle, or alternatively in the main body.
[0017] According to another embodiment, the momentum axis may be located at a distance from the second axis. In order to produce a momentum on the pawl, the leverage support and the second axis may be located at a distance from each other. The distance may vary depending of the size of the force required to dose and open the hinge.
[0018] According to another embodiment, the momentum may be defined by a seat that causes the handle to act as a lever arm on the catch. The latching member may be provided with a seat. The seat may be defined by an altering shape on the handle, such as a chamfer, notch or a radius, so when the handle is being moved, the chamfer, notch or radius pulls down over the main body, and the handle forces the pawl, by the created momentum, to move along the second axis. The handle may thus have an edge, that may be slightly angled as a chamfer towards the second axis, so when the handle is pulled, the transition between the angled edge and the straight edge, as it contact a flat surface of the main body, may cause a momentum. The seat may alternatively be shaped like a pin or an extrusion that extrudes from the main body. The seat may be designed so that the handle, that may have corresponding supports, may be lowered over the seat. When moving the handle between a raised position and a folded down position, a momentum may be produced around the seat and thereby a counter force develops on the opposite side of the seat, which may cause the catch to move in an opposite direction. The seat thus defines a momentum axis. The linear movement of the catch may be possible due to the rotational connection between the catch and the handle.
[0019] According to one embodiment, the handle is rotatable around a fifth axis, whereby the catch may be moved between the disengaged state and the open state when the handle is rotated. When the handle is in its raised position, it may be rotated around said fifth axis, thereby moving the catch between the disengaged state and the open state. The handle may be directly connected to the catch, causing the movement of the catch. It is also possible that the movement of the handle may be transferred via another rotational transfer means. As an example, the turning of the handle may occur at a distance from the second axis, requiring intermediate rotational transfer arrangements, like a cog wheel. Also, this may be needed if the handle's rotation and the catch's rotation are not parallel.
[0020] According to one embodiment, the fifth axis may coincide with the second axis (A 2 ). The second axis and the fifth axis may coincide if the distance allows for that. Also, by arranging the second axis and the fifth axis to coincide, any intermediate arrangements for rotational transfer may be avoided, which may provide for a more stable arrangement since any additional parts may increase the risk of failure of the hinge or require an increasing amount of service and maintenance.
[0021] According to one embodiment, the latching member comprises a lock, arranged to prevent the catch to move from its closed position to its disengaged position. By providing the disassemblable hinge with a lock, any unwanted and accidental opening of the hinge may be avoided. The lock may be placed so that any unintentional movement of the catch may be prevented. For instance, the lock may be placed in the handle to engage with a corresponding part on the main body, or alternatively the lock may be placed on the main body adapted to engage with a corresponding part on the handle. The lock may be operated manually by twisting, pressing, sliding, pushing or pulling a device that may allow the lock to release.
[0022] According to one embodiment, the lock may be arranged on the handle in order to prevent the handle to lift from its folded down position. Since the disassemblable hinge may be equipped with a handle to operate the pawl, the lock may be located near the handle to facilitate any operations by opening the hinge since.
[0023] According to one embodiment, the lock may be a keyed lock. Due to access limitations, the opening of the hinge may only be privileged to some selected people. For instance, if the hinge is mounted on an electric cabinet, the cabinet may only be opened by authorised electricians, and thus, only those staff may be equipped with a key to operate the disassemblable hinge. Also, the keyed lock may be another safety precaution in order to avoid accidental or unauthorised opening of the hinge.
[0024] According to one embodiment, the latching member further comprises a spring member, arranged to act with a spring force upon the catch. The latching member may be provided with a spring member. The spring member may be arranged close the shaft of the catch and may be adapted to act with a force on the catch. The spring may be tensioned when the catch is put in its closed state, and the spring member thus being compressed between the pawl and the main body. Because of the spring force acting to push the catch away from the hinge member, the spring force may help the catch to move into the disengaged state, when such movement is intended, for instance when the latch is released. This enables a manual opening action of the hatch that may require less hand force by a person. Also, since the spring member may be adapted to provide a certain tension to the catch when it is put in its closed state, the spring force may be helpful for stabilising the latch in a closed state, since it may then prevent the catch from rattling.
[0025] According to one embodiment, the spring member may be arranged adjacent to the shaft, wherein the spring member may be compressed when the catch is in a closed state. By placing the spring member adjacent to the shaft, the movement of the pawl may directly affect the spring member.
[0026] According to one embodiment, the spring member may be a coil spring. The spring member may be a coil spring, arranged around the catch shaft for immediate response of the catch by the coil spring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The invention will in the following be described in more detail with reference to the enclosed drawings, wherein:
[0028] FIG. 1 is a perspective view of a disassemblable hinge according to an embodiment of the invention.
[0029] FIG. 2 is a perspective view of a latching member according to an embodiment of the invention.
[0030] FIG. 3 is a perspective view of a hinge member according to an embodiment of the invention.
[0031] FIG. 4 is a perspective view of a disassemblable hinge in a closed state according to an embodiment of the invention.
[0032] FIG. 5 is a perspective view showing the bottom of a disassemblable hinge in a disengaged state according to an embodiment of the invention.
[0033] FIG. 6 is a perspective view showing the bottom of a disassemblable hinge in an open state according to an embodiment of the invention.
[0034] FIG. 7 is a schematic cross sectional view of a disassemblable hinge in a closed state according to an embodiment of the invention.
[0035] FIG. 8 is a schematic cross sectional view of a disassemblable hinge in a disengaged state according to an embodiment of the invention.
[0036] FIG. 9 is a schematic cross sectional view of the pawl and the hinge pin in a closed state according to an embodiment of the invention.
[0037] FIG. 10 is a schematic cross sectional view of the pawl and the hinge pin in a disengaged state according to an embodiment of the invention.
[0038] FIG. 11 is en exploded view of a disassemblable hinge according to an embodiment of the invention.
[0039] FIG. 12 is a perspective view of an opened and disconnected disassemblable hinge according to an embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
[0040] The present invention 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. In the drawings, like numbers refer to like elements.
[0041] In FIG. 1 , a schematic view of a closed disassemblable hinge 1 is shown. The disassemblable hinge 1 has a latching member 2 and a hinge member 3 . The latching member 2 has a main body 4 , which is provided with a number of mounting holes 15 at the base for mounting on a door 20 or a hatch 20 . The hinge member 3 is provided with a number of mounting holes 16 for mounting on a corresponding door frame 21 or similar. At the top side of the latching member, there is a handle 7 . The handle 7 in FIG. 1 is in a folded down position which means that the disassemblable hinge 1 is closed and the handle inoperable. The handle is connected to a shaft 12 via a hinged connection 17 . The shaft is connected to a pawl 22 (see FIG. 2 ). The lock comprises a keyed lock 11 in order to secure the handle 7 in a folded down position.
[0042] In FIG. 2 , the latching member 2 is shown having a hinge slot 6 , which runs across the latching member 2 and is adapted to receive the hinge member 3 . The latching member 2 comprises a catch 5 , which comprises a pawl 22 . The catch 5 also comprises a shaft, seen in FIG. 1 , which is connected to the handle 7 and thereby may be operated by the handle 7 . As seen in FIG. 3 , the hinge member 3 is provided with a hinge pin 13 which is adapted to be received in a corresponding hinge slot 6 on the latching member 2 to allow for a rotatable connection between the hinge member 3 and the latching member 2 , which defines a first rotational axis A 1 . The hinge pin 13 may be circular cylindrical in shape, and the hinge slot may also have the corresponding shape, to allow for a rotational movement between the hinge slot 6 and the hinge pin 13 . Since the hinge member 3 and the latching member 2 may be two separate parts, the hinge member 3 may be arranged so that the hinge pin 13 may be arranged in the hinge slot with low friction. The hinge member 3 may thereby swing freely relative to the latching member 2 when secured in the hinge slot 6 .
[0043] The disassemblable hinge 1 may be operated into at least three states: closed, disengaged and open. In FIGS. 4 , 5 and 6 , the three states are visually displayed. FIG. 4 shows a disassemblable hinge 1 in a closed state, in which state the disassemblable hinge 1 functions as a hinge between the door and door frame on which the latching member 2 and the hinge member 3 may be arranged. As seen, the pawl 22 is pressing against the hinge pin 13 , which sits locked between the hinge slot 6 and the pawl in a space 14 , and the handle 7 is in a folded down position. In the closed state, the hinge pin 13 is locked in the hinge slot 6 . There may be a slight clearance between the hinge pin 13 and the hinge slot 6 to allow the hinge member 3 and the latching member 2 to swing relative to each other around a first rotational axis A 1 , which may be defined by the hinge slot 6 and the hinge pin 13 . However, the size of the clearance may be adapted to the particular use of the disassemblable hinge, and may be tight enough to provide an air tight closure of the hatch. Alternatively, the hinge slot 6 may apply a tight fit to the hinge pin 13 , but then the mounting of the hinge pin 13 in the hinge member may allow for rotation. Further in FIG. 4 , it is also shown that the disassemblable hinge comprises a lock 10 . The lock 10 is engaged to prevent the disassemblable hinge to accidentally open. The lock 10 on the underside of the latching member 2 is placed on the handle 7 and has a corresponding slot 18 located on the main body 4 . The lock 10 and slot 18 is arranged so that when the handle is being forced into a folded down position, the lock 10 connects with the slot 18 and locks the handle 7 in its folded down position. The lock 10 may be operated with a keyed lock, as seen in FIG. 1 , but can also be operated by any other manual mechanical arrangement, such as a twisting, pressing, sliding, pushing or pulling arrangement. The lock 10 may also be operated with a motor. The lock 10 may also be of any other arrangement such as a clasp, hasp, pin or clip, in order to prevent the handle 7 from accidentally lift from its folded down position.
[0044] In FIG. 5 , the disassemblable hinge 1 is shown in a disengaged state. As seen, the lock 10 is released from the slot 18 and the handle 7 is raised. In response to the handle 7 moving from a folded down position to a raised position, the pawl 22 is moved relative to the hinge pin 13 axially along the second axis A 2 , expanding the space 14 that is limited by the hinge slot 6 and the pawl 22 , allowing the hinge pin 13 to move relative to the latching member 2 . However, the space 14 is expanded slightly, but not enough for the hinge pin 13 to escape from the grip by the pawl 22 . The hinge pin 13 is hence still locked between the pawl 22 and the hinge slot 6 . The handle may be raised to a near upright position, in which the handle 7 can be rotated relative to the main body 4 around a fifth axis A 5 .
[0045] FIG. 6 shows the disassemblable hinge in an open state. In the open state, the handle 7 has been raised fully, and rotated around the axis A 5 in order to operate the pawl 22 into rotating out of the disengaged state into the open state. The handle 7 has been rotated approximately 90 degrees to move the pawl 22 to the open state. The pawl 22 is then removed from the hinge pin 13 and the hinge pin 13 may be released from the space 14 , and subsequently the hatch may be opened by separating the latching member 2 and the hinge member 3 . In order to close the hatch, a reverse manoeuvre is done by first placing the hinge pin 13 in the hinge slot, then rotating the pawl 22 into the disengaged state by operating the handle 7 , see FIG. 5 . The pawl 22 is then again locking the hinge pin 13 in the space 14 . Subsequently, the handle 7 can be lowered, causing the pawl to compress against the hinge pin 13 and thereby narrowing the space 14 , see FIG. 4 . The pawl may cause a compression on the hinge pin 13 by allowing the pawl 22 to move axially along the second axis A 2 towards the hinge pin.
[0046] In order to create the pawl's 22 axial movement as a response to lowering the handle 7 , a momentum is produced by the handle 7 to act upon the pawl via a shaft 12 . FIG. 7 and FIG. 8 show schematically the movement of the pawl 22 relative to the hinge pin 13 . As seen in FIG. 7 , the pawl 22 is in the closed state, pressing against the hinge pin 13 , creating a space 14 limited by the pawl 22 and the hinge slot 6 . The hinge pin 13 is thereby locked in the space 14 , and a hinge function between the latching member 2 and the hinge member 3 is provided. In FIG. 8 , the pawl is in the disengaged state, having expanded the space 14 between the pawl 22 and the hinge slot 6 . By expanding the space, the hatch may be partially opened, possibly to equalise any pressure that may have been trapped behind the hatch, for instance if the hatch is a service hatch in a pressurised ventilation duct. Having the pressure equalised before complete opening of the hatch may secure the hatch from flinging open by accident onto the maintenance staff. The hinge pin 13 is however still locked inside the space 14 , preventing the hatch from being fully opened.
[0047] FIG. 9 and FIG. 10 shows a cross section of the disassemblable hinge from the side, showing the shape of the handle 7 that may allow for the handle 7 to produce a momentum. As seen, the handle 7 is provided with a chamfered edge 19 , a flat edge 23 and a seal 8 , which function to create a momentum around a momentum axis A 4 , when tilted relative to the main body 4 . When the handle 7 is in a slightly raised position, as seen in FIG. 10 , the handle 7 leans on a chamfered edge 19 on the handle 7 . As the handle 7 is lowered towards the main body 4 , the chamfered edge 19 is pressed against the flat surface of the main body 4 . As the handle is further lowered, as seen in FIG. 9 , the transition from the chamfered edge 19 via the seat 8 to a flat edge 23 on the handle will cause leverage and produce momentum on the pawl 22 . This momentum may force the pawl 22 to move in the opposite direction axially along the second axis A 2 , in the extension of the pawl 22 due to the counter force resulting from the momentum. This is possible due to the connection between the catch 5 and the handle 7 . The pawl 22 will as a result press against the hinge pin 13 . The rotational movement of the handle 7 around the third axis A 3 may thus produce the axial movement of the pawl by the pawl responding to the momentum acting around the momentum axis A 4 . Also, by allowing the seat 8 to slide freely relative to the main body, it prevents any tension forces to arise in the shaft. By pressing the pawl against the hinge pin, it provides a compression function that may secure the hatch to be air tight, which may be crucial if the hatch is mounted on a ventilation duct. It is possible that the seat is incorporated in the main body 4 as a support or a pin, extruding from the main body 4 .
[0048] In FIG. 11 , the disassemblable hinge 1 is seen in an exploded view. The handle is connected to the pawl 22 via a shaft 12 which is extending along a second axis A 2 . The pawl 22 is movable to correspond to the movement of the handle 7 , such that when the handle 7 is turned around the fifth axis A 5 , the pawl 22 will turn. Further, the handle is connected to the shaft 12 via a hinged joint 17 , which defines the third axis A 3 , as seen in FIG. 1 . The shaft 12 may be separate or incorporated with the pawl 22 . As seen in FIG. 2 , the handle 7 is rotatable around a fifth axis A 5 . In FIG. 2 , the fifth axis A 5 coincides with the second axis A 2 . However, the fifth axis A 5 may be located at a distance from the second axis A 2 if there may be a need. For instance, if the distance between the handle and the shaft is big, the second axis A 2 and the fifth axis A 5 may be located further apart, having spurred or cogged wheels to transfer the rotation of the handle 7 to the pawl 22 .
[0049] Near the shaft, a coil spring 9 is arranged. The coil spring 9 may be provided in order to act with a spring force upon the pawl 22 when the pawl 22 is in its dosed state. As the pawl 22 is in its dosed state, the spring 9 may be tensioned. When the lock 10 is released, the spring force of the spring 9 may act on the pawl 22 to force it to move axially along the second axis A 2 into the disengaged state. Further in FIG. 11 , is seen a number of mounting holes 15 , 16 which are provided in order to fasten the hinge member 3 onto a door frame 2 (not shown) and the latching member 2 onto a door 20 .
[0050] FIG. 12 shows a disassemblable hinge in a fully open state wherein the hinge member 3 and the latching member 2 are completely separated. | The invention relates to a disassemblable hinge ( 1 ) having a latching member ( 2 ), adapted to be associated with an openable door ( 20 ), and a hinge member ( 3 ), adapted to be associated with a corresponding door frame ( 21 ). The latching member ( 2 ) comprises a main body ( 4 ) and a catch ( 5 ), wherein said main body ( 4 ) comprises a hinge slot ( 6 ) adapted to receive said hinge member ( 3 ), wherein said catch ( 5 ) is rotatably engageable with said hinge member ( 3 ) around a first axis (A 1 ). The catch ( 5 ) is movable between a closed state and an open state, and into a disengaged state. The catch ( 5 ) and said hinge slot ( 6 ) defines a space ( 14 ) for housing said hinge member, wherein said catch ( 5 ), in its closed state, locks said hinge member ( 3 ) in said space ( 14 ). The space ( 14 ) is expanded when said catch ( 5 ) is moved from said closed state to said disengaged state. The catch ( 5 ) is moved from said disengaged state to said open state by rotating said catch ( 5 ) around a second axis (A 2 ), thereby releasing said hinge member ( 3 ) from said space ( 14 ). Thereby a disassemblable hinge is provided enabling a secure opening operation in a two step manoeuvre. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in or relating to spread spectrum signalling schemes and has particular but not exclusive application to the transmission of low power spread spectrum signals from low power transmitters which may be included in message receiving apparatus such as selective call receivers, for example digital pagers or hand held digital signal processing apparatus.
U.S. Pat. No. 4,882,579 discloses an acknowledge back (ack-back) paging system in which a central station transmits a sequence of addresses of a group of M different ack-back pagers for whom there are paging signals and after an interval this is followed by a sequence of messages to the group of ack-back pagers. The order of the messages is related to the order of the addresses in the transmitted sequence in a predetermined manner. The users of the group of addressed ack-back pagers indicate a response, for example by pressing a button, to their respective pagers thus providing ack-back data. The pagers in the group of addressed ack-back pagers then simultaneously transmit back to the central station their ack-back signals using different pseudo-random codes, a different pseudo-random code being allocated to each of the pagers in the group. In order to permit simultaneous transmissions the pagers must send the transmitted acknowledgement signal with extreme accuracy in frequency. In order to facilitate accurate frequency tuning the central station transmits a burst of reference carrier in a time interval between the transmissions of the sequence of addresses and the sequence of messages and the pagers have to include frequency control circuitry which permits such accuracy in frequency tuning. Additionally power control techniques are applied by the pagers to regulate transmitter output power.
OBJECTS AND SUMMARY OF THE INVENTION
An object of the present invention is to facilitate distinguishing between different simultaneously transmitted spread spectrum signals in a manner which does not affect the overall rate of message throughput and involve additional complication of the selective call receiver.
According to a first aspect of the present invention there is provided a communications system comprising a primary station having transmitting and receiving means, means for formatting messages to be transmitted by the transmitting means, and one or more secondary stations, the or each secondary station having receiving means for receiving messages from the primary station and means for transmitting signals as spread spectrum signals, said receiving means in the primary station being adapted to receive and decode the or each of the spread spectrum signals, said primary station further comprising means for frequency analysing either an unspread part of the signal as received or the spread spectrum signal after despreading.
According to a second aspect of the present invention there is provided a primary station for use in the communications system in accordance with the first aspect of the present invention, the primary station comprising transmitting and receiving means, means for formatting messages to be transmitted by the transmitting means, said receiving means being adapted to receive and decode the or each of a plurality of spread signals, said primary station further comprising means for frequency analysing either an unspread part of the signal as received or the spread spectrum signal after despreading.
According to a third aspect of the present invention there is provided a method of distinguishing between each of a plurality of substantially simultaneously occurring different spread spectrum signals which may include frequency offsets, comprising frequency analysing either an unspread part of the signal as received or the spread spectrum signal after despreading.
By means of the present invention it is possible to recover the or each of a plurality of simultaneously transmitted spread spectrum signals without having to transmit bursts of reference carder and having to provide frequency control circuits in the selective call receivers. Furthermore the present invention enables the effects of Doppler shift to be taken into account without any special measures having to be adopted.
In a first embodiment a digitised version of the received signal is despread using each of the codes which may have been used and each time the raw data is frequency analysed and the resulting spectrum is examined to see if there is a peak indicating that the code used for despreading was correct.
In a second embodiment a burst of carrier precedes the spread spectrum signal and at the primary station the received signal is analysed to see what frequencies are present and each frequency is used to de-rotate the received signal and after each de-rotation a check is made for the presence of any one of the spreading codes.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a diagram illustrating a message transmission system for transmitting data messages,
FIG. 2 is a block schematic diagram of a primary station comprising a system controller and a base station transceiver,
FIG. 3 is a block schematic diagram of a secondary station,
FIG. 4 is a diagram illustrating a raw signal plotted against time, t,
FIG. 5 is a block schematic diagram illustrating features of the primary station which enable frequency offsets and Doppler shifts to be allowed for,
FIG. 6 is a diagram illustrating a despread signal plotted against time, t,
FIG. 7 illustrates a power spectrum of a clean signal plotted against frequency f,
FIG. 8 illustrates a power spectrum of a signal having Doppler spread plotted against frequency f,
FIG. 9 illustrates a variant of the invention in which a secondary station transmits a frequency burst immediately preceding the spread spectrum signal, and
FIG. 10 is a block schematic diagram of those features of the primary station which enable the signal having the format shown in FIG. 9 to be recovered.
In the drawings the same reference numerals have been used to indicate corresponding features.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The system shown in FIG. 1 may comprise a system for transmitting relatively long data messages such as telescript or E-mail or a paging system. For convenience of description the present invention will be described with reference to a high rate paging system operating in accordance with a protocol known by the Applicant as the Advanced Paging Operators Code (APOC), which has provision for sending address code words and concatenated message code words in cycles having a duration of 6.8 secs. Each cycle comprises a plurality of batches, for example 3 batches of equal duration. Each batch comprises a synchronisation (sync) code word concatenated with n frames, each of which is constituted by m code words.
The paging system comprises a paging system controller 10 which is connected to at least one base station transceiver 12, if necessary by land lines or other suitable links. In the event of there being more than one base station transceiver they may be geographically spaced apart and may operate in a quasi-synchronous mode.
Selective call receivers or secondary stations SS1,SS2 are provided, each of which comprises a transceiver which is able to receive transmissions from the transceiver 12 and is able to transmit a limited number of types of messages, including acknowledgements, at significantly lower power than the output power of the transceiver 12, for example 30 dB lower. The messages are transmitted as spread spectrum signals typically at an information rate of one thousandth of that transmitted by the transceiver 12 and a spreading sequence length of the order of 10 4 , for example 8191 chips per bit.
In one embodiment of the system, the paging system controller 10 attempts to overcome the near/far problem without resorting to transmitter power control in the secondary stations by transmitting a set of invitation signals at a plurality of different power levels ranging between predetermined lower and upper limits, for example progressively increasing power levels, and secondary stations receiving the invitation signals respond to the invitation signal having the lower or lowest power and having responded do not reply to higher powered invitations in the same set which will be received by more distant secondary stations. The advantage of staggering the power levels of the invitation signals is that the strength of the replies at any one instant will be comparable thereby mitigating against the near/far problem instead of the conventional method of applying power control to transmitters.
FIG. 2 shows an arrangement of a system controller 10 connected to the transceiver 12 which transmits a sequence of invitation signals at different power levels. The system controller 10 comprises an input 18 for data messages to be relayed via the transceiver 12. The messages are held in a store 20 from where they are relayed to a formatting stage 22 which appends an address code word to the message and divides the message into a plurality of concatenated code words of a pre-determined length, each code word including error detection/correction bits and optionally an even parity bit. The address code words are held in a store 24. A processor 26 is provided which controls the operation of the system controller in accordance with a program which is stored in a memory 28. Also connected to the processor 26 are a clock/timer stage 30, an invitation signal generator 32 and a store 34 for storing details of the code sequences which may be used by the secondary stations in transmitting their responses to the invitation messages. Once the data messages in the store 20 have been formatted in the stage 22 the processor 26 causes them to be relayed by the base station transceiver 12. The formatting of the data messages may conform to any known message format such as APOC, CCIR Radiopaging Code No 1 (otherwise known as POCSAG) or to any other signal format which is known or yet to be devised. Once the messages have been transmitted, the processor arranges to transmit the invitation-to-respond signals generated in the stage 32. In one mode, after each transmission of an invitation signal at a progressively increasing power level, a time interval is provided in which a secondary station may respond. Once the time interval has elapsed then the invitation signal is repeated at increased power levels up to a maximum power level, each invitation being followed by a time period for reply.
The processor 26, following the transmission of an invitation signal, switches the transceiver 12 to receive and is ready to accept signals received by the transceiver 12, the outbound propagation path to the or each secondary station being substantially the same as that of the inbound propagation path. In order to identify, each of the responses which is sent as a spread spectrum signal, each of the code sequences is mixed sequentially with the received signals which are held in a buffer and when a correlation is obtained then the response is noted and further code sequences are mixed with the received signal in order to recover any other responses which may be present.
In another mode, the respective invitation signals are transmitted successively and a plurality of time slots are provided for receiving responses as spread spectrum signals, there being one time slot per power level. Optionally the response sequences may be divided into sub-sequences and the sub-sequences interleaved over a plurality of time slots in order to overcome the effects of any short term fading.
In a variant of the last mentioned mode, a plurality of sets of invitation signals are transmitted and a secondary station transmits a response to the lowest powered invitation signal received at a suitable moment following the transmission of the last set of invitation signals.
As a response lasts for substantially a second if it is transmitted in a single burst; this is long compared with typical fade rates. Thus if a secondary station is in a deep fade when it chooses its slot it may produce a signal at the receiver 20 dB above the planned strength for the slot. Since a fading signal often falls well below its average, but only goes about 3 dB stronger, it may be better to use a measure of the average signal strength in order to choose the slot. An indirect measure of the signal strength which avoids the need for dedicated circuitry is to deduce the average signal strength from the ordinals of the invitation signals received in the concatenated sets. However, it is necessary to optimise the time over which the average is determined because if too long is taken the average may be out of date when the response is transmitted.
Another effect of signal strength variation may be on the false rate. If the signal varies it will alter the correlations. For this reason it is necessary to choose codes having good short-term balance of ones and zeroes in the products. Thus fades will affect a roughly equal number of ones and zeroes.
FIG. 3 is a block schematic diagram of a secondary station SS having the capability of transmitting responses to invitation signals as spread spectrum signals. The secondary station SS comprises an antenna 36 which is coupled to a receiver stage 38. An output of the receiver stage 38 is coupled to an input of a decoder 40. A microcontroller 42 is coupled to the output of the decoder 40 and controls the operation of the secondary station in accordance with a program held in a read only memory (ROM) 44. The microcontroller 42 has inputs/outputs, as appropriate, coupled to annunciating means 46 which may be audio, visual and/or tactile, a keypad 48, data output means, for example an LCD driver 50 which is coupled to an LCD panel 52, and a random access memory (RAM) 56 for storing any messages which have been received and decoded.
In operation the receiver stage 38 is energised in response to the particular battery economising protocol followed by the secondary station SS. Optionally the decoder 40 and the microcontroller 42 may "sleep" when not required, the microcontroller 42 being woken by an internal timer (not shown) or an interrupt signal and in so doing waking up other stages of the secondary station, as appropriate. When an address code word is received, it is demodulated, decoded, error corrected and checked to see if it is one assigned to the secondary station or an invitation to send a message to the primary station. Assuming it is an address code word assigned to the secondary station then depending on the programming of the microcontroller 42, the annunciating means 46 may be activated to inform the user that a call has been received. However a user by actuating a key or keys of the keypad 48 can inhibit one or more of the output devices of the annunciating means. If a short message at the same data rate as the address code word is concatenated with the paging call then once it has been decoded and error checked/corrected, the microcontroller 42 causes the decoded message to be stored in the RAM 56. By actuating a key or keys of the keypad 48, a user can instruct the microcontroller 42 to read-out the message from the RAM 56 to the LCD driver 50 which will cause the message to be displayed on the screen 52. The operation described so far is typical for many alphanumeric message pagers conforming to the POCSAG standard.
The illustrated secondary station SS includes a low power transmitter 58 whereby acknowledgements and/or short messages can be relayed to the or any in-range base station transceiver. The actual acknowledgement or message is generated by the microcontroller 42 and will be transmitted as a spread spectrum signal. One or more near orthogonal pseudo-random code sequences may be stored or generated in a stage 60. The microcontroller 42 controls the reading out of a code sequence from the stage 60 which is coupled to a transmitter 58. The code sequence may be one of a set of near orthogonal sequences or a time shifted version of such a sequence. The chosen sequence may represent the identity of the secondary station and/or the number of a message received and/or coded reply as shown below.
Code Sequence 1--secondary station in the area for the purposes of registration only.
Code Sequence 2--Received last message.
Code Sequence 3--Read message(s).
Code Sequence 4--Answer "Yes".
Code Sequence 5--Answer "No".
Code Sequence 6--Resend last message.
As an alternative to allocating sets of predetermined code sequences to secondary stations allocated to respective frames, the paging system controller and the secondary stations may each store the same block of code sequences, say 1000 code sequences. When a data message is to be transmitted to an addressed secondary station the system controller anticipates that one of say 20 possible answers may be possible and the overall transmission of the data message includes an indication that twenty of the 1000 possible code sequences have been allocated dynamically to the secondary station for use in transmitting its answer, each code sequence representing one of twenty possible answers. Once a response to an invitation signal has been received and relayed to the system controller it is compared with each of the twenty dynamically allocated code sequences and the code sequence which achieves the best correlation is deemed to give the answer to the message. Once the answer has been determined the allocation of the twenty code sequences for an answer from that secondary station is withdrawn, either explicitly or implicitly.
In a practical situation strings of messages are transmitted sequentially to different secondary stations and in those cases where answers are required, the number of possible answers may vary,consequently the number of code sequences from the batch of, say 1000, possible code sequences allocated by the system controller for an answer from a particular secondary station will vary accordingly. However as stated above the allocation is temporary.
The description so far has not taken account of the fact that the spread spectrum signals may be affected by frequency offsets and Doppler shifts causing the phase of the received spread spectrum signal to vary in a semi-random way at, say, the Doppler rate. This is illustrated in FIG. 4 which shows a raw signal consisting of a binary phase code signal denoted by the arrows, subject to phase variations, in noise. The effect of these phase variations is to cause the signal to integrate to an arbitrary value depending on the phase value rendering the output of the normal correlation detector useless.
Overcoming frequency offsets in the selective call receiver by constraining the transmitter to say a 10 Hz frequency (as opposed to a typical carrier frequency tolerance of 3 to 5 ppm) would be prohibitively expensive and render the selective call receiver too expensive.
In accordance with the present invention the effects of frequency offsets and Doppler shifts are taken into account by the system controller 10 (FIGS. 1 and 2) as will be described with reference to FIGS. 5 to 8. Referring to FIG. 5, the spread spectrum signals are received by the receiver section of the transceiver 12 which provides quadrature related frequency down-converted I and Q signals on its outputs 60,61. The I and Q signals are digitised in an analogue to digital converter 62 which provides digitised versions of the raw data which are stored in a raw sample store 64. The raw samples are then read out to a multiplier 66 to which a code generator 68 is connected. The store 34 (FIG. 2) supplies details of code sequences to the generator 68 which produces a succession of code sequences, each of which is multiplied with the raw sample to produce a sequence of despread signals, for example as shown in FIG. 6, in which the offset frequency is present in the noise. Each of the despread samples is held in a store 70.
In order to take into account the possible presence of an offset frequency, each despread sample is frequency analysed in an analyser 72 such as a Fourier or FFT analyser. The results of the frequency analysis are stored in a power spectrum store 74. In a stage 76 each power spectrum is scanned for the presence of a peak which exceeds a threshold and causes an output to be produced indicating the presence or absence of a code.
In the case of a code being present this is indicated to the processor 26 which from the code identified deduces the meaning of the response signal.
FIG. 7 illustrates a power spectrum for what may be regarded as a clean signal in that it has a clearly defined peak. In contrast FIG. 8 illustrates a power spectrum for a signal which includes a Doppler spread causing the peak to be of a lower amplitude and less well defined.
In the event of a large number of signals being present then, in order to reduce the search time, the despread sample store 70 and the spectrum store 74 (FIG. 5) each comprise at least two parts A,B and data is multiplexed so that whilst data is being written into, say, part A of the despread sample store 70, data is being read out of the other part B, and vice versa as indicated in the broken lines. The same applies to the spectrum store 74.
Although FIG. 5 illustrates the despreading and frequency analysis being done in separate stages, the entire operation can be done in a suitably programmed digital signal processor.
In a variant of the method in accordance with the present invention, shown in FIG. 9, the initial part 78, say 0.2 seconds, of the transmission from a secondary station comprises unmodulated carrier (an unspread part) to which a second part 80 comprising the spread spectrum signal is concatenated.
FIG. 10 illustrates the relevant part of the system controller in which the quadrature related components I,Q of the signal recovered from the receiver 12 are digitised in the ADC 62 and the digitised signal samples undergo frequency analysis in a Fourier analysis stage 72 to determine the offsets of any signals present. These offsets are applied to the store 34 in turn in order to recover the corresponding code details which are supplied to the controller (not shown) in order to determine the signal associated with the recovered code.
From reading the present disclosure, other modifications will be apparent to persons skilled in the art. Such modifications may involve other features which are already known in the design, manufacture and use of communications systems and component parts thereof and which may be used instead of or in addition to features already described herein. Although claims have been formulated in this application to particular combinations of features, it should be understood that the scope of the disclosure of the present application also includes any novel feature or any novel combination of features disclosed herein either explicitly or implicitly or any generalisation thereof, whether or not it relates to the same invention as presently claimed in any claim and whether or not it mitigates any or all of the same technical problems as does the present invention. The applicants hereby give notice that new claims may be formulated to such features and/or combinations of such features during the prosecution of the present application or of any further application derived therefrom. | A communications system including a primary station and at least one or more secondary stations. The secondary station transmits signals as spread spectrum signals and a receiver in the primary station receives and decodes the spread signals. Frequency offsets in the received spread spectrum signals are dealt with by digitizing the received signals to produce raw data samples which are despread, frequency analyzed and the spectrums derived are scanned for peaks exceeding a predetermined threshold and the outputs indicate the presence or absence of codes. | 7 |
FIELD OF THE INVENTION
The invention relates to a lighting device comprising a light source and a lens positioned in front of the light source, which lens is provided with a light entrance surface on a side facing the light source and a light exit surface on a side remote from the light source.
The invention also relates to a lens.
BACKGROUND OF THE INVENTION
Such a lighting device, which is known from EP 2009345 A2, comprises a lens having a first optical refractive element arranged around a peripheral edge and a second optical refractive element centrally located on the lens. Between the light source, such as a light emitting diode (LED), and the lens a reflector is located. A forward emitted portion of the light of the LED goes directly to the lens whilst a sideward emitted portion is reflected by the reflector before it goes to the lens.
A disadvantage of this known lighting device is that the perceived luminance of the lens is of the same order as the luminance of the light source. In the case of a high power LED an intense and blinding light will be emitted by the lighting device.
The use of such a lighting device with high power LEDs for general indoor lighting is difficult because of the extreme high luminance of the LED. In order to avoid direct exposure of the observer to the high luminance of the LED, luminance transformers may be added. However, such luminance transformers have the disadvantage that they lead to a decrease of the optical efficiency and an increase of the costs of the lighting device.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a lighting device with a simple structure, a relatively high optical efficiency and luminance transformation to avoid glare.
This object is accomplished with the lighting device according to the invention in that the lens comprises a number of strip-shaped interconnected elongated light guiding elements, of which first ends and spaced apart second ends comprise the light entrance surface and light exit surface, respectively, and light beams emitted by the light source are transmitted by total internal reflection in the elongated light guiding elements from the first ends to the spaced apart second ends.
Due to the strip-shaped elongated light guiding elements and the spaced apart second ends, a lens with an open structure is obtained. Owing to the strip-shaped elongated light guiding elements, the length in a first direction from the first end to the second end is in the same order or much smaller as the length of the elongated light guiding elements in a second direction perpendicular to the first direction. The open structure provides a relatively large light exit surface compared to the light entrance surface. The brightness of the light source is distributed over a relatively large light exit surface, whereby the observed brightness is strongly reduced. Light beams from the light source are transmitted by total internal reflection, due to which a high optical efficiency of the lens is obtained. Lighting devices with such a lens are applicable for a wide range of indoor and outdoor applications.
An embodiment of the lighting device according to the invention is characterized in that at least the strip-shaped second ends of the elongated light guiding elements extend parallel to each other.
In this manner, the light exit surface will have a rectangular shape due to which the light emitted by the lighting device may look similar to the light emitted by elongated fluorescent tubes.
Preferably, the elongated light guiding elements extend parallel to each other from the first ends to the second ends, which makes it possible to manufacture the lens by means of extrusion, so that a relatively large length in the second direction perpendicular to the first direction from the first end to the second end can be achieved.
A device with such a lens is suitable as a light line for shop lighting or a light line for a bus, train or airplane, or tunnel lighting. Such a lens is also suitable for a waterproof luminaire, since only the small entrance area where the LED or the LEDs are located, must be waterproof, together with both side ends.
Another embodiment of the lighting device according to the invention is characterized in that at least the second ends of the elongated light guiding elements are ring-shaped strips located concentrically with respect to each other.
In this manner, the light exit surface will have a cylindrical shape due to which the light emitted by the lighting device may look similar to the light emitted by incandescent light bulbs.
Preferably, the elongated light guiding elements are ring-shaped from the first ends to the second ends, such that each elongated light guiding element is cup-shaped.
A device with such a lens is suitable for home lighting, or as a downlighter for office lighting or shop lighting.
Yet another embodiment of the lighting device according to the invention is characterized in that at least a part of the elongated light guiding elements are at least connected to each other near the first and/or second ends.
A continuous light entrance surface and/or exit surface can thus be obtained, providing the lens with a smooth appearance. The areas where the elongated light guiding elements are interconnected are preferably as small as possible to prevent disturbance of the total internal reflection in the elongated light guiding elements.
Another embodiment of the lighting device according to the invention is characterized in that the area of the light exit surface of the lens is at least 100 times and preferably at least 10,000 times larger than the light emitting area of the light source.
Due to the enlargement of the light exit surface with respect to the light emitting surface of the light source, a decrease in perceived luminance is obtained. Depending on the desired luminance, the ratio between light entrance surface and light emitting surface is chosen as well as the number and shape of the elongated light guiding elements.
Another embodiment of the lighting device according to the invention is characterized in that a surface of the first end of the elongated light guiding element extends substantially perpendicularly to the light beams of the light source directed towards said elongated light guiding element.
All light emitted by the light source towards an elongated light guiding element will enter the elongated light guiding element so that the optical efficiency will be optimal.
Yet another embodiment of the lighting device according to the invention is characterized in that the light exit surface has an oblique, convex or concave shape.
The shape of the light exit surface further improves the light emitted by the lighting device, the visual appearance thereof, and determines to a large extent the beam pattern emerging from the lighting device. This is of particular interest for applications in which beam control is important, for example in automotive headlight systems, for example for generating a dim light beam.
Another embodiment of the lighting device according to the invention is characterized in that the lens is made of acryl, polycarbonate or other transparent material.
From such materials relatively cheap lenses can easily be produced.
Another embodiment of the lighting device according to the invention is characterized in that the lens is made by injection moulding or extrusion.
Such a manufacturing process is relatively easy. In the case of injection moulding, the lens can be assembled out of several parts to avoid draft angle problems.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail with reference to the drawing, in which:
FIGS. 1A and 1B are, respectively, a cross sectional view and a perspective top view of a first embodiment of the lighting device according to the invention,
FIG. 2 is a cross sectional view of the lens of the lighting device as shown in FIG. 1 , with light beams emitted by the light source and internally reflected by elongated light guiding elements of the lens,
FIG. 3 is a perspective view of a second embodiment of the lighting device according to the invention,
FIG. 4A is a cross section of a third embodiment of the lighting device according to the invention,
FIGS. 4B, 4C and 4D are different embodiments of second ends of the elongated light guiding elements,
FIG. 5 is a perspective bottom view of the third embodiment of the lighting device as shown in FIG. 4A ,
FIG. 6 is a cross section of a fourth embodiment of the lighting device according to the invention,
FIG. 7 is a cross section of a fifth embodiment of the lighting device according to the invention,
FIG. 8 is a cross section of a sixth embodiment of the lighting device according to the invention.
DETAILED DESCRIPTION OF EMBODIMENTS
In the Figures, like parts are indicated by the same reference numerals.
FIGS. 1A, 1B and 2 show a first embodiment of a lighting device 1 according to the invention. The lighting device 1 comprises a high power LED 2 as light source and a lens 3 . The lens 3 comprises a number of elongated light guiding elements 4 which are interconnected near spaced apart second ends 5 by means of a plate 6 . First ends 7 of the elongated light guiding elements are located near the LED 2 . The first ends 7 are spaced apart, such that the distance between the first ends 7 is much smaller than the distance between the second ends 5 at the plate 6 . The elongated light guiding elements 4 are cup-shaped, such that both the first ends 7 and the second ends 5 form ring-shaped strips. The first ends 7 of the elongated light guiding elements 4 are each provided with a light receiving surface 8 . The light receiving surfaces 8 of all the elongated light guiding elements 4 form a light entrance surface of the lens 3 . The light receiving surfaces 8 are located with respect to each other in a manner such that all light beams of the LED 2 will enter one of the light receiving surfaces 8 and no light beam will enter an opening 9 between the elongated light guiding elements 4 . Preferably, each light receiving surface 8 extends substantially perpendicularly to the light beams entering said light receiving surface 8 . The two centrally located elongated light guiding elements 4 are connected to each other with their second ends 7 , however just beyond the first ends 7 the elongated light guiding elements 4 are spaced apart. Between the elongated light guiding elements 4 openings 9 are present which become wider in a direction away from the LED 2 . The strip-shaped elongated light guiding elements 4 are relatively long in a direction from the LED 2 towards the plate 6 and in a circumferential direction. The elongated light guiding elements 4 are curved and dimensioned so that a light beam 10 , 11 entering the light receiving surface 8 will be totally reflected inside the elongated light guiding element 4 by inner and outer surfaces 12 , 13 of the elongated light guiding element 4 until the light beam 10 , 11 reaches the second end 5 of the elongated light guiding element 4 and leaves the second end 5 through the light exit surface 14 of the plate 6 .
Due to the elongated light guiding elements 4 , the curved form thereof and the openings 9 between the elongated light guiding elements 4 , the light exit surface 14 of the plate 6 interconnecting the second ends 5 of the elongated light guiding elements 4 is much larger than the light entrance surface as formed by the light receiving surfaces 8 of the elongated light guiding elements 4 . Preferably, the light exit surface 14 is at least 100 times and more preferably at least 10,000 times as large as the light emitting surface 2 ′ of the LED 2 . The light emitting surface 2 ′ of the LED 2 is for example 1×1 mm to 3×3 mm and the luminance is for example 10 7 cd/m 2 . Preferably, the perceived luminance should be in the order of 10 4 cd/m 2 to 5×10 4 cd/m 2 . The light exit surface of the lens should therefore preferably be in de order of 5×10 −4 m 2 to 10 −2 m 2 . The number of elongated light guiding elements 4 is preferably at least 3 and at the most 50. The luminance of the LED 2 is strongly fragmented and a much lower luminance is perceived by the observer. However, due to the total internal reflection the optical efficiency of the lens 3 is high and nearly no light is lost.
The lens 3 is made of acryl, polycarbonate or other transparent material and is preferably made by injection moulding. It can be made out of several parts to overcome draft angle problems during the injection moulding process.
FIG. 3 shows a second embodiment of a lens 23 of a lighting device according to the invention. The lens 23 has a similar cross section as the lens 3 and as shown in FIG. 1 . However, instead of a round shape, the lens 23 has a more rectangular shape. The lens 23 comprises a number of strip-shaped elongated light guiding elements 24 extending parallel to each other. The elongated light guiding elements 24 are interconnected near second ends 5 by means of a rectangular plate 26 . First ends 27 of the elongated light guiding elements 24 are located near a passage 31 into which a number of LEDs 2 can be positioned in a row or array. The first ends 27 are spaced apart, the distance between the first ends 27 being much smaller than the distance between the second ends 25 , i.e. at the location where the second ends enter the plate 26 . The first ends 27 of the elongated light guiding elements 24 are each provided with a light receiving surface 28 , the light receiving surfaces 28 of all the elongated light guiding elements 24 thus forming a light entrance surface of the lens 23 . The light receiving surfaces 28 are located with respect to each other in a manner such that all light beams of the LEDs 2 will enter one of the light receiving surfaces 28 and that no light beam will enter an opening 29 between the elongated light guiding elements 24 .
Light beams of the row of LEDs in the passage 31 will be guided by total internal reflection through the elongated light guiding elements 24 in a manner as shown in FIG. 2 . The lens 23 can be made by means of extrusion so that a relatively long lens of for example 1 meter in the extrusion direction can be obtained. Such a lens can be used for a lighting device for a bus, train, airplane or parking garage, for example.
The total light emitting surface of the row or array of LEDs 2 is the sum of the light emitting surfaces 2 ′ of all the LEDs 2 . Preferably, the light exit surface of the lens 23 at the plate 26 is at least 100 times and more preferably at least 10,000 times as large as the total light emitting surface of the LEDs 2 .
Other shapes of lenses can be made by milling the outer surface of the lens 23 .
FIGS. 4A and 5 show a third embodiment of a lens 33 of a lighting device according to the invention. The lens 33 comprises cup-shaped curved elongated light guiding elements 34 . First ends 37 of the elongated light guiding elements 34 are located against each other and form a light entrance surface 36 . Second ends 35 of the elongated light guiding elements 34 are spaced apart, such that the distance between the second ends 35 is much larger than the distance between the first ends 37 . Between the elongated light guiding elements 34 openings 39 are located. Near the second ends 35 the elongated light guiding elements 34 are provided with light exit surfaces 38 , such that the light exit surface of the lens 33 is formed by the area in which the light exit surfaces 38 are located. The area of the light entrance surface 36 is much smaller than the area of the light exit surface 38 of the lens 33 due to which the perceived luminance of the lighting device is much lower than the luminance of the LED 2 positioned opposite the light entrance surface 36 . The second ends 35 of the elongated light guiding elements 34 can be provided with a convex light exit surface 40 , a concave light exit surface 41 or an oblique light exit surface 42 as shown in FIGS. 4B, 4C, 4D , respectively, to amend the emitted light as desired.
FIG. 6 shows a fourth embodiment of a lens 43 of a lighting device according to the invention. The lens 43 differs from the lens 33 in that the second ends 35 are located in a convex plane rather than in a common flat plane.
FIG. 7 shows a fifth embodiment of a lens 53 of a lighting device according to the invention. The lens 53 differs from the lens 33 in that the thickness of the elongated light guiding elements 54 near the first ends 57 is larger near the outside of the lens 54 than near the inside, whilst the thickness near the second ends 55 of all elongated light guiding elements 54 is equal.
FIG. 8 shows a sixth embodiment of a lens 63 of a lighting device according to the invention. The lens 63 differs from the lens 53 in that the second end 65 of the outer cup-shaped elongated light guiding element 64 is flared so that the light exit surface 68 thereof faces away from the light exit surfaces 58 of the other elongated light guiding elements 54 .
It is also possible to manufacture a more rectangular lens, such as shown in FIG. 3 with a cross section as shown in FIG. 6, 7 or 8 .
It is also possible to extend the outer elongated light guiding elements 34 so that the second ends are located in a convex plane, a rippled plane or any differently shaped plane.
It is also possible to provide the light exit surface of the elongated light guiding element with a micro structure, such as a frosted structure or diffusion structure, to further improve the light distribution.
It is also possible to connect the elongated light guiding elements to each other somewhere between the first and second ends either by a light guiding material, an opaque material or a holder.
Preferably, the elongated light guiding elements are rigid. However, it is also possible to manufacture flexible elongated light guiding elements so that the position of the light exit surface of each elongated light guiding element can be amended as desired. | A lighting device ( 1 ) comprises a light source ( 2 ) and a lens ( 3, 23, 33, 43, 53, 63 ) positioned in front of the light source ( 2 ). The lens ( 3, 23, 33, 43, 53, 63 ) is provided with a light entrance surface on a side facing the light source ( 2 ) and a light exit surface ( 14, 38 ) on a side remote from the light source ( 2 ). The lens ( 3, 23, 33, 43, 53, 63 ) comprises a number of strip-shaped interconnected elongated light guiding elements ( 4, 24, 34, 54, 64 ), of which first ends ( 7, 27, 37, 57 ) and spaced apart second ends ( 5, 25, 35, 55, 65 ) comprise the light entrance surface and light exit surface, respectively. Light beams emitted by the light source ( 2 ) are transmitted by total internal reflection in the elongated light guiding elements ( 4, 24, 34, 54, 64 ) from the first ends ( 7, 27, 37, 57 ) to the spaced apart seconds ends ( 5, 25, 35, 55, 65 ). | 5 |
FIELD OF THE INVENTION
[0001] The present invention is in the field of fishing (Class 43), and relates to holders (subclass 54.1) comprising a receptacle specifically designed for use in fishing for holding the bait. Specifically, the present invention relates to live bait holders (subclass 55) designed to keep such bait in a fresh condition. More specifically, the invention relates to live bait holders including some means for freshening the water, and for protecting the live bait against special harm when the holder is placed in water (subclass 56).
SUMMARY OF THE INVENTION
[0002] The present invention is a dynamic flow live bait holder for in water use. The bail holder is “dynamic flow” in that it is adapted to utilize motion of the holder while in use to pump ambient water into the bait holder and internal water out, as a means for freshening the internal water. Additionally, the present live bait holder has an interior/receptacle space for holding the bait which has no internal corners. The corner-less interior space is a feature that provides for protecting the live bait against certain kinds of harm when the holder is placed in water.
[0003] The present dynamic flow live bait keeper comprises a keeper body, which is a hollow and buoyant disc-shaped housing for containing the bait. The body or housing is formed of two concave disc shaped members faced together. The disc shaped member form the top and bottom portions of the keeper body, and define the interior space. Substantially, the keeper body has no definable sides joined at an angle in the interior space. The largest cross-section of the interior space is substantially oblong and of sufficient dimensions to allow the bait fish to swim without bunching up (e.g., in corners). The corner-less feature of the interior space facilitates the object of the present invention of protecting the live bait against harm when the bait holder is placed in water by allowing the bait to be able to swim in a continuous course and to avoid bunching up against walls and corners in the receptacle space.
[0004] The present live bait holder has water & air vent-ports disposed on the keeper body. Top-ports are positioned on the top-portion of the keeper body to vent air and allow excess water to escape from the interior space, and bottom-ports are positioned on the bottom-portion of the keeper body primarily to allow water to enter the interior space of the keeper body. It is a feature of the present invention that there be bottom-ports, and that the bottom-ports are positioned toward the forward-end of the bottom-portion of the keeper body to allow water to enter the interior space. A hatch assembly is disposed on the top-portion of the keeper body and is operable to provide access to the interior space of the bait holder. A tether attachment is disposed on the forward end of the bottom-portion of the keeper body. When in use in the water (e.g., tethered to the angler or to a boat), the bait holder maintains its forward end into a wind and/or a current at a surface of the water.
[0005] Generally, the buoyancy of the present live bait holder is adjusted so that at neutral buoyancy, its draft when placed in water is proximate the plane of the keeper body's largest interior cross-section. Buoyancy can easily be adjusted by a user by the addition of weight to a desired place on/in the keeper body. It is also a feature of the present invention that the forward-end of the top portion of the keeper body curves downward. This feature serves to more forcefully drive the forward-end downward when the forward-end gets submerged in a current, to increase the pressure driving ambient water into the bottom-ports in the bottom-portion of the keeper body. Additionally, a porpoise weight can be disposed near the front end of the keeper body to promote movement of the forward-end of the keeper body with a rising and falling motion in response to the wind and current at the surface of the water. This motion helps to force water through the bottom-ports and into the interior space of the keeper body, to provide the dynamic flow of ambient water into the present live bait holder.
DESCRIPTION OF THE INVENTION
[0006] Referring now to the drawings, the details of preferred embodiments of the present invention are graphically and schematically illustrated. Like elements in the drawings are represented by like numbers, and any similar elements are represented by like numbers with a different lower case letter suffix. The present invention is an in the water, dynamic flow live bait holder. The “dynamic flow” feature of the bait keeper derives from the structural elements of the bait keeper and their interaction when the bait keeper is placed in water, as will be explained below.
[0007] The dynamic flow bait holder has a keeper body which is a hollow and buoyant, and substantially disc-shaped container. The keeper body has a forward end, and an aft end as well as a top-portion and a bottom-portion. In one embodiment, the bottom-portion of the forward end has a tether attachment means. Additionally, the top-portion of the keeper body has a closeable hatch assembly, which allows access to a “corner-less” interior space of the body. The interior space of the keeper body is “corner-less” in that a perimeter around the largest dimension of the interior space is curved (and substantially circular) and there are no corner (i.e., sharp angles) in the interior space. This is an important structural feature of the present invention which helps live bait to be able to avoid bunching up (at a corner) and to keep swimming. The keeper body also has a number of vent ports on its top-portion and bottom-portion, which allow water flow between the interior space and the environment outside of the keeper body.
[0008] The keeper body has a hatch opening through its top-portion, which opening enables a user to access the interior space of the bait keeper. The hatch assembly is disposed on the top-portion of the keeper body to allow the hatch opening to be closed to prevent bait from escaping from the interior space of the keeper body. The hatch assembly includes a hatch door, a hinging means attaching the hatch assembly to the keeper body, and a latch for securing the hatch door closed. The interior space of the keeper body is “corner-less” in that a perimeter around the largest dimension of the interior space is curved (and substantially circular) and there are no corner spaces (sharp angles) in the interior space. This is an important structural feature of the present invention which helps live bait to be able to avoid bunching up (at a corner) and to keep swimming, which helps to keep the bait fresh longer. It is this feature that defines the substantially circular and oval shape of the bait keeper.
[0009] In use, the present dynamic flow live bait keeper is placed in the water where a person (such as a fisherman) intends to use it. The bait keeper is buoyant and floats in the water. Once the bait holder is placed in the water, it will fill with water to its neutral buoyancy level. Live bait is placed into the interior space of the keeper body through the hatch door and the hatch door closed. Similarly, bait may be removed from the bait holder as desired by the user. One end of a tether line is attached to the tether attachment of the keeper body. The other end of the line is attached to the fisherman his/herself, to a fishing boat or water craft, or to something stationary in the water. The force of the wind, or current in the water, or the motion the bait keeper over the water takes the bait keeper to the end of the tether line. Selection of an appropriate composition and length of tether line is readily accomplishable by a fisherman of ordinary skill in the art. Once the forces on the bait keeper take it to the end of the tether line, the forward end of the keeper body points into the force(s) acting on it. Optionally, a skeg may be added to the bottom-portion of the keeper body to facilitate keeping the forward end pointed into the force acting on the keeper body.
[0010] Once the bait keeper is taken to the end of the tether line, the force continues to act on it. Even very small forces, such as ripples and swells in the water, or movement of the fisherman or water craft, will cause the keeper body to rock back and forth (i.e., to porpoise forward end to aft end) in the water. The keeper body of the bait holder may be disposed to float level in still water, but preferable it floats in still water with a slight forward end down tilt. In a preferred embodiment, the forward end is heavier than the aft end to accomplish a nose or forward end down tilt to the bait holder. The nose down tilt disposition of the forward end can be accomplished by having the front end of the keeper body have a thickness that is greater than the thickness anywhere else on the keeper body. Alternatively or additionally, a porpoise weight can be added to the front end. The porpoise weight is a denser-than-water putty or resin applied to the inside wall of the interior space, proximate the forward end. Molding the porpoise weight into the wall of the front end and/or using a dense putty as the porpoise weight both have the advantage of maintaining the “corner-less” element of the interior space of the keeper body. Other weighting means are known to and selectable by one of ordinary skill in the art for practice in the present invention that do not compromise the “corner-less” element of the keeper body. For example, a fin or skeg (not shown) could be added to the front end of the keeper body to add weight to the front end and to help stabilize the keeper body in line with the direction of the force on it.
[0011] The degree of nose (forward end) down tilt can be adjusted by a user by adding or removing a buoyancy means to the bait holder. For example, a buoyancy means in the form of a closed-cell foam strip fixed to the inside wall of the interior space. Other weighting and buoyancy adjustment means are known to and selectable by one of ordinary skill in the art for practice in the present invention.
[0012] The “dynamic” limitation of the present live bait holder refers to the water pumping action of the keeper body as it rises and fall (porpoises) in the water. The point of attachment of the other end (not shown) of the tether line is disposed so that when the bait holder tugs at the end of the tether line, the front end of the keeper body tends to rise up out of the water. This can be accomplished by attaching the other end of the tether line to a point that is out of the water. The benefit of the dynamic limitation of the bait holder derives from the fact that in open water a floating object is almost never still. And as noted above, even very small forces, such as ripples and swells in the water, or small movement of the fisherman or boat will cause the keeper body to rock back and forth or to porpoise in the water.
[0013] As the bait holder rocks back and forth in the water, the front end of the keeper body rises out of the water. Due to the weight of the keeper body front end and because the kinetic energy of the water contained within the interior space is greater than the water outside the keeper body, the bait holder is no longer neutrally buoyant in the water. This is not withstanding that some of the interior water flows out of the bait holder through the bottom-portion ports. The increase in the kinetic energy of the front end of the keeper body due to its mass and the water it contains causes the front end to forcibly reenter the water. As the front end enters the water (it tends to pass through the neutral buoyancy level of the keeper body), the bottom-portion ports submerge below the surface of the water. Water then enters the interior space of the keeper body, replacing an amount of the water that had flowed out of the interior space when the front end of the of the keeper body was out of the water. The top-portion vent ports vent displaced air and excess water from the interior space and minimize potential water pressure build-up in the interior space regardless of the water pressure outside of the bait holder. As the front end returns toward neutral buoyancy, excess water in the interior space flows out through the bottom-portion ports.
[0014] In the above manner, as the present dynamic flow live bait holder rocks or porpoises back and forth in the water, some portion of the water contained in its interior space is removed and replaced with fresh water. Consequently, the water in the interior space is constantly refreshed. Additionally, the water pressure in the interior space is relative constant and substantially independent of the water outside of the bait holder even when the force is relatively high, as when the bait holder is being towed behind a boat. The constant pressure feature of the present live bait holder is an advantage that helps keep live bait fresh.
[0015] While the above description contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as exemplifications of one or another preferred embodiment thereof. Many other variations are possible, which would be obvious to one skilled in the art. Accordingly, the scope of the invention should be determined by the scope of the appended claims and their equivalents, and not just by the embodiments. | Disclosed is a live bait keeper having a cornerless interior and dynamic flow of ambient water through it for freshening the water and protecting bait against harm when the holder is in water. The holder has a hollow, disc-shaped keeper body having forward and aft ends and cornerless interior space. The keeper is buoyant. A top hatch accesses the interior where bait is held. In use, ports on the top-portion of the keeper vent air and water from the interior, and bottom-ports disposed toward the forward-end of the keeper allow water to enter the interior. A tether attachment is disposed on the bottom-portion at the forward end below the neutral buoyancy plane of the keeper body, and as a tether maintains the forward end into the wind and/or current, the keeper rocks fore and aft forcing water into the bottom-ports to provide dynamic water flow into the bait holder. | 0 |
The Government has rights in this invention pursuant to Subcontract No. GE10A0130M under Prime Contract N0003072C0108 awarded by the U.S. Navy.
BACKGROUND OF THE INVENTION
This invention relates broadly to high-energy oxidizers for solid, rocket propellants. More specifically, it relates to the preparation and use in propellants of cocrystals of cyclotetramethylenetetranitramine (HMX) and ammonium perchlorate.
The currently most widely used type of solid, rocket propellant comprises essentially a dispersion of finely divided inorganic oxidizer particles together with a powdered, metallic fuel, in an elastomeric binder. Such propellants are commonly made by mixing a major amount of the finely divided oxidizer with powdered metal and a minor amount of liquid, curable organic polymer, a curing agent for the organic polymer, and small amounts of certain special purpose additives. The resulting mixture is usually heated to an elevated temperature to cure the polymer to elastomeric form with the oxidizer dispersed therethrough.
The thrust that a given rocket structure develops depends importantly on the specific impulse of the propellant used therein, and the specific impulse in turn depends importantly on the nature of the oxidizer employed.
Although ammonium perchlorate has been probably the most successful and widely used oxidizer for solid rocket propellants, its high degree of solubility in water tends to affect aging properties of solid propellant adversely, primarily by the formation of perchloric acid from the ammonium perchlorate and ambient moisture. This necessitates the use of desiccants and hermetic seals with such rocket motors, especially in humid climates. Such undesirable products that may also be formed with residual moisture in the propellant can attack the aluminum powder, that is a common ingredient of propellant, to cause gassing and a resultant production of voids in the propellant. Such unplanned voids can greatly increase the burning surface of the propellant, and, hence, its burning rate, to an undesirable extent.
Cocrystals of ammonium perchlorate with burning-rate depressants have been described in the prior art literature as having been successfully used in solid propellant; but these also have been water soluble, and, hence, have done nothing to solve the problems associated with such water solubility in solid propellant.
SUMMARY OF THE INVENTION
The present invention, which overcomes these problems, is a new oxidizer, insoluble in water, comprising cocrystals of HMX and ammonium perchlorate. The invention also includes its preparation and use in solid propellant.
The cocrystals are prepared by dissolving HMX crystals in a solvent, and also dissolving ammonium perchlorate crystals in a solvent that is compatible and miscible with the first. The two solutions are then mixed together and the solvents removed by some desiccating process, such as by spraying in a vacuum, evaporation, etc. Size of the crystals is determined in the conventional manner, i.e., by control of time and temperature allowed for crystal growth.
The resulting crystals are included in solid, rocket propellant in the same manner as crystals of ammonium perchlorate or other common oxidizers. However, they have certain advantages that tend to improve both the shelf life and the mechanical properties of the resulting propellant. The cocrystals of the present invention are essentially insoluble in water, so that gassing and other problems associated with water solubility of the oxidizer are obviated. The cocrystal has been found to have surface characteristics that promote improved bonding to the propellant binder, compared to those of either HMX or ammonium perchlorate.
Objects of the invention are to provide a high-energy oxidizer for solid, rocket propellants that is inexpensive and easy to manufacture from readily-available materials; and that will provide rocket propallant having improved properties and shelf life.
Other objects and advantages of the invention will become apparent in the following detailed description.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Cocrystals of the present invention are prepared by dissolving crystals of HMX in a solvent; dissolving crystals of ammonium perchlorate in a second quantity of solvent; mixing the two solutions; and removing the solvent by some evaporation process.
Although it is possible that the crystals HMX and of ammonium perchlorate could be dissolved in two different kinds of solvent that are miscible and nonreactive, it is preferred that the two solvents be of the same material. A preferred and effective solvent for this purpose is dimethyl sulfoxide. Other solvents that have been found to be useful are acetone, dimethyl formamide, nitromethane, and methylisobutyl ketone. Also, if desired, the crystals of HMX and ammonium perchlorate may be dissolved together in the same container of solvent.
Stoichiometric proportions of HMX and ammonium perchlorate in the resulting cocrystals have been found to be 62.5% and 37.5% by weight, respectively, or 50 parts of HMX to 30 parts of ammonium perchlorate.
Average size of the cocrystals is determined in the conventional manner, i.e., by regulating the time allowed for crystal growth. This involves also regulating the temperature and concentration of the solution, and the pressure and technique used for the drying process. The smallest crystals are obtained by flash drying or spraying a concentrated solution into a vacuum. Larger crystals are obtained by slower means of removing the solvent, such as by evaporation. A preferred means of removing the solvent is by evaporation in a vacuum.
EXAMPLE
At a temperature of about 75° F, 120 grams of HMX crystals and 120 grams of ammonium perchlorate crystals were added to a beaker containing 496 grams of dimethyl sulfoxide. The mixture was stirred until all solids were completely dissolved. The solution was then placed in a partial vacuum at a pressure of about 13 cm of mercury absolute and at a temperature of 80° F for 3 days. At the end of that period, the solvent had completely evaporated, leaving cocrystals of HMX and ammonium perchlorate. The crystals were hexagonal in cross section and elongated; and were found to be substantially insoluble in water.
The crystals were washed with water and dried; and were then subjected to a physical and chemical analysis, wherein the stoichiometric proportions were established and the heat of reaction was found to be 526.8 cal./gm.
In a similar experiment, HMX crystals were dissolved in acetone, and ammonium perchlorate crystals were dissolved in a different container of acetone. The two solutions were then mixed and vacuum desiccated, resulting in formation of cocrystals identical to those described above.
The cocrystals begin to form in the solution at saturation thereof, and grow as the solvent is removed by some technique involving evaporation. For the sake of securing crystals of a desired size and uniformity, it may be found that, in certain applications, the optimum yield per unit of time will indicate the desirability of recovering the cocrystals from the solution before all of the solvent has been removed. In such cases, cocrystals of the desired size may be removed by filtering the solution through a screen or series of screens. Undersized crystals may be recycled by returning them to the solution and redissolved either by adding more solvent, by raising the temperature thereof, or both. In this way the process of preparing the cocrystals may be made to be continuous. Also, the evaporated solvent may be continually recovered by well-known techniques and returned to the solution in the desired quantities.
As has been described in the prior literature regarding other cocrystals of ammonium perchlorate, the new oxidizer of the invention may be substituted for ammonium perchlorate in the otherwise conventional formulations for solid propellants. Such propellants are cited in a report titled "Cocrystallizing Additives with Ammonium Perchlorate and Their Effect on the Burning Rate of Polyurethane Propellants" by S. T. Balke. Elastomeric binders used in these propellants were polyurethane and polyisobutene. Other commonly used binders are hydroxylterminated polybutadiene and isophorone diisocyanate.
A typical propellant formulation useful for the invention is the following in parts by weight.
______________________________________ Parts______________________________________Cocrystals of HMX and ammonium perchlorate 40 to 80(ranging from 30-300 microns, weight meandiameter)Carboxyl-terminated polybutadiene 15 to 35(mol. wt. from 500-6,000)Curing composition 0.5 to 6(0.05 to 1 part iron octoate, and 0.5 to 5 prts imineepoxide-the latter made of 1-10 parts by weight oftris(1-(2-methyl) aziridine) phosphine oxide to eachpart by weight of trifunctional epoxide resinAluminum powder 4 to 24______________________________________
The dry ingredients are thoroughly mixed with the liquid prepolymer. It is then cast into a vertically-positioned, rocket motor case, in which a mandrel for forming a central, longitudinal perforation in the propellant is typically supported. The filled case is then placed in an oven and heated to about 135° F until the binder is cured to form an elastomeric polymer. The central mandrel is then withdrawn from the propellant charge.
An invention has been described that provides an advance in the art of solid propellant technology. Although it has been set forth in considerable detail, it should be noted that many details may be altered without departing from the scope of the invention, as it is defined in the following claims. | Crystals of cyclotetramethylenetetranitramine (HMX) are dissolved in a suitable solvent, as are crystals of ammonium perchlorate. The two solutions are then mixed thoroughly and desiccated. This produces cocrystals of HMX and ammonium perchlorate that may be used as an oxidizer in rocket propellant, pyrotechnic materials, or in gas generators. Stoichiometric proportions are 50 parts of HMX to 30 parts of ammonium perchlorate. | 2 |
FIELD OF THE INVENTION
The present invention relates generally to automotive light modules and light manifolds therefor, and more particularly relates to light manifolds for near field lenses collecting and directing light laterally relative to the light source.
BACKGROUND OF THE INVENTION
Light emitting diodes (LED's) are fast becoming a preferable light source for automotive lighting applications, as they consume less power but provide light output which is acceptable for such applications. In order to employ LED's for automotive applications, high levels of efficiency must be obtained in both light collection as well as light distribution. Typically, reflectors or lenses or light pipes are utilized to collect and distribute the light for the particular lighting application. Unfortunately, not all automotive applications, such as the stop function of a tail light, have been effectively produced utilizing an LED light source in such reflectors, lenses or light pipes.
Accordingly, there exists a need to provide methods and structures for light distribution which meets the requirements of specialized applications.
BRIEF SUMMARY OF THE INVENTION
One embodiment of the present invention provides a light manifold for a light module which facilitates reproduction of automotive light functions. Generally, the light manifold distributes light from a light source and includes the main body of light transmitting material. The main body defines a longitudinal axis and a lateral axis. The main body has opposing first and second surfaces, the first and second surfaces generally facing longitudinally. The first surface has a series of alternating angled portion and lateral portions. The angled portions are angled relative to both the longitudinal and lateral axes for reflecting light towards the second surface. The lateral portions include a plurality of ridges structured to reflect incident light towards the second surface.
According to more detailed aspects, the lateral portions are generally parallel to the lateral axis and preferably are angled about 45 degrees relative to both the longitudinal and lateral axes. Each angled portion has an upper longitudinal edge and the plurality of ridges have upper longitudinal edges positioned lower than the upper longitudinal edge of an adjacent radially inward angled portion. Preferably, the plurality of ridges are defined by V-shaped grooves formed into the first surface of the main body. The angled portions are positioned sequentially in the longitudinal direction. The main body preferably includes a lateral facing surface receiving light from the light source, and preferably from a near field lens positioned inside the main body and having a flat outer laterally facing surface abutting against the laterally facing surface of the main body.
Another embodiment of the light manifold constructed in accordance with the teachings of the present invention includes a main body of light transmitting material and having a disc shape defining a longitudinal axis. The main body has opposing first and second surfaces generally facing longitudinally. The main body is circumferentially divided into a plurality of wedge sections, each wedge section having a series of radially spaced apart angled portions formed into the first surface. The angled portions are angled relative to the longitudinal axis for reflecting light towards the second surface. The radial spacing of the angled portions of the first wedge section are different than the radial spacing of the angled portions of a second wedge section.
According to more detailed aspects, each wedge section has a radial length, and the radial length of the first wedge section is different than the radial length of the second wedge section. Preferably, the plurality of wedge section alternate between the first and second wedge sections. Each wedge section further includes a series of radially spaced apart inclined sections, the inclined sections being angled relative to the longitudinal axis at a degree greater than the degree the angled sections are angled relative to the longitudinal axis. For example, the angled sections may be angled at about 45 degrees while the inclined sections are angled greater than about 45 degrees, and preferably at about 68 degrees. The radially outer most angled portion may be shared by all wedge sections. As with the prior embodiment, the plurality of angled portions are spaced apart radially and positioned sequentially in the longitudinal direction.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings:
FIG. 1 is a perspective view of a light manifold constructed in accordance with the teachings of the present invention;
FIG. 2 is side view of the light manifold depicted in FIG. 1 ;
FIG. 3 is a cross-sectional view of the light manifold depicted in FIGS. 1 and 2 ;
FIG. 4 is a perspective view, partially cut-away, of another embodiment of the light manifold constructed in accordance with the teachings of the present invention;
FIG. 5 is cross-sectional view of the light manifold depicted in FIG. 4 ; and
FIGS. 6 and 6 a are a side view and an enlarged portion of the side view of another embodiment of a light manifold constructed in accordance with the teachings of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Turning now to the figures, FIGS. 1–3 depict a light manifold 20 for use with the light module having a near field lens 10 and light source 11 . Generally, the light manifold includes a disc-shaped main body 22 constructed of a light transmitting material, and preferably a plastic such as acrylic although any light transmitting material may be employed. The main body 22 defines a longitudinal axis 14 along which light is directed, and a lateral axis 16 perpendicular to the longitudinal axis 14 . As used herein, the lateral direction may also be referred to as the radial direction, and encompasses all directions which are generally transverse to the longitudinal axis 14 . The main body includes a light emitting surface 24 and a light reflecting surface 26 . The light reflecting surface 26 will be referred to herein as the first surface 26 and the light emitting surface 24 will be referred to as the second surface 24 . The main body 22 also includes an inner laterally facing surface 25 defining a pocket receiving the near field lens 10 . Generally the inner laterally facing surface 25 is flat and annular, corresponding to the flat and annular outer surface of the near field lens 10 .
The main body 22 of the manifold 20 receives light from the light source 11 and near field lens 10 through the inner laterally facing surface 25 for further redirection by the first surface 26 . The near field lens 10 is preferably constructed as a side-emitting NFL, one preferred construction being described in copending U.S. patent application Ser. No. 11/274,071 filed on Nov. 15, 2005 concurrently herewith, the disclosure of which is incorporated herein by reference in its entirety. Generally, the NFL 10 is structured to collect, longitudinally collimate and redirect the light laterally along the lateral axis 16 , and may be separately formed or integrally formed with the manifold 20 . The first surface 26 includes a series of alternating angled portions 28 and lateral portions 30 . The angled portions 28 are angled relative to both the longitudinal and lateral axes for reflecting light towards the second surface 24 . Preferably, the angled portions 28 are angled at about 45 degrees although a wide variety of angles may be employed to provide a certain beam spread or pattern depending on the particular automotive function desired. The lateral portions 30 are generally parallel to the lateral axis 16 , and therefore typically do not reflect the light. By the terms generally and about, it is meant that the surfaces are generally within 3 degrees of perfectly parallel or perpendicular. It will also be seen that the angled portions 28 are positioned sequentially moving in the longitudinal direction (i.e. along axis 14 ) to redirect the light longitudinally at different lateral or radial positions.
As best seen in FIGS. 1 and 2 , the main body 22 includes a plurality of wedge sections, which here have been depicted as alternating first wedge sections 32 and second wedge sections 34 . The first and second wedge sections 32 , 34 span different radial lengths. Similarly, the first and second wedge sections 32 also include alternating angled portions 28 and lateral portions 30 which are positioned at different radial locations. It can also be seen that the first and second wedge sections 32 , 34 include different numbers of angled portions 28 . For example, the first section 32 has been depicted as having three angled portions 28 , while the second wedge section 34 has been depicted as having only two angled portions 28 .
Accordingly, it will be recognized that those skilled in the art that the light manifold 20 may be constructed out of any number of different wedge sections 32 , 34 having any number of different angled portions 28 which can also be positioned at various radial positions and at various angles. All of these variables thus provide increased adaptability and the opportunity for uniquely creating a light distribution pattern or beam spread which achieves a certain function or application, like a particular light assembly of an automobile such as a stop light, brake light, turn light or the like.
Turning now to FIGS. 4 and 5 , another embodiment of the light manifold 120 has been constructed in accordance with the teachings of the present invention. As with the prior embodiment, the light manifold 120 includes a main body 122 having a first surface 126 for redirecting light through a second surface 124 . The main body 122 defines an inner laterally facing surface 125 receiving light from a light source 111 having a side emitting NFL. The main body 122 is circumferentially divided into a plurality of first and second wedge sections 132 , 134 each having slightly different constructions. As with the prior embodiment, the first surface 126 is structured to include a plurality of alternating angled portions 128 and lateral portions 130 .
Unlike the prior embodiment, the first surface 126 also includes a plurality of inclined portions 129 positioned between the angled portions 128 and lateral portions 130 . The inclined portions 129 are angled at some degree relative to the longitudinal axis that is greater than the angle of the angled portions 128 . Preferably, the inclined sections 129 are angled at about 68 degrees relative to the longitudinal axis 14 . Thus, the first surface 126 follows a series including the angled portion 128 , lateral portion 130 and inclined portion 129 . In this manner, light is passing laterally through the main body 122 that strikes an inclined portion 129 will be redirected towards an angled portion 128 and reflected outwardly through the second surface 124 , at some increased angle relative to the longitudinal axis 14 . Accordingly, it will be recognized by those skilled in the art that through the provision of inclined portions 129 , a controlled amount of beam spread is provided by the light manifold 120 .
The first and second wedge sections 132 , 134 differ in their radial spacing and size of angled portions 128 , inclined portions 129 and lateral portions 130 . Like the prior embodiment, increased control is provided over the resulting beam pattern through the use of different wedge sections 132 , 134 . It will also be recognized that the radially outer most angled portion 128 is shared by all of the first and second wedge sections 132 , 134 . As such, a solid ring of light is provided along the outer periphery and a common outer diameter to the main body 122 is provided.
Turning now to FIGS. 6 and 6 a , another embodiment of a light manifold 220 constructed in accordance with the teachings of the present invention has been depicted. The manifold 220 of this embodiment is structured for use with a near field lens 210 having a bi-directional lens construction, which is described in more detail in copending U.S. patent application Ser. No. 11/274,071 filed concurrently herewith. The NFL 210 is structured to direct light in two laterally opposite directions along a longitudinal axis 16 . Accordingly, the manifold 220 includes a first body portion 222 a and a second body portion 222 b which are similarly constructed. Each main body portion 222 includes a first reflecting surface 226 and a second emitting surface 224 .
As best seen in FIG. 6 a , and similar to prior embodiments, the first surface 226 includes alternating angled portions 228 and lateral portions 230 . However, in this embodiment, the lateral portions 230 include a plurality of ridges 229 structured to reflect incident light towards the second surface 224 . In this manner, light distribution efficiency is improved. As shown in the figure, the angled portion 228 includes an upper longitudinal edge 231 and the plurality of ridges each have an upper longitudinal edge 233 . Generally, the lateral portion 230 and the upper edges 233 of the ridges 229 are positioned below the upper longitudinal edge 231 of the angled portion 228 . In this manner, the lateral portion 230 is somewhat shielded by the angled portion 228 , and therefore only collects non-collimated or other incident light. It will also be recognized that the second light emitting surface 224 includes a plurality of dimples 227 which are structured to focus certain portions of the emitted light. Preferably, the dimples 227 are positioned in lateral alignment and longitudinally above the angled portions 228 . It will be recognized that any number of different beam focusing or spreading optics may be employed on the second surface 224 of the light manifold 220 .
Accordingly, it will be recognized by those skilled in the art that the various light manifold constructions described herein provide numerous opportunities for customization and hence constructions which can address particular light distribution requirements such as for automotive functions.
The foregoing description of various embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise embodiments disclosed. Numerous modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled. | A light manifold for an automotive light module emitting light to the side of a longitudinal axis along which light is to be directed. The light module is structured in a manner that permits the creation of light distribution patterns for particular functions, such as the stop light function for an automobile, that are otherwise difficult to effectively produce. | 5 |
This invention was made with Government support under Contract DE-AC04-94DP85000 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.
BACKGROUND
The present invention relates generally to joint mechanisms, and more specifically to a new class of large displacement spherical joints. The spherical joint has long been a standard of mechanical design. The general nature of prior art spherical joints is shown in FIG. 1 . Here a spherical body 10 makes bearing contact with a bearing cup 12 on a bearing surface 11 . The term ‘bearing contact’ is intended to describe a juxtaposition between two mechanical components which allows them to easily move relative to each other restricted only by the structure of the bearing. The juxtaposition can be surfaces sliding on each other, with or without lubrication, or can be mediated by any of a wide range of conventional bearing elements, such as balls, rollers, and the like. The term ‘bearing surface’ shall be intended to include the mechanisms which comprise such mediated bearing contacts.
Such bearings generally perform best if bearing surface 11 is spherical in shape, and has a radius substantially equal to that of the spherical body 10 , but neither condition is strictly necessary. For example, bearing cup 12 can take the form of a hollow tube, with the bearing surface taking the form of a ring on which the spherical body and the bearing cup make bearing contact. In another example, bearing cup 12 can be replaced by three properly spaced and oriented flat bearing pads, and the resulting bearing surface will have equivalent functionality. Of course, such a bearing surface would be expected to wear at a much faster rate than the illustrated structure.
A first shaft 13 is affixed to spherical body 10 , generally but not necessarily aligned along a radius of the spherical body 10 . A second shaft 14 can be affixed to bearing cup 12 , although other mounting techniques, such as attaching bearing cup 12 to a joint base, can be used. Finally, spherical retainer 15 provides a second bearing surface 16 for spherical body 10 . The two bearing surfaces are positioned so that spherical body 10 cannot move, other than through rotation in place, relative to the bearing cup and the spherical retainer.
The structure described above allows considerable freedom of motion of the two shafts relative to each other. Using the orientation of the second shaft as a reference, the first shaft can move freely within a full cone angle α while at the same time rotating freely about its own axis.
The primary restriction on the amount of movement allowed by a spherical joint is the interference between the first shaft and the spherical retainer when an attempt is made to move the first shaft to a position outside the allowed full cone of motion. This interference results from the need to provide a mechanical retainer to keep the spherical body in contact with the bearing cup so that the rotary motion thereof is well-defined.
In most commercially available mechanically restrained spherical joints the available full cone angle α is less than 40 degrees, and examples are simply not available with α>60 degrees. As prior art spherical joints were primarily used to accommodate minor shaft misalignments, the limited full cone angle was not a serious limitation.
There is a variety of prior art spherical joint that allows access to larger full cone angles. In these joints, the spherical retainer does not appear, and the spherical body is held within the bearing cup by magnetic attraction. Such joints, however, cannot tolerate large tensile forces, and are susceptible to dislocation under small dynamic or static forces which do not directly press the spherical body into the bearing cup. Such magnetic spherical joints thus have very limited fields of usage.
New applications for spherical joints have recently arisen for which a large allowed full cone angle is a great advantage. These include many of the parallel mechanisms on which flexible machining platforms and robotic manipulators are now based. In such applications, the greater allowed full cone angle contributes to increasing the workspace of the machine. The result is dramatic increase in efficiency, in large part driven by reducing the total setup time as a workpiece is dismounted and reoriented.
There is a prior art spherical joint that has the potential for providing somewhat larger allowed deflection angles, perhaps to full cone angles as large as 120-140 degrees, although to Applicants knowledge such have not been commercially available. This is the joint described in U.S. Pat. No. 4,628,765, Dien and Luce, issued Dec. 16, 1986 (now expired). In this patent is disclosed a spherical joint comprising a spherical body 20 mounted within a ring-shaped bearing 21 which allows rotation in any direction (see FIG. 2 ). A pair of semi-circular yokes 22 and 23 oriented along perpendicular axes provide a means to characterize and control the position of a shaft 24 attached to the spherical body. The ring-shaped bearing 21 mechanically retains the spherical body 20 by enclosing a diameter of the spherical body. This, however, has the effect of limiting the allowed deflection angle to values substantially less than 90 degrees. Such a ring-shaped bearing is also difficult and expensive to incorporate into a commercial joint.
There are numerous ways in which a concatenation of revolute joints can be assembled to mimic the behavior of a spherical joint. An example is shown in FIG. 3, where a ‘spherical’ joint between a first shaft 30 and a second shaft 31 is implemented by combining the effect of a revolute joint 32 imbedded in the end of second shaft 31 with the effect of a revolute fork joint 33 mounted upon revolute joint 32 so that the axis of revolution of the two joints are perpendicular. First shaft 30 is mounted on revolute fork joint 33 via revolute joint 34 so that first shaft 30 is free to turn about its own axis. In this design, three pairs of axles and matching bearings, together with a collection of precision machined and assembled components, are required to mimic the behavior of a spherical joint. In addition, the joint stability which follows naturally from having a spherical body firmly set on an appropriate bearing surface can only be achieved here by insisting on extremely tight manufacturing tolerances. Maintenance, useful life, and other practical considerations fall solidly on the side of the true spherical joint. In the end, even though the joint illustrated in FIG. 3 mimics the behavior of a spherical joint capable of very large deflection angles, in most cases it is not a practical option.
There is a need for a precision spherical joint which is mechanically stable and capable of large (i.e., α>60 degrees) full cone angles while remaining resistant to mechanical joint dislocation. Applicants have addressed this need by developing a new type of spherical joint which satisfies these criteria and more.
SUMMARY
The present invention is of a new type of spherical joint, capable of very large deflection angles. The new joint is similar to conventional spherical joints in that a shaft is (usually) radially fixed to a spherical body, and that spherical body is then confined by bearing surfaces (usually, but not necessarily comprising a concave spherical bearing surface having a spherical radius nearly that of the spherical body) which together define a unique spherical locus which matches the size of the spherical body and within which the spherical body is confined. The new feature is a special type of spherical retainer, containing some of the bearing surfaces, which guides the relative motions of the shaft and the sphere so that the mechanical interferences which limit the accessible deflection angle of conventional spherical joints are relieved or avoided.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a schematic diagram of a prior art spherical joint.
FIG. 2 shows a schematic diagram of a second variety of prior art spherical joint.
FIG. 3 shows schematically a mechanism which mimics the behavior of a spherical joint using only revolute joints.
FIG. 4 shows schematically how a large displacement spherical joint based on prior art technology fails.
FIG. 5 shows schematically a camming spherical joint.
FIG. 6 shows schematically a camming spherical joint with a magnetic eccentric cam.
FIG. 7 shows schematically a camming spherical joint with flappers.
FIG. 8 shows schematically an arching band spherical joint.
FIG. 9 shows schematically an arching band spherical joint with shaft bearing.
FIG. 10 shows schematically a double arching band spherical joint.
DETAILED DESCRIPTION
Begin by illustrating the difficulties encountered when attempting to apply prior art concepts to large displacement spherical joints. FIG. 4 shows a spherical joint which allows access to large deflection angles, but not to large full cone angles. Spherical body 40 has a first shaft 41 radially affixed. Spherical body 40 rides on a bearing cup 42 , to which is radially affixed a second shaft 43 . (A joint base can be used in place of the second shaft.) Here, radially affixed means that the shaft axis intersects the center of the spherical body when the spherical body is placed on the bearing cup 42 . The bearing surface on which the spherical body rides on the bearing cup can take the form of a concave sphere, typically having a radius nearly equal to that of the spherical body. However, a conical bearing surface, or indeed any shape which, while the spherical body rests against the bearing cup, restricts the motion of the spherical body to simple rotations can be used.
A second bearing 44 is positioned so that the spherical body 40 rides on both the bearing cup and the second bearing, and so that the center of the spherical body is thereby constrained to reside at a single point. Note that this requires that the second bearing be located above the diameter of the spherical body 40 which is perpendicular to the axis of the second shaft 43 . A C-shaped bearing support structure 45 fixes the relative position of the bearing cup and the second bearing, thereby trapping the spherical body between them, and attaches to the second shaft (or the bearing cup, which attachment is functionally equivalent).
The resulting joint can reach extremely large deflection angles in most directions, the primary restriction being interference between the first shaft and the bearing cup. Unfortunately, this desirable behavior is not seen in all orientations. The first shaft can also interfere with the second bearing and the bearing support structure, thereby preventing function as a true spherical joint. A moment's contemplation will show that such interferences occur in any joint in which the spherical body is retained by the relative positioning of two or more bearings.
The present invention is of a spherical joint in which the spherical body is retained by the relative positioning of two or more bearings, but where additional structure guides and/or restricts the joint motion so as to avoid the resulting interferences.
One implementation of a large displacement spherical joint after the present invention appears in FIG. 5 . In this implementation of the present invention, called a camming spherical joint, spherical body 50 has first shaft 52 radially affixed, and rests in bearing cup 51 , thereby forming a first bearing surface. The bearing cup and the spherical body are enclosed within camming housing 53 . Camming housing 53 comprises a cam surface 54 and at least one mounting site for a bearing pad 55 . (As drawn, the joint of FIG. 5 has three bearing pads.) The bearing cup and the bearing pads are positioned so that a spherical bearing surface which matches the spherical body is thereby defined. The bearing cup can be fixed to the joint base 56 , or to the camming housing 53 . The bearing cup 51 can be spring-loaded with a spring 58 positioned between revolute joint 57 and the bearing cup 51 to maintain positive engagement of the bearing cup 51 with the spherical body 50 . Finally, the camming housing 53 is connected to the joint base 56 via revolute joint 57 , which allows free rotation of the housing about a vertical axis.
A camming spherical joint according to the present invention is capable of the full 3-axis freedom of a simple spherical joint. Unlike a conventional spherical joint, however, the shaft can rotate by more than 90 degrees about all axes perpendicular to the vertical axis.
To see this, imagine having the first shaft 52 oriented roughly vertically, and then pulling it down toward the joint base. The angle between the first shaft and the vertical is called the deflection angle. When the first shaft strikes the cam surface, the generic situation is that a force is generated perpendicular to the motion of the first shaft. A torque is thereby applied to the camming housing, causing said housing to rotate by means of revolute joint 57 about the vertical. In the process, the shaft is freed to move to still larger deflection angles. As shown in FIG. 5, the lowest part of the cam surface can allow first shaft 52 to move to extremely large full cone angles (α˜150 degrees).
The motion of the camming spherical joint is nominally free of singularities, owing to the automatic rotation of the camming housing to accommodate large deflection angles. However, given any real cam surface and first shaft, the joint will have a dead point at local extrema of the cam surface. The dead points associated with cam surface extrema which are also local minima are expected, and serve to define the largest possible deflection angles.
Other types of dead points, however, those associated with maxima and inflection points, interfere with the desired function of the joint. Even though such dead points can be made very small, they still reflect differences in function relative to a conventional spherical joint.
There are several ways to mitigate or eliminate the effects of these dead points. The simplest is to design the cam surface to have a sharp structure near the local maxima, and harden the surface of the first shaft. This is a brute force approach to minimizing the angular extent of the dead point, but is rather expensive in machining and heat treatment. Similar approaches which minimize but do not eliminate the effects of such dead points include adding a freely rotating collar 59 around the first shaft, or a bearing wheel or ball at the dead points, so that the first shaft rolls more easily away from the dead points. Those points, however, remain in such joints.
A second approach to avoiding the effects of dead points appears in FIG. 6 . This figure shows a camming spherical joint as in FIG. 5, but also including a magnetized eccentric cam 60 which engages the cam surface and is free to rotate about the first shaft. If the surface of the eccentric cam hits a local maximum of the cam surface (which would otherwise be a dead point), eccentric cam 60 rotates, thereby presenting an oblique surface to the cam surface and sliding down the cam surface away from the potential dead point.
The eccentric cam, however, also has dead points when interacting with the cam surface. These can be avoided by arranging an appropriate magnetic interaction between the magnetized eccentric cam and the camming housing near the potential dead points. One way to accomplish this is to embed a first magnetic deflector 61 into the cam surface near a dead point, and embed a second magnetic deflector 62 of opposite polarity into the eccentric cam, again near a dead point. As the eccentric cam and the dead point approach, the repulsion of the magnetic deflectors causes the eccentric cam to rotate, thereby moving the dead point of the cam away from the cam surface.
Another approach toward avoiding the problem of dead points at local maxima of the cam surface is shown in FIG. 7 . Here again appears a camming spherical joint as in FIG. 5, but now the regions of the camming housing near what would otherwise be dead points of the cam surface are replaced by a flapper 70 . This flapper is attached to the camming housing so that it is relatively free to move about the connection point, and is spring-loaded so it has an equilibrium position at some angular displacement away from the housing. This can be allowed by attaching the flapper by a spring loaded revolute joint (not shown). Alternately, the flapper can be an integral part of the camming housing, where flexure of the long axis of the flapper provides both the required rotary motion and the spring-loaded restoring force.
If the first shaft strikes what would have been a dead point, the flapper rotates. In doing so, the angle of its surface changes, thereby altering the perpendicular orientation of a dead point into an oblique contact that produced forces which torque the camming housing around its axis. As a result, no dead point is encountered.
A closely related group of large displacement spherical joints according to the present invention appears in FIG. 8 . These are the arching band spherical joints, which in some ways are the simplest of this new class of large displacement spherical joints.
A spherical body 80 , with a radially affixed first shaft 81 , rides on a bearing cup 82 attached to a joint base 83 . An arching band 84 is mounted to the joint base by means of a pair of revolute joints 85 and 86 . These revolute joints share a common axis of revolution, and that axis passes through the center of the spherical body when it rests on the bearing cup. The underside of the arching band 84 comprises a bearing surface that contacts the spherical body. Hence, the bearing cup and the underside of the arching band make up the two bearings that confine the spherical body and restrict it to rotary motion about its own center. The arching band 84 comprises an elongated aperture 87 , through which the first shaft penetrates.
The operation of an arching band spherical joint is straightforward. For motions of the first shaft along the arching band, the deflection angle is limited to about 75-80 degrees by the presence of the revolute joints 85 and 86 . Rotation of the first shaft in a perpendicular direction is limited only by material interference with the bearing cup of the joint base, and can be in excess of 150 degrees given proper design. The actual full cone angle accessible to such a joint is thus only about 160 degrees, even though in some directions cone angles as large as 300 degrees are possible.
Although the total amount of spherical motion allowed by the arching band spherical joints is generally less than that of the other implementations, this type of design is well-suited to integration with motors or other activators and/or motion encoders. As a result, arching band spherical joints can be a better choice for numerous robotic and machine tool applications than are the alternate implementations of the present invention.
It should be noted that when the arching band is tilted near or past the horizontal (with reference to FIG. 8 ), the degree of confinement is reduced, and the joint becomes susceptible to dislocation. This tendency can be countered by adding a shaft bearing 90 to the first shaft, positioned directly on top of the arching band, as shown in FIG. 9, which also shows a motor 91 driving the motion of the joint in one axis of rotation. This cap pins the first shaft and the spherical body into location, so that dislocations of the joint will not occur.
In order to have a spherical joint such that the orientation of the first shaft can be completely controlled or measured, a second arching band 100 comprising an elongate aperture 103 mounted on revolute joints 101 and 102 can be added to the above joint (see FIG. 10 ). The second arching band is usually oriented perpendicular to the first, and the common axis of rotation of the revolute joints 101 and 102 intersects the center of the spherical body, but neither of these are requirements for proper function, as the spherical motion is already defined by the first arching band. In fact, depressing the common axis of rotation of the revolute joints 101 and 102 can relieve the interference between the first shaft and the second arching band so that adding the second arching band need not significantly limit the angular flexibility of the joint.
The examples and implementations described above are intended to illustrate various aspects of the present invention, not to limit the scope thereof. The scope of the invention is set by the claims interpreted in view of the specification. | A new class of spherical joints has a very large accessible full cone angle, a property which is beneficial for a wide range of applications. Despite the large cone angles, these joints move freely without singularities. | 8 |
RELATED U.S. APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO MICROFICHE APPENDIX
Not applicable.
FIELD OF THE INVENTION
The mud cooler is the offshore version of a series of world class drilling oil coolers that the applicant has developed for the oil-and gas industry.
BACKGROUND OF THE INVENTION
The mud cooler is the offshore version of a series of world class drilling oil coolers that the applicant has developed for the oil-and gas industry. Special about this drilling oil cooler is that the drilling oil does not come into contact with the ultimate cooling medium seawater. This is possible because use is made of two separate heat exchangers, which are built up of titanium cooling plates. In the first heat exchanger the drilling oil gives off its temperature to a mixture of water and glycol. In the second heat exchanger this mixture in its turn gives off its warmth to the seawater.
As an extra safety measure sensors are provided in the seawater outlet, which detect any possible oil leakage at once.
BRIEF SUMMARY OF THE INVENTION
Method and apparatus for the cooling of drilling fluids (also referred to as mudcooler), characterized in that use is made of two heat exchangers, wherein the drilling fluid (or warm drilling oil) is led through the first heat exchanger and is cooled by a mixture of glycol and water, while the glycol/water mixture is circulated in a closed circuit through a second heat exchanger, whereby the glycol/water mixture is cooled by seawater.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a top view of the embodiment of an apparatus for cooling drilling liquids according to the present invention.
FIG. 2 is a side view of the embodiment of an apparatus for cooling drilling liquids according to the present invention shown in FIG. 1 .
FIG. 3 is another side view of the embodiment of an apparatus for cooling drilling liquids according to the present invention shown in FIG. 1 .
FIG. 4 shows a detailed view of an expansion tank used in the embodiment of the apparatus for cooling drilling liquids according to the present invention shown in FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
Drilling Oil Cooler
The mud cooler is the offshore version of a series of world class drilling oil coolers that the applicant has developed for the oil-and gas industry. Special about this drilling oil cooler is that the drilling oil does not come into contact with the ultimate cooling medium seawater. This is possible because use is made of two separate heat exchangers 1 and 2 , which are built up of titanium cooling plates. In the first heat exchanger 2 the drilling oil gives off its temperature to a mixture of water and glycol. In the second heat exchanger 1 this mixture in its turn gives off its warmth to the seawater.
As an extra safety measure sensors are provided in the seawater outlet, which detect any possible oil leakage at once.
The mud cooler MC 001 has the following advantages:
It is very suitable for the cooling of drilling oils at high pressure/high temperature (HP/HT) drillings; It lengthens the lifespan of the drilling equipment; It is environmentally friendly; It improves working conditions; It is doubly protected against oil leakages.
The mud cooler MC 001 is built in a . . . Ft container and weighs . . . Kg. The onshore units are provided with one heat exchanger with titanium plates and are cooled with air. The offshore units are provided with two heat exchangers 1 and 2 with titanium plates. In the first heat exchanger 2 the drilling oil is cooled with a mixture of water and glycol.
This mixture in its turn is cooled in the second heat exchanger 1 with seawater. By using two heat exchangers 1 and 2 it is prevented, in the case of a leakage, that oil from the drilling oil can end up directly in the sea. Further as an extra safety measure sensors are provided on the seawater outlet in order to be able to detect at once any possible oil leakages.
Usually the cooling starts when the temparature of the drilling oil is about 55 to 60 degrees Celsius, while it is always attempted to keep this below 80 degrees. Its is usual that the mixture, depending on the drilling depth, warms up ten to fifteen degrees during a circulation. More and more HT/HP (high temperature/high pressure) boreholes are drilled. It is neccesary to apply mudcoolers in order to improve the working conditions, to protect the environment and to prevent damages to the drilling equipment. The unit can play an important role in this.
Offshore drilling oil cooler.
The offshore drilling oil cooler or mud cooler is carried out with two plate type heat exchangers. The warm drilling oil is pumped through the first heat exchanger 2 and this is cooled by a mixture of glycol and water.
The mixture of glycol/water is circulated in a closed circuit through a second heat exchanger 1 .
This mixture is cooled by seawater.
As can be seen in FIG. 1 , on the seawater return pipe 10 , a sensor 3 is connected by sample line 9 . Sensor 3 detects at once any possible oil leakages.
At the drilling oil side as well as at the glycol/water side, flowmeters 7 and 8 are connected by a closed circulation circuit 11 .
These serve to control the cooling capacity and to detect any possible pollution of the plate packages.
At the drilling oil side of the first plate heat exchanger a manifold is provided in order to, in the case of contamination, turn the flow in order to flush back in this manner the contamination.
By using two heat exchangers 1 and 2 , it is prevented in the case of leakage of the drilling oil cooler that oil ends up directly in the sea.
Technical specification “offshore mudcooler”.
Heat exchanger mud/glycol cooler The plate type heat exchanger 2 is equipped with titanium plates and provided with EPDM clip on sealing.
The capacity of the heat exchanger is 2000 kW based on a flow of 750 lem mud with an inlet temperature of 85° C. and 2000 l/min ethylene glycol with an inlet temperature of 45° C. The fluid direction is countercurrent and the design pressure is 10 bar.
Heat exchanger glycol/seawater cooler 1 .
The plate type heat exchanger 1 is equipped with titanium plates with EPDM clip on sealing. The capacity of the heat exchanger is 2000 kW based on a flow of 2000 lem ethylene glycol with an inlet temperature of 59° C. and an outlet temperature of 45° C. Seawater flow is based on 100 m3horizontal with an inlet temperature of 25° C.
The fluid direction is countercurrent and the design pressure is 10 bar.
Circulation pump.
The circulation pump 5 is used to pump the ethylene glycol mixture through the plate heat exchangers of mud and glycol cooler in a closed circuit system 11 . One central expansion tank 6 of approx. 50 ltrs will be mounted on the highest level and will be delivered with a Murphy levelswitch/gauge. The expansion tank 6 is also provided a make-up line to the circulation pump 5 .
The circulation pump 5 is of the vertical in-line type with a capacity of 2000 L/min at 16 mwc total head and is driven by a directly mounted explosion proof electric motor with an output of 7.5 kW at 400 V/50 Hz and 440 V/60 Hz. The arrows on the closed circuit system 11 in FIG. 1 illustrate how the circulation pump pumps the glycol mixture through the closed circuit system 11 .
Starter Panel
The starter panel is explosion proof according to Cenclec standard EN 56014 and EN 50018, with all necessary starters and safety devices.
The unit is complete with a flow meter on the mud line 4 and an oil detector 3 mounted on the seawater return line.
The outside dimensions of the unit are:
Length
4500 mm
Width
2150 mm
Height
3000 mm
Quan-
Item
tity
Filename
Remarks
1
1
SEAWATER/GLYCOWAT.COOLER
S1 INLET
S2 OUTLET
S3 INLET
S4 OUTLET
2
1
GLYCOLWATER/MUDCOOLER
S1 OUTLET
S2 INLET
S3 OUTLET
S4 INLET
3
1
OIL DETECTOR
4
1
FLOWMETER
READING
ITEM 7
AND 8
5
1
PUMP
6
1
EXPANSION TANK
7
1
FLOWMETER
8
1
FLOWMETER | Method and apparatus for the cooling of drilling fluids (also referred to as mudcooler), includes use of two heat exchangers, wherein the drilling fluid (or warm drilling oil) is led through the first heat exchanger and is cooled by a mixture of glycol and water, while the glycol/water mixture is circulated in a closed circuit through a second heat exchanger, whereby the glycol/water mixture is cooled by seawater. | 4 |
BACKGROUND
1. Field of Invention
This invention belongs to the family of anchoring devices, particularly one of the safety types, to anchor objects one wants to insure the stability of, or even protection against theft.
2. Description of the Prior Art
The search for means for anchoring objects to the ground, such as for the firm holding of temporary transportable shelters, is a constant preoccupation. A review of the prior art has revealed the following patents:
U.S. Pat. No. 425,385 McKay, W. W. April 1890. This patent describes an anchoring device comprising a ring forming a large circumferential band, pierced by two holes at 30° from a vertical diametral axis; the holes making a V with a third hole placed opposite to the other two. Rods are inserted in these two holes, to make two angular poles. The ring is used to secure a rope, the tension of which putting pressure onto the rods, thus preventing their removal.
GB 0,022,461 Gartland et al, October 1909. This patent shows an anchoring device comprising a ring that has two holes at 30°, diametrically opposed to two other holes pierced in the ring wall and forming an X with the first two holes. Rods are diagonally inserted in these holes to form angular poles. A third vertical rod fixes the ring into the ground. This invention has an application where one of the rods has a bulge that keeps it inside the ring and makes the third rod useless because the captive rod can be driven into the ground. This device is not easily padlocked.
U.S. Pat. No. 4,063,567 Martin et al, 20 Dec. 1977. This patent illustrates a ground anchoring device that prevent tents exposed to strong winds to collapse. It is made of an elongated rod, with a curved section FIG. 4a, on which a hook can be attached on the superior part, and that is diagonally driven into the ground and held in place by a nail driven into the ground perpendicularly to the rod. This device cannot be easily dismantled and cannot be padlocked.
DE 3814-387-A Schecker, R, May 1987. This patent shows an anchoring device that holds in position sheets of plastic film used in greenhouses. this device comprises an angle iron on which are welded two pipes in which are inserted two rods driven in the ground. The rods are placed apart and their position provides no means for fixing them together permanently.
OBJECTS AND ADVANTAGES
The main objective of this invention is to provide a portable, dismountable anchoring device driven into the ground, that allows any object to be anchored, using a flexible chord or an adapter that can anchor any tridimensional object.
Another objective is to provide a portable anchoring device that can be used with a padlock, making easier the dismantling of the device or the removal of objects of which the user wants to insure the stability, or even its protection against theft.
Another objective of this invention is to provide a portable device that is light, not bulky, easy to use and inexpensive. More generally, it is to supply for general use a portable anchoring device that comprises a first and a second rods to be driven into a strong surface, the device comprising in combination:
a sliding restraining sleeve comprising a first and a second tubes to be superposed and positioned crosswise, the first tube to insert the first rod and the second tube to insert the second rod, both tubes being firmly tied together,
an adapter comprising means for tying a tridimensional object to the strong surface and means for slidingly tying the first tube, the crosswise insertion of rods through the first and second tubes and through the strong surface causing the anchoring of the object to the strong surface.
SUMMARY OF THE INVENTION
A portable anchoring device that comprises a first and second. rods, each comprising a superior end, a middle part and an inferior end, the inferior end intended to be driven into the ground, a cruciform sliding restraining sleeve forming a cross above the ground, the branches of the cross forming a first tube to insert the first rod and a second tube to insert the second rod, both tubes being firmly tied together, the superior end of each rod comprising an eyelet fixed permanently to the superior end and adapted to be superimposed upon the eyelet of the mating rod, the superimposed eyelets providing a common opening to place a padlock or a safety chain.
Each rod has certain characteristics: the rods have a rough surface, the superior end of each rod allows percussion; the middle part allows sliding and the inferior end comprises a sharp point. In addition, the second rod comprises a safety catch preventing the removal of the rod from the second tube, after its insertion.
The eyelets are placed face to face and oriented along a plane corresponding to the plane of the rods; each of the eyelets has undergone a twisting at 90°, one to the left, the other to the right, the eyelet of a rod inserted in a tube facing a user, covering the eyelet of a rod inserted in the opposite tube.
Also it is an object to provide an adapter to anchor any tridimensional object, such adapter comprising an angle iron, a side of the angle iron being fixed on one face of the tridimensional object and the second side being provided with an assembling tube joining with the tying device.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be further understood from the following description with reference to the drawings in which:
FIG. 1 is a perspective view of the portable anchoring device
FIG. 2 is a perspective view of the device of FIG. 1 in use
FIG. 3 is a high angle view of the superimposed eyelet 40 of FIG. 1
FIG. 4 is an enlarged view in the area of arrow 4 of FIG. 1
FIG. 5 is an enlarged view, partially sectioned, of section 5 of FIG 1,
FIG. 6 is a perspective view of the device comprising an adapter 52,
FIG. 7 is an enlarged view of adapter 52 of FIG. 6, turned to the left,
FIGS. 8A, B, C, D show the installation of the adapter 52,
FIG. 9A and 9B are alternative views.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the invention is illustrated in FIG. 1 where the same characterizing elements are identified by the same numbers.
The device illustrated in FIG. 1 comprises two metallic rods, a first rod 20 angularly oriented from left to right, from top to bottom, and a second rod 22 oriented from right to left, from top to bottom. The first rod 20 is covered with asperities and comprises a flat part 26, at a superior end 28, and a point 30 at an inferior end 32. The second rod 22 is similar to the first rod 20, but for a safety catch 34 (FIG. 4) placed above the point 30 1 of the inferior end 32 1 of the second rod 22. The superior end 28 of both rods is obstructed by a weld 36 of a metallic disc 38 slightly sunken, to which is welded a first metallic eyelet 40 of the first rod 20, the first metallic eyelet 40 resulting from the twisting of a metallic bow 39 originally placed in the same direction as the metallic disc 38. For the first rod 20, the first metallic eyelet 40 results from the twisting of the bow counterclockwise, while for the second rod 22, a second metallic eyelet 41 results from the twisting of the bow clockwise. Two tubes, of a diameter superior to the one of the rods, a First tube 42, positioned from left to right and facing the user and a second tube 44, positioned from right to left, welded together in a cross-shaped form 45 (FIG. 5) are used as a restraining sleeve 48 for the two rods. The first rod 20, inserted in the first tube 42, remains detachable while the second rod 22, inserted in the second tube 44 is blocked by the safety catch 34.
FIG. 2 illustrates the restraining sleeve 48 of the superior end 28 of the first and second rods 20 and 22, the first and second metallic eyelets 40 and 41, positioned in an opposed and parallel direction, so the first metallic eyelet 40 of the rod 20 superposed itself on the second metallic eyelet 41 of the second rod 22 to create a single eyelet 47 (FIG. 3) that can be tied with a padlock 49 (FIG. 3), tying the first rod 20 to the second rod 22 at their superior ends 28 and 28'.
A variant of this embodiment comprises an adapter 52 illustrated in FIG. 6. This adapter 52 shown in perspective (FIG. 7) is an L-shaped angle iron of which a perforated left side 54 comprises two holes 56 placed equidistantly on a median line and of which a right side 58 has an assembly tube 60 fixed by a sleeve weld 61 on its centre and positioned diagonally from left to right, from top to bottom. Another embodiment has the tubes located within a monolithic block 62 comprising two diagonal apertures, placed perpendicularly and in superimposed planes. This monolithic block 62 may comprise means for tying to a structure to fix in position. Two curved rods 64 with formed eyelets 66 a their extremities, comprise a percussion disk 68 and a collar closed at the junction between the rod and the eyelet.
METHOD OF UTILIZATION
This portable anchoring device may be used with or without the adapter 52. Without it (FIG. 1) the method for using the device comprises these steps:
place the restraining sleeve 48 with the first tube 42 free, facing the user;
slide the restraining sleeve 48 until achieving an X-shaped position, the inferior end 32 1 of the second rod 22 positioned below and to the left of the user;
retract the second rod 22 inserted in the second tube 44 until the safety catch 34 is in contact with the tube 44;
press the inferior end 32 1 of the second rod 22 against the ground, at this time the second rod 22 will have a 45° axis with the ground.
drive the second rod 22 into the; ground, according to the angle defined by the second tube 44 of the restraining sleeve 48, with the assistance of a hammering tool acting upon the flat disk 26',
insert the first removable rod 20 into the first tube 42 free and drive it into the ground, as for the second rod 22, according to the angle defined by the first tube 42 of the restraining sleeve 48, hammering onto the flat disk 26;
press the rods into the ground, until the superior ends 28 and 28 1 are at the level of the restraining sleeve 48;
turn the first and second metallic eyelets 40 and 41 of the first and second rods 20 and 22 and place them so the first eyelet 40 of the first rod 20, facing the user, covers the second eyelet 41 of the second rod 22 (FIGS. 2-3),
padlock the first and second metallic eyelets 40 and 41.
In case where the material is likely to offer resistance when turning the rods 20 and 22 when totally driven into the ground, the user should see that the eyelets 40 and 41 are in an appropriate position before driving in the rod completely into the ground.
When using the adapter 52 (FIG. 6), the method varies according to the orientation of the adapter 52; for instance when in superior horizontal position (FIG. 8A) and when in inferior horizontal position (FIG. 8B), the second tube 44 of the restraining sleeve 48 will be sled in the assembly tube 60 from right to left, consequently the first rod 20 will slide in the first tube 42 from left to right. On the other hand, in left position (FIG. 8C) and in vertical right position (FIG. 8D), the second tube 44 of the restraining sleeve 48 will be inserted into the assembly tube 60 from left to right and consequently the first rod 20 will be inserted in the first tube 42 from right to left
So when the adapter 52 (FIG. 1) is used, the utilization mode comprises the following steps:
put the adapter 52 onto a tridimensional object, in a plane either horizontally superior FIG. 8A, horizontally inferior FIG. 8B, vertically left FIG. 8C or vertically right FIG. 8D and secure it with bolts in the holes 56. When in horizontally superior position the assembly tube is in position at 225° anticlockwise to the junction line of the two parts of the angle iron, in horizontally inferior position the angle being 45°, in vertical left position, the angle being -45° and in a vertically right position the angle being of 135°;
place the first tube 42 facing the user to direct the first rod at the required angle to circumvent obstacles;
retract the second rod 22 inserted in the second tube 44 until the safety catch 34 is in contact with the tube 44;
press the inferior end 32 1 of the second rod 22 against the ground, at this time the second rod 22 will have its longitudinal axis at 45° with the ground;
drive the second rod 22 into the ground, according to the angle defined by the second tube 44 of the restraining sleeve 48, with the assistance of a hammering tool against the flat disk 26 1 ;
insert the first removable rod 20 into the other tube 42 and drive it into the ground, as for the second rod 22, according to the angle defined by the first tube 42 of the restraining sleeve 48, while hammering onto the flat disk 26;
press the rods into the ground, until the superior ends 28 and 28 1 are at the level of the restraining sleeve 48;
turn the first and second metallic eyelets 40 and 41 of the first and second rods 20 and 22 and place them so the first eyelet 40 of the first rod 20 facing the user, covers the second eyelet 41 of the second rod 22;
padlock the first and second metallic eyelets 40 and 41.
While the present invention has been shown in the drawings and fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention; it will be apparent to those of ordinary skill in the art that many modifications thereof may be made without departing from the principles and concepts set forth herein. Hence, the proper scope of the present invention should be determined only by the broadest interpretation of the appended claims so as to emcompass all such modifications and equivalents.
Other embodiments are possible and limited only by the scope of the appended claims:
______________________________________PARTS LIST______________________________________20 first rod 62 monolithic block22 second rod 63 curved rod24 asperities 66 formed eyelet26 flat disk 68 percussion disk28 superior end30 point32 inferior end34 safety catch36 weld38 metallic ring39 metallic arch40 first metallic eyelet41 second metallic eyelet42 first tube44 second tube45 cross-shaped weld47 single eyelet48 restraining sleeve49 padlock52 adapter54 perforated side56 holes58 assembled face60 assembly tube61 tube welding______________________________________ | In an anchoring device to be driven into the ground, important features are that it be dismountable, safe and easy to manipulate. In this invention, the anchoring device is provided with a cross with two sliding members, two rods with pointed ends and a head, the heads being equipped with superposable eyelets that may be padlocked. The eyelets allow the anchoring of an object which one wants to insure the stability of and even its protection against theft. The anchoring device may comprise two angle irons, a first of which allowing the anchoring of a tridimensional object and a second comprising a tube to receive and orientate one of the two members of the cross. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This is a division of application Ser. No. 737,196, filed Oct. 29, 1976, now U.S. Pat. No. 4,123,525, which in turn is a continuation-in-part of application Ser. No. 463,176, filed Apr. 22, 1974, the latter application being now abandoned.
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to sublimable agricultural chemical compositions in the form of rough granules, pulverized powders or tablets comprising triisopropyl-s-trioxane (hereinafter referred to as trioxane (1)) or tritertiarybutyl-s-trioxane (hereinafter referred to as trioxane (2)) as a diluent or carrier and one or more agricultural chemical mixed therewith. In the above, the term agricultural chemicals means insecticides, fungicides, rodenticides, herbicides, supplemental agents and the like, and the term sublimable agricultural compositions includes a broader range of materials such as insecticides for environmental sanitation, especially for domestic use.
II. Description of the Prior Art
Conventionally, agricultural chemical compositions including fungicides, insecticides, rodenticides, herbicides, supplemental agents or the like have been used in the form of wettable powders, emulsions, powders, granules, aerosols and the like. Among them, those in the form of powder and grain each comprise a carrier or a diluent in a powdery state such as sulfur, silicon, talc, diatomaceous earth, silica, calcium hydroxide, apatite, calcite, dolomite, gypsum, mica, pyrophyllite, clay, pumice and the like and one of the agricultural chemicals mixed therein.
SUMMARY OF THE INVENTION
A main object of the present invention is to provide diluents or carriers superior in properties to conventional ones as above-mentioned.
Most of the conventional diluents or carriers used in solid agricultural compositions were inorganic substances or compounds and agricultural chemicals merely attached to their surface or were mixed therewith. Such conventional carriers were also unable to prevent the decomposition of agricultural chemicals and remained in the soil after used without subliming.
In contrast, when either mixed directly with an agricultural chemical or mixed therewith after melting, the two trioxanes of the present invention produce agricultural chemical compositions in which the agricultural chemical is contained in a crystalline trioxane. Therefore, the chemical hardly decomposes or changes in nature. When the composition is used on the soil, both of the trioxanes of the present invention gradually sublime with the result that the chemicals remain effective for a long period of time. Neither trioxane remains in the soil. The sublimable agricultural chemical compositions of the present invention may be sprinkled in the air, on the soil, or in a paddy field.
Trioxane (1) or (2) used as a diluent or carrier for manufacturing the sublimable agricultural chemical compositions in the present invention are characterized by the following advantages over conventional carriers or diluents.
Trioxane (1), produced by cyclizing and trimerizing isobutylaldehyde with mineral acid, halogen, zinc chloride, phosphorous pentoxide and the like, is a pure white crystal showing vapor pressures of 0.31 mmHg at 20° C. and 0.95 mmHg at 30° C. with its melting point at 62.5° C. Another pure white crystal trioxane (2), also compounded by cyclizing and trimerizing trimethylacetaldehyde in the same method as above, shows vapor pressure of 0.12 mmHg at 20° C. and 0.38 mmHg at 30° C. and has a melting point of 92.0° C.
Both of the trioxanes are chemically stable, water-insoluble, and lighter in specific gravity than water which enables them to float on the surface of water, such property being advantageous for their adhesion to partially submerging plants such as paddy (rice) and the like. These two trioxanes are tasteless and odorless and are able to maintain their form in the form of rough grain or pulverized powder even if they contain oil up to 20%, said property being advantageous for scattering. The materials are also moderately sublimable, which means they do not accumulate within the soil. Sublimable agricultural compositions in the form of rough grains or pulverized powders produced by mixing either trioxane with one or more agricultural chemicals are such that they attach to watery agricultural plants without undesirably scattering over a wide territory, wherein the compositions remain effective over a long period of time due to the moderate sublimability of the carriers. The compositions also produce the same effect when scattered on the soil.
The trioxanes of the present invention are nontoxic to men and domestic animals and harmless to plants. We attempted to determine the LD 50d or median lethal dose of trioxane (1) by use of rats and mice, but these attempts were in vain. Even as large a dose as 10,000 mg per kilogram of body weight caused no death. Also, trioxane (1) did not show either chronic or inhalation toxicity, nor did this material produce any toxic substances with activated sludges. This shows that said trioxane is very stable and is in no way toxic. Trioxane (2) presumably has similar properties to trioxane (1) in this regard.
As described before, either trioxane (1) or (2) can be mixed with an insecticide so as to volatilize the insect-killing vapor for a long period of time, which means that the product is desirable on a commercial scale for environmental sanitation, especially for domestic use.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples serve to illustrate the preferred method for preparing the compositions of the present invention, the examples imposing no limitation on the scope of claims in the present invention. (Hereinafter, "parts" denotes "weight parts".)
EXAMPLES
(Examples 1-16 cover insecticides, 17-20 fungicides, and 21-27 herbicides.)
1. 970 parts of trioxane (1) was mixed evenly with 30 parts of S-(1,2-dicarbethoxyethyl)-O,O-dimethyldithiophosphate (hereinafter called malathion), to produce an insecticidal composition in the form of rough powders for control of insects in a paddy field.
2. 980 parts of trioxane (1) was mixed thorougly with 20 parts of dimethyl-2,2-dichlorovinyl phosphate (hereinafter called DDVP) to produce an insecticidal composition in the form of rough powders for control of Musca domestica and insects on mulberry and tea trees.
3. 950 parts of trioxane (1) was mixed evenly with 50 parts of O,O-diethyl-O-(2-isopropyl-4-methyl-pyrimidyl(6))-thiophosphate (hereinafter called Diazinon) to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
4. 970 parts of trioxane (1) was mixed thoroughly with 30 parts of O,O-dimethyl-O-(3-methyl-4-nitrophenyl)thiosphophate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
5. 930 parts of trioxane (1) was mixed evenly with 70 parts of ethyl-O,O-dimethyldithiophosphorylphenylacetate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
6. 990 parts of trioxane (1) was mixed evenly with 10 parts of O,O-dimethyl-1-hydroxy-2,2,2-trichloroethyl-phosphate to produce an insecticidal composition in the form of rough powders for control of the flies, mosquitoes and cockroaches.
7. 950 parts of trioxane (1) was mixed evenly with 50 parts of O,O-dimethyl-O-(3-methyl-4-methylthiophenyl) thiophosphate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
8. 930 parts of trioxane (1) was mixed evenly with 70 parts of O,O-dimethyl-S-phthalimido-methyl dithiophosphate to produce an insecticidal composition in the form of rough powders for control of insects on cotton.
9. 985 parts of trioxane (1) was mixed thoroughly with 15 parts of ethyl-O-p-nitrophenyl phenylphosphonothioate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
10. 980 parts of trioxane (2) was mixed evenly with 20 parts of 2-sec.-butylphenyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
11. 950 parts of trioxane (2) was mixed evenly with 50 parts of 1-naphthyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
12. 990 parts of trioxane (2) was mixed evenly with 10 parts of 2-isopropoxyphenyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
13. 980 parts of trioxane (2) was mixed evenly with 20 parts of 2-isopropylphenyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
14. 980 parts of trioxane (2) was mixed evenly with 20 parts of 3,4-xylyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
15. 970 parts of trioxane (2) was mixed evenly with 30 parts of m-tolyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
16. 980 parts of trioxane (2) was mixed evenly with 20 parts of 3,5-xylyl-N-methylcarbamate to produce an insecticidal composition in the form of rough powders for control of insects on paddy, fruit trees and vegetables.
17. 830 parts of trioxane (1) was mixed evenly with 170 parts of O,O-diisopropyl-S-benzylthiophosphate to produce a fungicidal composition in the form of pulverized powders for killing fungus on paddy, etc.
18. 975 parts of trioxane (1) was mixed evenly with 25 parts of O-ethyl-S,S-diphenyldithiophosphate (hereinafter called EDDP) to produce a fungicidal composition in the form of pulverized powders for killing fungus on paddy, etc.
19. 970 parts of trioxane (2) was mixed evenly with 30 parts of O-butyl-S-ethyl-S-benzyl-phosphorodithioate to produce a fungicidal composition in the form of pulverized powders for killing fungus on paddy, etc.
20. 996.6 parts of trioxane (2) was mixed evenly with 3.4 parts of the hydrochloric salt of Kasugamycin to produce a fungicidal composition in the form of pulverized powders for killing fungus on paddy, etc.
21. 910 parts of trioxane (1) was mixed evenly with 90 parts of 2,4,6-trichlorophenyl-4'-nitrophenyl ether to produce a herbicidal composition in the form of pulverized powders for controlling weeds in paddy fields.
22. 988 parts of trioxane (1) was mixed thoroughly with 12 parts of allyl-2-methyl-4-chlorophenoxy acetate (hereinafter called MCP) to produce a herbicidal composition in the form of pulverized powders for controlling weeds in paddy fields.
23. 915 parts of trioxane (2) was mixed thoroughly with 70 parts of S-(4-chlorobenzyl)-N,N-diethyl-thiocarbamate and 15 parts of 2-methylthio-4,6-(bis ethylamino)-1,3,5-triazine to produce a herbicidal composition for controlling weeds in paddy and plowed fields.
24. 915 parts of trioxane (1) was mixed thoroughly with 85 parts of 3-amino-2,5-dichlorobenzoic acid to produce a herbicidal composition in the form of pulverized powders for killing weeds in soybean fields.
25. 910 parts of trioxane (2) was mixed thoroughly with 90 parts of 3-(3,4-dichlorophenyl)-1,1-dimethylurea to produce a herbicidal composition in the form of pulverized powder for killing weeds.
26. 915 parts of trioxane (2) was mixed thoroughly with 85 parts of 3,4-dichloropropionanilide to produce a herbicidal composition in the form of pulverized powder for killing weeds in paddy fields.
27. 910 parts of trioxane (1) was mixed thoroughly with 90 parts of S-(4-chlorobenzyl)-N,N-dimethyl-thiocarbamate to produce a herbicidal composition in the form of pulverized powder for killing weeds in paddy fields.
EXPERIMENTAL EXAMPLE 1
Paddy (Norin No. 8) was planted in three pots having a diameter of 12 cm. One gram of the malathion composition prepared in Example 1 was sprinkled on the paddy in the first pot. One gram of powder containing 97% of talc and 3% of malathion was sprinkled on the paddy in the second pot. No chemical was sprinkled on the one in the third pot for use as a control. On the day that the chemical was sprinkled, the fifth day and the eighth day thereafter, 20 larvae of Nephotettix bipunctatus cincticeps were released in each pot and the number of killed larvae was counted after 24 hours to determine the killing rate. The tests were carried out in a thermostatic chamber and were repeated three times. The results of the tests are as follows:
______________________________________When released Killing Rateafter Fifth day Eight daysprinkling The same day after after______________________________________Malathion + 100 90 ⊖trioxane (1)Malathion + 100 61 5talcNo chemical 0 0 0(control)______________________________________ These results show that the composition consisting of malathion and trioxane (1) remains effective for a longer period of time.
EXPERIMENTAL EXAMPLE 2
A mixture of trioxane (1), 30.0 grams, DDVP, 2.5 grams and Diazinon, 2.5 grams, said three chemicals having been thoroughly mixed with each other, were formed into a tablet measuring 60 mm in diameter and 12 mm in thickness. The single tablet was hung in a 1 m 3 box at the center thereof for determining the insect-killing effect of the tablet, putting 20 Musca domestica in the box in a closed state on every test-conducting day, the testing results being shown in the table below:
______________________________________ Time requiredDays of testing, for entirelystarting with killing muscathe setting of Weight of the domesticathe test-tablet tablet (Unit:g) (Unit:minute)______________________________________ 1st day 28.5 55 3rd day 25.9 60 5th day 24.3 6010th day 20.1 9020th day 12.5 18030th day 6.2 300______________________________________
EXPERIMENTAL EXAMPLE 3
A mixture of trioxane (2), 20 grams, DDVP, 3 grams and Diazinon, 1 gram, the three constituents having been mixed thoroughly with each other, was formed into a tablet 60 mm in diameter and 8 mm thick. Said tablet was put in to test a method quite identical with Example 24, except that the testing period this time was longer by 10 days than in the case of Experimental Example 3, the results being shown in the table below:
______________________________________ Time required forDays of testing, entirely killingstarting with the Muscathe setting of Weight of the domesticathe test-tablet tablet (Unit:g) (Unit:minute)______________________________________ 1st day 22.0 60 3rd day 20.1 60 5th day 18.5 8010th day 15.1 10020th day 11.0 18030th day 7.5 33040th day 4.5 540______________________________________
EXPERIMENTAL EXAMPLE 4
Paddy (Norin No. 8) was planted in six pots having a diameter of 12 cm. After it has put forth tillers, 1 gram of the powdery EDDP composition prepared in Example 18 was sprinkled on two pots. One gram of a powdery composition consisting of 97.5% of talc and 2.5% of EDDP was sprinkled on the other two pots. No chemicals were sprinkled on the remaining two pots for use as control. The paddy in one of each pair of the pots was inoculated on the day after sprinkling with Piricularia oryzae germs by spraying a suspension containing them. The paddy in the other of each pair of the pots was similarly inoculated on the fifth day after sprinkling. On the seventh day after inoculation, the area of the still-infected portions was measured and indicated in terms of percentage against the infected area of the control paddy.
______________________________________ Ratio to infected area of control paddy (in %) A B______________________________________EDDP + 0 8trioxane (1)EDDP + talc 0 47No chemicals 100 100used (control)______________________________________ A: When inoculated on the day after sprinkling B: When inoculated on the fifth day after sprinkling
EXPERIMENTAL EXAMPLE 5
Four pots having a diameter of 10 cm were filled with soil of a paddy field to the depth of 10 cm, on which 50 grains of seeds of barnyard grass (Echinochloa crusgalli, Beauv., var. edulis, Honda) were sowed. A small amount of soil was put thereon and wetted with water. One gram of pulverized powder of the MCP composition prepared in Example 22 was sprinkled on the first pot. On the second pot was sprinkled, one gram of powder consisting of 12 parts of MCP and 988 parts of diatomaceous earth. On the third pot was sprinkled one gram of trioxane (1) powder only. No chemical was sprinkled on the fourth pot for use as a control. Twenty days later, the extent of germination of the grass in these four pots was checked to determine the effect of herbicidal compositions. After the first check, 50 grains of the same seed were sowed on the first, second and third pots. In the case of the third pot, the grass that had sprouted was removed before re-sowing. Twenty days after re-sowing, it was observed how much the germination was controlled. The effect of herbicidal compositions was evaluated against the control in the fourth pot.
______________________________________ At first check At second check (in %) (in %)______________________________________1st pot 0 42nd pot 0 783rd pot 100 --4th pot 100 100______________________________________
The above experiments show that trioxane (1) has no herbicidal effect, does no harm to plants, and remains effective for a longer period of time because of the small amount of decomposition of the herbicide compared to the conventional MCP powder.
The amount of the carrier in respect to the active agricultural ingredients is not critical. The mixing ratio is essentially the same as with conventional carrier-agricultural chemical combinations and depends on the type of material employed, the purpose of use, ease of use, the safety requirements in respect to men and animals, etc.
A typical agricultural composition in accordance with the present invention contains about 80%-99.8% of a carrier. | An improvement is provided in sublimable agricultural chemical compositions in the form of rough grains, pulverized powders or tablets which comprises at least one agricultural chemical and a carrier therefor. The improvement resides in the employment as the carrier, triisopropyl-s-trioxane or tritertiary-butyl-s-trioxane. | 0 |
FIELD OF THE INVENTION
The subject invention generally pertains to a room or building thermostat and more specifically to a method of programming such a thermostat, wherein the thermostat can in effect program itself for various daily and/or weekly temperature setpoints upon learning temperature setting habits of a user and can do such self-programming without ever knowing the actual time of day or day of the week.
BACKGROUND OF RELATED ART
Furnaces, air conditioners and other types of temperature conditioning units typically respond to a thermostat in controlling the air temperature of a room or other area of a building. Currently, thermostats can be classified as manual or programmable.
With manual thermostats, a user manually enters into the thermostat a desired temperature setpoint, and then thermostat controls the temperature conditioning unit to bring the actual room temperature to that setpoint. At various times throughout the day, the user might adjust the setpoint for comfort or to save energy. When operating in a heating mode, for instance, a user might lower the setpoint temperature at night and raise it again in the morning. Although manual thermostats are easy to understand and use, having to repeatedly adjust the setpoint manually can be a nuisance.
Programmable thermostats, on the other hand, can be programmed to automatically adjust the setpoint to predetermined temperatures at specified times. The specified times can initiate automatic setpoint adjustments that occur daily such as on Monday-Friday, or the adjustments might occur weekly on days such as every Saturday or Sunday. For a given day, programmable thermostats can also be programmed to make multiple setpoint adjustments throughout the day, such as at 8:00 AM and 11:00 PM on Saturday or at 6:00 AM and 10 PM on Monday through Friday. Such programming, however, can be confusing as it can involve several steps including: 1) synchronizing the thermostat's clock with the current time of day; 2) entering into the thermostat the current date or day of the week; and 3) entering various chosen days, times and setpoint temperatures. One or more of these steps may need to be repeated in the event of daylight savings time, electrical power interruption, change in user preferences, and various other reasons.
Consequently, there is a need for a thermostat that offers the simplicity of a manual thermostat while providing the convenience and versatility of a programmed thermostat.
SUMMARY OF THE INVENTION
An object of the invention is to provide an essentially self-programmable thermostat for people that do not enjoy programming conventional programmable thermostats.
An object of some embodiments of the invention is to provide a programmable thermostat that does not rely on having to know the time of day, thus a user does not have to enter that.
Another object of some embodiments is to provide a programmable thermostat with both daily and weekly occurring settings, yet the thermostat does not rely on having to know the day of the week, thus a user does not have to enter that.
Another object of some embodiments is to provide a programmable thermostat that does not rely on onscreen menus for programming.
Another object of some embodiments is to provide a thermostat that effectively programs itself as it is being used as a manual thermostat.
Another object of some embodiments is to provide a thermostat that automatically switches from a manual mode to a programmed mode when it recognizes an opportunity to do so.
Another object of some embodiments is to provide a thermostat that automatically switches from a programmed mode to a manual mode simply by manually entering a new desired setpoint temperature.
Another object of some embodiments is to observe and learn the temperature setting habits of a user and automatically program a thermostat accordingly.
Another object of some embodiments is to provide a self-programming thermostat that not only learns a user's temperature setting habits, but if those habits or temperature-setting preferences change over time, the thermostat continues learning and will adapt to the new habits and setpoints as well.
Another object of some embodiments is to minimize the number of inputs and actions from which a user can choose, thereby simplifying the use of a thermostat.
Another object of some embodiments is to provide a thermostat that can effectively self-program virtually an infinite number of setpoint temperatures and times, rather than be limited to a select few number of preprogrammed settings.
Another object of some embodiments is to provide a simple way of clearing programmed settings of a thermostat.
One or more of these and/or other objects of the invention are provided by a thermostat and method that learns the manual temperature setting habits of a user and programs itself accordingly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a thermostat controlling a temperature conditioning unit.
FIG. 2 shows an example of algorithm for a thermostat method.
FIG. 3 shows another example of algorithm for a thermostat method.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1-3 show a thermostat 10 and a method for automatically programming it. Initially, thermostat 10 might first appear and function as an ordinary manual thermostat. Thermostat 10 , for instance, includes a manual input 12 (e.g., dial, keyboard, pointer, slider, potentiometer, pushbutton, etc.) that enables a user to manually enter a manual setpoint 14 that defines a manually entered setpoint temperature 16 . The manually entered setpoint temperature 16 is the user's desired target temperature for a comfort zone 18 . Upon comparing the manually entered setpoint temperature 16 to the comfort zone's actual temperature 20 (provided by a temperature sensor 22 ), thermostat 10 provides an output signal 24 that controls a temperature conditioning unit 26 (e.g., furnace, heater, air conditioner, heat pump, etc.) to heat or cool air 28 in comfort zone 18 , thereby urging the comfort zone's actual temperature 20 toward the manually entered setpoint temperature 16 .
A digital display 30 can be used for displaying the current setpoint temperature, and another display 32 can show the comfort zone's actual temperature. Displays 30 and 32 could be combined into a single display unit, wherein the combined display unit could show the current setpoint temperature and the zone's actual temperature simultaneously or in an alternating manner. Thermostat 10 might also include a selector switch 34 for manually switching between a cooling mode for cooling zone 18 and a heating mode for heating zone 18 . Items such as display 30 , selector switch 34 , manual input 12 , and output 24 are well known to those of ordinary skill in the art. One or more of such items, for example, can be found in a model CT8775C manual thermostat provided by Honeywell Inc. of Golden Valley, Minn.
Although thermostat 10 can operate as a regular manual thermostat by controlling unit 26 as a function of a differential between the actual zone temperature and the most recently entered manual setpoint temperature, thermostat 10 includes a microprocessor 36 (e.g., computer, CPU, firmware programmed chip, etc.) that enables thermostat 10 to observe the temperature setting habits of the user (e.g., person that manually enters setpoint temperatures into the thermostat). After several manual settings, microprocessor 36 may learn the user's preferred setpoint temperatures and timestamps them with the aide of a timer 38 . With one or more learned setpoint temperatures and timestamps 48 , microprocessor 36 can begin anticipating the user's desires and automatically adjust the thermostat's setpoint temperatures accordingly. Thus, thermostat 10 can begin operating as a programmed thermostat, rather than just a manual one.
Since a user's desired temperature setpoints and time preferences might change for various reasons, any manually entered setpoint temperature 16 overrides the currently active setpoint temperature regardless of whether the current setpoint temperature was manually entered or was automatically activated as a learned setpoint temperature. Once overridden, another learned setpoint temperature might later be activated at a learned time to return thermostat 10 back to its programmed mode. Thus, thermostat 10 is somewhat of a hybrid manual/programmable thermostat in that it can shift automatically between manual and programmed operation.
To assign timestamps 48 to manually entered setpoint temperatures, timer 38 can actually comprise one or more timers and/or counters. In some embodiments, for example, timer 38 includes a continuously running daily or 24-hour timer that resets itself every 24 hours. The time increments can be in minutes, seconds, or any preferred unit. In some cases, timer 38 is a continuously operating weekly or 168-hour timer that resets itself every seven days. The increments can be in days, hours, minutes, seconds, or any preferred unit. The weekly timer could also be a seven-increment counter that indexes one increment every 24 hours in response to a daily or 24-hour timer. Timer 38 , however, is not necessarily synchronized with the actual time of day or day of the week. Such synchronization preferably is not required; otherwise the user might have to manually enter or set the correct time and day of the week.
In the case where timer 36 comprises a weekly timer in the form of a 7-increment counter triggered by each 24-hour cycle of a daily timer, timestamp 48 might a be a two-part number such as (X and Y) wherein X cycles from 1 to 7 as a weekly timer, and Y cycles from 0 to 1,439 (1,440 minutes per day) as a daily timer. In this case, a timestamp 48 might be (3 and 700) to indicate 700 minutes elapsed during day-3. Whether day-3 represents Monday, Tuesday or some other day is immaterial, and whether the 700-minute represents 2:00 AM, 7:30 PM or some other time of day is also immaterial. As one way to provide a programmable thermostat that can operate independently of an actual time of day clock and to provide thermostat 10 with other functionality, microprocessor 36 can be firmware programmed to execute one or more of the following rules:
Rule-1 —Upon receiving a manually entered setpoint temperature, microprocessor assigns an (X and Y) timestamp 48 to the manually entered setpoint temperature, wherein the timestamp indicates when the setpoint temperature was entered relative to other timestamps. The manually entered setpoint temperature and its timestamp 48 are stored in memory for later reference.
Rule-2 —Microprocessor 36 looks for patterns of manual setpoints, wherein each manual setpoint has a manually entered setpoint temperature and a timestamp 48 .
A daily pattern, for example, can be defined as three consecutive days in which a series of three similar manually entered setpoint temperatures (e.g., within a predetermined deviation of perhaps 2° F. or 5° F. of each other) have similar daily timestamps 48 (e.g., each Y-value being within a predetermined deviation of perhaps 90 minutes of each other). Such a daily pattern can then be assigned a learned daily setpoint temperature and a learned daily time. The learned daily setpoint temperature could be, for example, an average of the three similar manually entered setpoints temperatures or the most recent of the three. The learned daily time could be, for example, 20 minutes before the three similar timestamps. For future automatic settings, the 20 minutes might allow microprocessor 36 to activate the learned daily setpoint temperature before the user would normally want to adjust the setpoint.
A weekly pattern, for example, can be defined as three manual setpoints spaced 7 days apart (e.g., same X-value after one complete 7-day cycle) in which three similar manually entered setpoint temperatures (e.g., within 2° F. or 5° F. of each other) have similar timestamps 48 (e.g., each Y-value being within 90 minutes of each other). Such a weekly pattern can then be assigned a learned weekly setpoint temperature and a learned weekly time. The learned weekly setpoint temperature could be, for example, an average of the three similar manually entered setpoints temperatures spaced 7 days apart or the most recent of the three. The learned time could be, for example, 20 minutes before the three similar timestamps.
Rule-3 —Automatically activate a learned daily setpoint temperature at its learned daily time (at its assigned Y-value), whereby thermostat 10 controls unit 26 based on the learned daily setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters a manually entered setpoint temperature (adjusts the temp), b) another learned daily setpoint temperature becomes activated at its learned daily time, or c) a learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-4 —Automatically activate a learned weekly setpoint temperature at its learned weekly time (at its assigned X and Y values), whereby thermostat 10 controls unit 26 based on the learned weekly setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters a manually entered setpoint temperature (adjusts the temp), b) a learned daily setpoint temperature becomes activated at its learned daily time (but see Rule-5), or c) another learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-5 —A weekly pattern overrides or supersedes a daily pattern if their assigned timestamps 48 are within a predetermined period of each other such as, for example, within three hours of each other based on the Y-values of their timestamps.
Rule-6 —If a user enters a manually entered setpoint temperature, thermostat 10 controls unit 26 in response to the manually entered setpoint temperature and continues to do so until interrupted by one of the following: a) the user enters another manually entered setpoint temperature (adjusts the temp), b) a learned daily setpoint temperature becomes activated at its learned daily time, or c) a learned weekly setpoint temperature becomes activated at its learned weekly time.
Rule-7 —If a user enters two manually entered setpoint temperatures within a predetermined short period of each other, e.g., within 90 minutes of each other, the first of the two manual entries is disregarded as being erroneous and is not to be considered as part of any learned pattern.
Rule-8 —If a learned daily setpoint temperature is activated at a learned time and is soon interrupted by the user entering a manually entered setpoint temperature within a predetermined short period (e.g., within 3 hours), and this occurs a predetermined number of days in a row (e.g., 3 days in a row as indicated by the X-value of timer 38 ), then the daily pattern associated with the learned daily setpoint temperature is erased from the memory.
Rule-9 —If a learned weekly setpoint temperature is activated at a learned time and is soon interrupted by the user entering a manually entered setpoint temperature within a predetermined short period (e.g., within 3 hours), and this occurs a predetermined number of weeks in a row (e.g., 2 weeks in a row as indicated by an additional counter that counts the cycles of the X-value of timer 38 ), then the weekly pattern associated with the learned weekly setpoint temperature is erased from the memory.
Rule-10 —Actuating switch 34 between cool and heat or actuating some other manual input can be used for erasing the entire collection of learned data.
Rules 1-10 might be summarized more concisely but perhaps less accurately as follows:
1) Assign timestamps 48 to every manually entered setpoint temperature.
2) Identify daily patterns (similar manually entered temperatures and times 3 days in a row), and identify weekly patterns (3 similar manually entered temperatures and times each spaced a week apart). Based on those patterns, establish learned setpoint temperatures and learned times.
3) Activate learned daily setpoints at learned times, and keep them active until the activated setpoint is overridden by the next learned setpoint or interrupted by a manually entered setpoint.
4) Activate learned weekly setpoints at learned times, and keep them active until the activated setpoint is overridden by the next learned setpoint or interrupted by a manually entered setpoint.
5) If a learned weekly setpoint and a learned daily setpoint are set to occur near the same time on given day, the learned daily setpoint is ignored on that day because the day is probably a Saturday or Sunday.
6) Whenever the user manually adjusts the temperature, the manually entered setpoint temperature always overrides the currently active setting. The manually entered setpoint remains active until it is interrupted by a subsequent manual or learned setting.
7) If a user repeatedly tweaks or adjusts the temperature within a short period, only the last manually entered setpoint temperature is used for learning purposes, as the other settings are assumed to be trial-and-error mistakes by the user.
8) If a user has to repeatedly correct a learned daily setpoint (e.g., correct it 3 days in a row), that learned setpoint is deleted and no longer used. Using 3 days as the cutoff avoids deleting a good daily pattern due to 2 days of corrections over a weekend.
9) If a user has to repeatedly correct a learned weekly setpoint (e.g., correct it 2 weeks in a row), that learned setpoint is deleted and no longer used.
10) Switching between heating and cooling, for at least 5 seconds or so, deletes the entire collection of learned data.
To execute one or more of the aforementioned rules, microprocessor 36 could operate under the control of various algorithms, such as, for example, an algorithm 40 of FIG. 2 , an algorithm 42 of FIG. 3 , a combination of algorithms 40 and 42 , or another algorithm altogether.
Referring to the example of FIG. 2 , a block 44 represents receiving a plurality of manual setpoints 14 that are manually entered at various points in time over a period, each of the manual setpoints 14 provides a manually entered setpoint temperature 16 that in block 46 becomes associated with a timestamp 48 via timer 38 . Timer 38 can run independently or irrespective of the actual time of day and irrespective of the actual day of the week. In blocks 50 and 52 , thermostat 10 controls unit 26 as a function of a differential between the actual zone temperature 20 and a currently active manually entered setpoint. In block 54 , microprocessor 36 recognizes patterns with the manually entered setpoints. Based on the patterns, in block 56 microprocessor 10 establishes learned setpoint temperatures and corresponding learned times. In block 58 , some time after controlling unit 26 in response to the manually entered setpoint temperatures (block 50 ), automatically switching at the learned time to controlling the temperature conditioning unit in response to the learned setpoint temperature. This might continue until interrupted by block 60 , wherein microprocessor 36 encounters another recognized pattern or upon receiving another manual setpoint, at which point unit 26 is controlled in response thereto.
Referring to the example of FIG. 3 , a block 62 represents microprocessor 36 receiving temperature feedback signal 20 from temperature sensor 22 . Sensor 22 could be incorporated within thermostat 10 , as shown in FIG. 1 , or sensor 22 could be installed at some other location to sense the room temperature such as the temperature of air 28 entering unit 26 . Blocks 64 , 66 and 68 represent microprocessor 36 sequentially receiving first, second and third manually entered setpoint temperatures. Blocks 70 , 72 and 74 represent thermostat 10 controlling unit 26 at sequential periods in response to a differential between the comfort zone temperature and the various manually entered setpoint temperatures. Block 76 represents assigning timestamps 48 to the various manually entered setpoint temperatures. A block 78 represents microprocessor 36 identifying a learned setpoint temperature based on the first, second and third manually entered setpoint temperatures. In block 80 , thermostat 10 controls unit 26 in response to a differential between the learned setpoint temperature and the actual zone temperature. Block 82 represents subsequently receiving a fourth manually entered setpoint temperature. Block 84 represents controlling unit 26 in response to the fourth manually entered setpoint temperature. Some time after that, thermostat 10 returns to controlling unit 26 in response to the learned setpoint temperature, as indicated by block 86 .
Although the invention is described with respect to a preferred embodiment, modifications thereto will be apparent to those of ordinary skill in the art. The scope of the invention, therefore, is to be determined by reference to the following claims: | A hybrid manual/programmable thermostat for a furnace or air conditioner offers the simplicity of a manual thermostat while providing the convenience and versatility of a programmable one. Initially, the hybrid thermostat appears to function as an ordinary manual thermostat; however, it privately observes and learns that is configured to learn from a user's manual temperature setting habits settings and eventually programs program itself accordingly. If users begin changing their preferred temperature settings due to seasonal changes or other reasons, the thermostat continues learning The thermostat may be configured to learn and will adapt to those changes as well. For ease of use, the thermostat does not require an onscreen menu as a user interface. In some embodiments, the thermostat can effectively program itself for temperature settings that are set to occur at particular times daily or just on weekends, yet the user is not required to enter the time of day or the day of the week a user's manual temperature settings over time. | 5 |
The present invention relates to a column for separation of substance mixtures, preferably on a preparative scale, with a liquid medium.
Liquid chromatography is used for separation of mixtures of substances. Thereby, such mixture is introduced in a column filled with an adsorptive agent, whereupon a liquid, referred to as an eluent, is allowed to flow through the column. Separation is achieved by the components of the mixture being retarded to a different degree by the adsorptive agent. Liquid chromatography is used for preparative *or analytical purposes. For analytical purposes, the substance mixture is introduced in the column in a liquid phase, whereupon an eluent is allowed to flow through the column and into a detector which records the amount of passing substance.
Preparative chromatography is carried out with the purpose of producing pure compounds, or isolating compounds from a mixture of substances. The amount of substance which is introduced into the column for such purpose is one to several powers of ten greater than what is introduced into a column for analytical purposes.
In preparative chromatography, in cases where the substance mixture is dissolved in a suitable liquid, the mixture may be introduced into the column via tubing connected to the end of the column. In other cases, the substance mixture is introduced in a solid phase. A standard procedure is to adsorb the mixture, in a separate operation, on an appropriate adsorbent material, which is thereafter introduced into the column on top of the adsorptive agent. The substance mixture may comprise synthetic products or natural products, e.g. plant extracts. Traditionally, long columns are used in this context, the top end of which is open. The column is packed with an adsorptive agent to a certain level, followed by the substance mixture. The uppermost part of the column is used as a reservoir for the eluent, which is allowed to pass through the adsorptive agent with the aid of gravity. This type of column allows for continuous supply of eluent. When higher flow rates are desired, than what can be achieved with a hydrostatic pressure alone, the eluent may be forced through the column by closing the top end of the column and applying gas pressure. The latter method, as currently applied, is referred to as "flash chromatography". Although this is an inexpensive solution, the method has drawbacks. Glass columns may explode by too high pressures applied, with the risk of glass splinter flying about, and further, the system has to be decompressed on filling or exchange of eluent. Decompression can cause formation of blisters whereby inhomogenities occur in the packing of the adsorptive agent.
Forcing of the eluent through the column with a pump bids great advantages. Supply of eluent and change of composition of the eluent can be done in a continuous manner on the suction side of the pump. With medium pressures, the compressibility of the liquid is negligible. Due to this, the risk of glass splinter flying about on breakage is small in use of columns which completely filled up with solid phase and liquid. Due to said fact, it is advantageous to supply the eluent to the column through a hollow piston, which can be brought into close contact with the adsorptive material, whereupon it is made to seal against the wall of the column.
This type of chromatography is sometimes referred to as medium pressure chromatography, which is carried out at a pressure up to a few tens of bar, e.g. 4 bar (0.4 MPa). Several manufacturers supply columns where requirements of sealing against the column walls are complied with. In many instances, columns are employed, designed as a cylinder of relatively thick glass (2-8 mm) wherein the length of the column may be made adjustable by means of a piston in the column. Usually the inlet or outlet of the column runs through the piston and piston shaft in flexible tubing which exits at the end of the piston shaft, alternatively a tube is provided having a connection for flexible tubing opening at the end thereof. Usually the piston is provided with a device which prevents it from rotating during compression of the O-ring.
Numerous inconveniences occur with this type of design. If the O-ring is compressed too strongly, the column may rupture. If the piston shaft is made of plastic material, too hard tightening of the screw may cause the piston shaft to break or the compression threads to be damaged. Further, a dead lumen occurs between the lowermost part of the piston and the O-ring. A problem with such a column is that, on use of aggressive liquid media, certain organic solvents in particular, the O-ring may be affected and cause leakage and contamination of the liquid medium. As most columns on the market are intended for biochemical separations, no particular attention has been paid, in choice of material for the constructive details, to resistance against solvents such as chloroform, methylene chloride and ethyl acetate, which are usually occurring eluents in organic chemistry. These solvents may cause the O-ring to swell, which may bring about rupture of the column or render the piston difficult to remove. A column provided with the mentioned O-ring seal, where the piston shaft is made of plastic material has been supplied by Amicon Ltd. Upper Mill, Stonehouse, Gloustershire GL10 2BJ GB.
Pharmacia LKB Biotecnology, Sweden have supplied a column named SR Column System, which, in the place of an O-ring employs a piston having a conical outer surface, and a ring arranged around said piston having a conical inner surface, where the conical surfaces are pressed against each other with a similar mechanism as in the column having the O-ring seal, thus that the ring will seal against the column wall. In this column it appears that the conical surfaces have the same cone angle, and the piston is locked in the column from the outset. With this construction, the ring has to be strongly tightened initially, to avoid leakage. Thereby, like in the column having the O-ring seal, a risk occurs of rupture of the column wall. Columns of the previously known kinds are further impaired with the problem of a dead volume around the periphery of the upper end of the piston.
According to the present invention, these drawbacks are avoided in a column for separation of substance mixtures with a liquid medium, comprising a cylindrical tube with a separation space therein having a closure at each end, whereby the separation space has an inlet and an outlet, respectively, through a channel in each end thereof, whereby at least one of the closures is a movable piston trough which one of said channels runs and together with a channel in a piston shaft connected to the piston makes up the inlet or the outlet, whereby said piston has a socket which is radially expandable by axial pressing of two interacting conical parts, for sealing of the piston against the inner wall of the column. The invention is characterized in, that the piston comprises an expandable socket abutting, in its resting position, against the inner cylindrical surface of the column, and having a conical opening, widening towards the separation space with a certain cone angle, that the piston further comprises an inner part having an outer surface conically tapering in the direction away from the separation space and abutting with its periphery against the periphery of the conical opening, that said inner part has a cone angle greater than the cone angle of the expandable socket, which inner part can be pressed against the expandable collar, by tightening means operable from the outside of the column, to cause a first expansion thereof, and that the channelled piston shaft is lockable against the column by a locking means having a certain resilience in the longitudinal direction of the column, and that said resilience is arranged thus that it allows for pressing said inner part back under the action of the pressure of a liquid in the separation space, to achieve a further expansion of the expandable socket, to sealing against the column wall.
By "cone angle" is intended the top angle between the generatrices of the imagined full conical surfaces in which the respective conical surface is comprised, in an unloaded state. The angle of the respective conical surface to the column wall is half the cone angle.
The expandable socket can be made with a bottom, and/or a washer or similar device may be placed between the expandable part and the piston shaft. The inner part of the piston is designed in such way that, when pressed against the expandable socket, it is not locked against the bottom thereof , the washer or the end of the piston shaft, respectively.
While the tightening means, operable from the outside, can consist of a screw means arranged at the outer end of the piston shaft, as described above as known, in a preferred embodiment of the invention, the tightening means, operable from the outside is a thread means arranged between the inner part of the piston and the piston shaft, which is operable by turning the piston shaft.
In a further preferred embodiment of the invention, the locking means having a certain resilience is a fitting threadable onto the column or an equivalent holding means, such as a snap device, holding a lid having a built-in elasticity, which lid secures the piston shaft via securing means. In the case where the channel in the piston shaft is a tubing connected to the channel of the piston, it is preferred that the tubing outside the column runs through an opening arranged in the side of the piston shaft. In all columns on the market the inlet and outlet tubing exits concentrically with the piston shaft, i.e. trough the outermost end of the piston shaft, or is connected to the outer end of the piston shaft tube. This is disadvantageous, since the tubing will be folded and damaged if the column is lowered against a support surface during packing of the column. In the present invention, the inlet or outlet tubings are run out at the side of the piston shaft tube through a hole intended therefor, close to the outer end of the piston shaft tube. By this arrangement, the column may be supported on the piston shaft tube on packing of the column, without the tubing being damaged. With such arrangement, further, arrangement of a rotation device at the lower end of the piston shaft is facilitated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is more closely described with reference to the enclosed drawing, showing a column according to an embodiment of the invention, partly in side view, partly in section (FIG. 1A) and a partial enlargement (FIG. 1B).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The column shown in the drawing comprises a column tube made of glass, having external threads at one end thereof and similar threads, not shown, at the other end of the column tube. The threads each engage a threaded cap 3,3'. An opening is shown in the planar end of the cap 3. In the column tube, a piston 5 and a similar piston 5' are movable. The pistons together delimit a separation space 6, the volume of which is variable by displacement of either or both pistons. In the piston 5 a channel 7 opens, which may be an outlet or an inlet, referred to here as an outlet channel. Said channel continues via a plug 8 in which a tubing 9 is attached, which is a continuing portion of the outlet channel. A similar inlet channel, not shown, in the piston 5' is connected to a tubing 9'. Tubing 9, 9' runs through a piston shaft 10, 10', and exits through a hole 11, 11' arranged in the side of the piston shaft.
The piston 5 comprises an expandable part 12, made of elastic material such as polytetrafluorethene. Part 12 comprises a collar 13, the periphery of which abuts against the inner surface of the column tube. Collar 13 has an inner surface 13a conically opening with a certain cone angle, e.g. 15° in a column having an inner diameter of 15 mm, and 34° in a column having an inner diameter of 30 mm, and a bottom part 14 integrated with the collar. Via a washer 15 the expandable part 12 is supported against the end of the piston shaft 10 directed towards the separation space. An inner part 16 of the piston 5 has a conical outer surface 17, tapering conically in the direction away from the separation space, said conical outer surface having a greater cone angle, e.g. 30° in a column having the diameter 15 mm and 50° in a column having the diameter 30 mm. The inner part 16 is attached via a threaded central tap 16a engaging an inner thread in the piston shaft. When the inner part 16 is forced into the expandable part 12, the conical surfaces 13a and 17 are brought into contact with each other, whereby part 12 is pressed against the column wall.
A slotted disk 18 has a conical central part 19, which has inner threads which by radial compression of the disk can be brought into engagement with threads 20 on the exterior of the piston shaft, by the conical part being pressed into a central opening in an elastically resilient disk 21, the periphery of which is supported against a flange 22 left by the opening 4 in the end of the cap 3. A optional knurled end 23, 23', which can be replaced by a through-going turning pin, is shown arranged on the end of the piston shaft 10, 10'.
A manner of using the column shown as an example is described in the following.
The piston 5, or 5' in the alternative, is adjusted to a desired position with the inner part 16 loosely abutting the collar 13. The cap 3 is screwed onto the threads 2, whereby the resilient disk 21 presses the central part 19 of the slotted disk into engagement of the threads 20. A first dilation of the collar 13 is brought about by turning the piston shaft 10, whereby the friction against the inner wall of the column tube 1 prevents parts 12 and 16 of the piston from rotating, at least to a maximal torque, at which rupture of the column is prevented by the piston starting to rotate. The maximal torque can be influenced by selection of material in the parts of the piston and selection of the area by which the collar 13 abuts the inner wall of the column. The separation space 2 is filled with an adsorptive agent and the second of pistons 5,5' is adjusted into a desired position and is locked in a similar manner as the first one. The mixture that is to be separated is filled via the inlet channel 9' (9 in the alternative). Eluent is introduced under an moderate overpressure through the inlet channel, and the liquid which flows out through the outlet channel is collected in fractions. The eluent exerts a pressure on the upper side of the inner part of the column. By the resilient disk allowing the piston shaft to move outwards, the inner part 16 of the piston is pressed into the expandable part 12, which expands. It is important that there is an open space 12a between the bottom part and the inner part of the piston, thus that expansion can be achieved in the two expansion phases.
While the column tube is normally made of glass, the expandable socket of the piston is preferably made of polytetrafluorethene or a similar polymer material inert against occurring solvents. The inner part of the piston, as well as the piston shaft and the supporting disk, when occurring, can be made of highly alloyed corrosion resistant steel, but strong polymer materials known for such purposes can also be employed, whereby care should be taken in order that the parts of the inner part touched by the liquid medium should be as inert against the liquid medium as is the expandable socket. | Described is a column for separation of substance mixtures with a liquid. A cylindrical tube has a closure at each end. At least one of the closures is a movable piston. The piston has a socket which is radially expandable by axial pressing of two interacting conical parts for sealing of the piston against the inner wall of the column. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The invention described and claimed hereinbelow is also described in German Patent Application DE 10 2010 046 019.2 filed on Sep. 18, 2010 and German Patent Application DE 10 2011 012 767.4 filed on Mar. 1, 2011. These German Patent Applications, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
[0002] The invention relates to a method for manufacturing a tubular knitted article, which has plain stitches and purl stitches in each stitch row, on a flat knitting machine comprising at least two diametrically opposed needle beds, wherein, at least past a vertical section of the knitted article, purl stitches follow the plain stitches of a stitch row in a subsequent stitch row, and plain stitches follow the purl stitches of this stitch row in the subsequent stitch row.
[0003] Tubular knitted articles can be manufactured as smooth-surface knitted articles which, however, tend to roll up at the edges of the knitted article. They can also be formed as ribbed knitted articles, in which case plain stitches and purl stitches alternate, thereby producing a knitted article having high transverse elasticity and relatively high longitudinal elasticity. A method for manufacturing such a tubular ribbed knitted article is disclosed in BE 789902 A1, for example. In that case, the plain stitches and purl stitches for the front part and the back part are formed in alternation using one stroke of the carriage in each case. A large quantity of thread material is inlaid into the knitted article to connect the loops on the front needle bed and the rear needle bed. The result is an unstable knitted article having high elasticity.
SUMMARY OF THE INVENTION
[0004] The problem addressed by the present invention is that of manufacturing a tubular knitted article having high stability and relatively low elasticity in the longitudinal direction, and which does not roll up at the edges of the knitted article.
[0005] The problem is solved by a method for manufacturing a tubular knitted article, which has plain stitches and purl stitches in each stitch row, on a flat knitting machine comprising at least two diametrically opposed needle beds, wherein, at least past a vertical section of the knitted article, purl stitches follow the plain stitches of a stitch row in a subsequent stitch row, and plain stitches follow the purl stitches of the stitch row in the subsequent stitch row in each case, comprising the steps:
a) Manufacture a tubular basic knitted article using at least one stitch row, wherein every needle of one needle bed occupied by a loop is opposite an empty needle of the other needle bed; b) Form plain stitches on the first and/or second needle bed after transferring the loops to be knitted as purl stitches to the opposite needle bed; c) Return the loops transferred in step b) to their original needles; d) Form purl stitches on the first and/or second needle bed after they have been transferred to the opposite needle bed; e) Return the loops transferred in step d) to their original needles; f) Form plain stitches on the first and/or second needle bed using the needles that formed purl stitches in step d), after the plain stitches formed in step b) have been transferred to the opposite needle bed; g) Return the loops transferred in step f) to their original needles; h) Form purl stitches on the first and/or second needle bed using the needles that formed plain stitches in step b), after these loops have been transferred to the opposite needle bed; i) Return the loops transferred in step h) to their original needles; j) Repeat steps b) through i).
[0016] According to this method, a tubular knitted article is produced, in which plain stitches and purl stitches alternate not only within one stitch row, but also in the direction of the wales. By utilizing this weaving technique, it is ensured that the edges of the knitted article do not roll up. In addition, by alternating plain stitches and purl stitches in the direction of the wales as well, the knitted article is provided with slight elasticity in the longitudinal direction. Such tubular knitted articles can therefore be used preferably to manufacture drive belts or coverings for furniture or the like, for which slight longitudinal expansion and high stability are desired in order to ensure high dimensional stability of the knitted articles.
[0017] A further feature of a tubular knitted article manufactured according to the method according to the invention is that the inner side and the outer side of the tubular knitted article have the same appearance. By producing the plain stitches and the purl stitches in alternation, the plain stitches on the visible side are covered by floating threads of the purl stitches on the visible side. The knitted article takes on a braided appearance as a result.
[0018] A further advantage of producing the plain stitches and the purl stitches in alternation is that the amount of thread required to manufacture the knitted article can be kept relatively low.
[0019] The knitted article can be manufactured in different ways in order to set the desired longitudinal and transverse elasticity. One possibility for obtaining particularly high stability in the transverse and longitudinal directions of the knitted article is to alternate plain stitches and purl stitches in an offset manner in one stitch row and in the wales.
[0020] In a further possible embodiment of the method, steps b) to e) can be repeated at least once, and steps f) to i) can also be repeated at least once. If the knitted article is manufactured this way, the sections with plain stitches and purl stitches are located at the same points across several stitch rows in the circumferential direction of the knitted article before the plain stitches and purl stitches become mutually offset, i.e. purl stitches are formed using the needles that previously formed the plain stitches, and vice versa. If the knitted article is manufactured in this manner, it has greater elasticity in the longitudinal direction than if plain stitches and purl stitches are offset in every successive stitch row.
[0021] The order of plain stitches and purl stitches within one stitch row can also be varied. For instance, the stitch rows can be knitted in a 1:1-, 2:2- or 3:3-right/left construction, i.e. one plain stitch and one purl stitch, or two plain stitches and two purl stitches, or three plain stitches and three purl stitches are formed in alternation in each case across the entire stitch row. The number of plain stitches and purl stitches does not have to be the same, of course. The stitch rows can therefore also be knitted in a 2:1-, 3:1- or 3:2-right/left construction, i.e. they can have more plain stitches than purl stitches. Conversely, it is also possible to provide more purl stitches than plain stitches, and to knit the stitch rows in a 1:2-, 1:3- or 2:3-right/left construction, for example.
[0022] The transverse elasticity of the knitted article can be influenced in particular by selecting different constructions for each stitch row.
[0023] Preferably, a regular construction pattern is selected for the entire knitted article. Irregular distributions of plain stitches and purl stitches in the stitch rows can be selected, however, at least in areas.
[0024] The tubular knitted article can be knitted according to the method as a closed tube or a tube that is open on one side.
[0025] A weft thread can also be inlaid into the tubular knitted article in a few stitch rows by forming tuck loops using the weft thread on empty needles of a needle bed. The transverse expansion of the knitted article can be reduced to a desired level in this manner. The knitted article is thereby provided with even greater stability. Potential materials for the weft threads are glass fibers, aramids, or similar stable materials.
[0026] The invention also relates to a knitted article that comprises plain stitches and purl stitches in each stitch row, wherein purl stitches follow the plain stitches of a stitch row in a subsequent stitch row, and plain stitches follow the purl stitches of the stitch row in the subsequent stitch row, and which is manufactured according to a method according to one of the claims 1 to 6 on a flat knitting machine having at least two diametrically opposed needle beds.
[0027] Preferred embodiments of a method according to the invention are described in detail below with reference to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1-FIG . 7 show a sequence of knitting rows for executing one pass of a first method;
[0029] FIG. 8-FIG . 14 show a sequence of knitting rows for executing one pass of a second method.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] All knitting rows R 0 to R 24 of both methods are shown in a so-called yarn course display. The front needle bed V and the rear needle bed H are indicated schematically in each case. The needles of the front needle bed are indicated by dashes labelled with upper case letters A to Z, and the needles of the rear needle bed H are indicated by dashed labelled with lower case letters a to z.
[0031] The needle occupancy at the onset of production of the tubular knitted article on the front needle bed V and the rear needle bed H is shown in row R 0 , wherein a loop is present on every second needle, and an empty needle of the other needle bed H, V is situated opposite every needle of a needle bed V, H on which a loop is present.
[0032] In row R 1 , every second loop of the rear part of the knitted article, i.e. the loops on needles d, h, l, p, t, x of rear needle bed H are transferred to the respective opposite empty needles D, H, L, P, T, X of the front needle bed V before plain stitches for the rear part of the knitted article are formed in row R 2 on needles b, f, j, n, r, v, z of the rear needle bed, the loops of which were not transferred. Next, in row R 3 , the loops of the rear part of the knitted article, which were transferred to the front needle bed in row R 1 , are returned to their original needles d, h, l, p, t, x. In row R 4 , every second loop of the front part of the knitted article, i.e. the loops of needles A, E, I, M, Q, U and Y of the front needle bed, is transferred to the respective opposite empty needle a, e, i, m, q, u and y of the rear needle bed H before plain stitches for the front part of the knitted article are formed in row R 5 on needles C, G, K, O, S, W of the front needle bed, the loops of which were not transferred. Next, in row R 6 , the loops of the front part of the knitted article, which were transferred to the rear needle bed in row R 4 , are returned to their original needles A, E, I, M, Q, U and Y of the front needle bed V.
[0033] In rows R 1 to R 6 , plain stitches were therefore formed on the front needle bed (needles C, G, K, O, S, W) and the rear needle bed (needles b, f, j, r, v, z) using every second needle in each case.
[0034] Next, in row R 7 , every second loop of the rear part of the knitted article, i.e. the loops on needles d, h, l, p, t, x of the rear needle bed are transferred again to the respective opposite empty needle D, H, L, P, T and X of the front needle bed. Next, in row R 8 , loops are formed on the loops of the rear part of the knitted article, which were transferred to needles D, H, L, P, T and X of the front needle bed in row R 7 . In row R 9 , the loops of the rear part of the knitted article, which were formed on the front needle bed in row R 8 , are then returned to their original needles d, h, l, p, t and x of the rear needle bed. They appear as purl stitches on the visible side of the rear part of the knitted article. Next, in row R 10 , every second loop of the front part of the knitted article, i.e. the loops of needles A, E, I, M, Q, U and Y of the front needle bed are again transferred to the particular opposite empty needle a, e, i, m, q, u and y of the rear needle bed, before loops are formed in row R 11 on the loops of the front part of the knitted article that were transferred to needles a, e, i, m, q, u, y of the rear needle bed in row R 10 . Next, in row R 12 , the loops of the front part of the knitted article, which were formed on the rear needle bed in row R 11 , are returned to their original needles A, E, I, M, Q, U and Y of the front needle bed. They therefore appear as purl stitches on the visible side of the rear part of the knitted article.
[0035] In rows R 7 to R 12 , purl stitches were formed on the respective opposite needle bed in the front and rear part of the knitted article using needles that carry every second loop. On the front needle bed, these are needles A, E, I, M, Q, U, Y, and on the rear needle bed they are needles b, f, j, n, r, v and z. Overall, a complete stitch row was therefore created in rows R 1 to R 12 on the front and rear needle bed using alternating plain stitches and purl stitches.
[0036] In row R 13 ( FIG. 4 ), the loops of the rear part of the knitted article b, f, j, n, r, v and z of the rear needle bed are transferred to the respective opposite empty needles B, F, J, N, R, V, Z of the front needle bed before plain stitches for the rear part of the knitted article are formed in row R 14 on needles d, h, l, p, t, x of the rear needle bed, the loops of which were not transferred. In row R 15 , the loops of the rear part of the knitted article, which were transferred to the front needle bed in row R 13 , are returned to their original needles b, f, j, n, r, v and z. Next, in row R 16 , every second loop of the front part of the knitted article, i.e. the loops of needles C, G, K, O, S, W of the front needle bed are transferred to the respective opposite empty needles c, g, k, o, s, w of the rear needle bed so that plain stitches for the front part of the knitted article can then be formed in row R 17 on needles A, E, I, M, Q, U, Y of the front needle bed, the loops of which were not transferred. Next, in row R 18 , the loops of the front part of the knitted article, which were transferred to the rear needle bed in row R 16 , are returned to their original needles C, G, K, O, S and W of the front needle bed.
[0037] In rows R 13 to R 18 , plain stitches were therefore formed in the front and rear part of the knitted article using the needles that formed purl stitches in rows R 7 to R 12 .
[0038] Next, in row R 19 , the loops of the rear part of the knitted article on needles b, f, j, n, r, v, z of the rear needle bed are transferred to the respective opposite empty needles B, F, J, N, R, V and Z of the front needle bed before loops are formed once more in row R 20 on the loops of the rear part of the knitted article, which were transferred in row R 19 to needles B, F, J, N, R, V and Z of the front needle bed. In row R 21 , the loops of the rear part of the knitted article, which were transferred to the front needle bed in row R 20 , are returned to their original needles b, f, j, n, r, v, z of the rear needle bed. They therefore appear as purl stitches on the visible side of the rear part of the knitted article. In row R 22 , every second loop of the front part of the knitted article, i.e. the loops of needles C, G, K, O, S and W of the front needle bed are transferred to respective opposite empty needles c, g, k, o, s, w of the rear needle bed before loops are formed in row R 23 on the loops transferred to needles c, g, k, o, s, w of the rear needle bed in row R 22 . After these loops of the front part of the knitted article formed in row R 23 are returned to their original needles C, G, K, O, S, W of the front needle bed in row R 24 , they appear as purl stitches on the visible side of the front part of the knitted article.
[0039] Overall, purl stitches were therefore formed in the front and rear part of the knitted article in rows R 13 to R 24 using the needles that formed plain stitches in rows R 1 to R 6 .
[0040] The procedure described for rows R 1 to R 24 is repeated until the desired number of stitch rows has been obtained.
[0041] In the variant method presented here, plain stitches and purl stitches are therefore formed in alternation in the longitudinal direction and in the transverse direction of the knitted article, and therefore the knitted article has the same appearance on the outside and the inside.
[0042] The method according to FIGS. 8 to 14 differs from the method according to FIGS. 1 to 7 by an inlaid weft thread which differs in rows RS 1 ( FIG. 8 ), RS 2 ( FIG. 9 ), RS 3 ( FIG. 11 ) and RS 4 ( FIG. 12 ). Tuck loops are formed with the weft thread using every fourth needle of a needle bed in each case. Loops are formed in subsequent rows R 2 , R 5 , R 14 and R 17 , and then the weft thread that was inlaid in the previous row is pressed off once more (not depicted).
[0043] It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods and constructions differing from the types described above.
[0044] While the invention has been illustrated and described as embodied in a device and method for manufacturing a tubular knitted article, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
[0045] Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention. | Manufacturing a tubular knitted article on a flat knitting machine includes using at least two diametrically opposed needle beds, which has plain stitches and purl stitches in each stitch row, wherein purl stitches follow the plain stitches of a stitch row in a subsequent stitch row, and plain stitches follow the purl stitches of the stitch row in the subsequent stitch row. | 3 |
PRIORITY CLAIM
[0001] This patent application claims the benefit of the priority date of U.S. Provisional Patent Application Ser. No. 60/448,616 filed on Feb. 19, 2003 and entitled Decorative Device Comprised of Modular And Interchangeable Components (Attorney Docket no. C&M1.0018-PRO) pursuant to 35 USC § 119, the entire contents of this provisional patent application are hereby expressly incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention pertains generally to the manufacture of decorative devices. More particularly, the present invention pertains to decorative products, such cornices that serve as decorative features for architectural structures. The preferred embodiment of the present invention is particularly, but not exclusively, useful as a product and a process that provides a cornice comprised of modular, interchangeable components.
[0004] 2. Description of the Prior Art
[0005] Decorative devices, such cornices, that serve as ornamental features for architectural structures are well known. The devices are also utilitarian in nature in that they may serve to hide curtain rods or other structures. More specifically, cornices are ornamental moldings or projections that crown a variety of structures such as buildings, windows, drapes, walls, or paintings.
[0006] [0006]FIG. 1 illustrates a typical cornice (or valance) 2 , in the prior art, from which curtains 4 are hung. As illustrated in FIGS. 2 and 3, cornice 2 is comprised of a main front decorative piece 6 and two side pieces 8 , 10 that are used to couple the main piece 6 to a supporting structure such as a wall 12 .
[0007] The main decorative piece 6 of cornice 2 is made from a single rigid block of material such as a wood, which is then molded or milled to a desired shape or design. The dimensions of this block must be commensurate to at least the largest dimensions used in the design of cornice 2 . For example, the height of the block must be at least as high as the longest decorative height 16 of cornice 2 , and its length should cover the entire length of drape 4 on wall 12 , wherein decorative height 18 is the shortest height. As to the width or thickness of the block, it should be as wide as the thickest decorative design width 20 of cornice 2 , as illustrated in FIG. 3, wherein design width 22 is the thinnest.
[0008] In the prior art, the process of molding singular parts from slabs of rigid material to assemble cornice has been costly and wasteful. If a singular part were damaged, the entire unit would become unusable. The block or slab dimensions of the raw work piece must have been equal to the largest dimensions of a design; with sections that are not part of the final designs milled into waste. Excess milling is a further source of waste. In addition, a cornice that is made from a single block of material is inflexible. Once a block is molded or milled to a certain design, it cannot be modified to fit another design. Instead, the entire cornice must be replaced if modification is required or desired.
[0009] In light of the above, it is an object of the present invention to provide a cornice for crowning a variety of architectural structures wherein each component of the cornice is modular and interchangeable with respect to previous subsequent components fabricated in manufacturing.
[0010] It is yet a further object of the present invention to provide a cornice and method of manufacture thereof that minimizes waste of unforged material.
[0011] It is yet still another object of the present invention to provide new and useful attachment means for individual components.
[0012] Yet another object of the present invention is to provide a cornice and process for manufacturing cornices that is relatively simple to use and comparatively cost effective.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention specifically addresses the above-mentioned objectives associated with the prior art by providing a cornice system using modular, interchangeable components. More particularly, one preferred embodiment of the present invention comprises a cornice for crowning a variety of architectural structures comprising: a horizontal base unit having a face section, a top section and a bottom section, at least one of the face section the top section and the bottom section further including connection means; and one or more decorative modules fastened to at least one of the top and bottom sections. In this preferred embodiment, all or any part of the components are manufactured from wood.
[0014] In this preferred embodiment of the present invention, each of the horizontal base units and decorative modules are modular and interchangeable components with respect to previous and subsequent components that may be fabricated. Each type of modular, interchangeable component is forged from a large block of rigid material, thereby minimizing waste of excess unforged material and thereby further minimizing waste in the event one component is forged incorrectly. In the preferred embodiments of the present invention, the rigid material is wood.
[0015] A second preferred embodiment of the present invention further includes a centerpiece module configured to fit over the face section of the modular horizontal base unit included in the first preferred embodiment. In addition, in this second preferred embodiment, the centerpiece module includes structure that has decorative features. The horizontal base unit, a particular embodiment, selectively includes one or more curved extension supports for insertion of the centerpiece module. Alternatively, one or more decorative modules may be provided which also include an insert channel for a secure insertion onto the centerpiece module.
[0016] The preferred embodiments of the present invention further include particular fasteners for components. More particularly, in a first fastener embodiment, the one or more decorative modules of the preferred embodiment may include a hollow “T” shaped channel, and the horizontal base unit includes a corresponding accommodating extension to join and secure the one or more decorative modules to the horizontal base unit. Alternatively, in a second fastener embodiment, the one or more decorative modules include a hollow inverted “L” shaped channel, and the horizontal base unit includes a corresponding accommodating extension to join and secure the one or more decorative modules to the horizontal base unit. In a third fastener embodiment, the horizontal base unit includes a hollow “T” shaped channel, and the one or more decorative modules include a corresponding accommodating extension to join and secure the one or more decorative modules to the horizontal base unit. In a fourth fastener embodiment, the horizontal base unit includes a hollow inverted “L” shaped channel, and the one or more decorative modules include a corresponding accommodating extension to join and secure the one or more decorative modules to the horizontal base unit.
[0017] In another aspect, a first preferred method of the present invention can be characterized as a method of using cornices for crowning a variety of architectural structures. This first preferred method of practicing the present invention comprises the following steps.
[0018] Obtaining a horizontal base unit, the horizontal base unit having a first mateable modular connection means.
[0019] Obtaining one of a plurality of decorative modules, the decorative module having a second mateable modular connection means.
[0020] Lastly, combining the decorative module to the horizontal base unit by connecting the first mateable modular connection means to the second mateable modular connection means to form a single cornice structure.
[0021] In another aspect, a second preferred method of the present invention can be characterized as a method of manufacturing cornices for crowning a variety of architectural structures. This second preferred method of practicing the present invention comprises the following steps.
[0022] Creating a plurality of horizontal base units, each of the horizontal base units having a first mateable modular connection means.
[0023] Creating a plurality of decorative modules, each of the decorative modules having a second mateable modular connection means.
[0024] Combining one or more decorative modules to one of the horizontal base units to form a single cornice; and
[0025] Lastly, repeating the combining to form second and subsequent cornices.
[0026] In this embodiment, each of the horizontal base units and each of the decorative modules are constructed from a single block of rigid material. Further, each of the horizontal base units are interchangeable, and each of said decorative modules are interchangeable. This methodology for creating the cornices minimizes waste of excess unforged material, and further minimizes waste in the event one component is forged incorrectly.
[0027] The stated preferred methods of implementing the present invention may further include the step of forging a plurality of centerpiece modules from a respective single block of rigid material, wherein each of the centerpiece modules is interchangeable.
[0028] Additionally, stated preferred methods of implementing the present invention may also further include the step of creating connection means for connecting the horizontal base unit to the decorative module. In a first connection embodiment, this creating connection step includes the step of channeling a “T” shaped groove in the decorative module and forming a corresponding accommodating extension in the horizontal base unit for securing the decorative module to the horizontal base unit. In a second connection embodiment, this creating connection step includes the step of channeling an inverted “L” shaped groove in the decorative module and forming a corresponding accommodating extension in the horizontal base unit for securing the decorative module to the horizontal base unit. In a third connection embodiment, this creating connection step includes the step of channeling a “T” shaped groove in the horizontal base unit and forming a corresponding accommodating extension in the decorative module for securing the decorative module to the horizontal base unit. In a fourth connection embodiment, this creating connection step includes the step of channeling a “T” shaped groove in the horizontal base unit and forming a corresponding accommodating extension in the decorative module for securing the decorative module to a horizontal base unit.
[0029] Yet another preferred embodiment of the present invention may be described as a cornice for crowning a variety of architectural structures, the cornice comprising: a horizontal base unit having a face section, a top section and a bottom section; one or more decorative modules fastened to either one of, or both of, said top and bottom sections, the decorative modules including insert channels; and a center piece module configured to fit over said face of said horizontal base unit, the center piece module having portions secured by the insert channels. Alternatively, this embodiment also includes hollow “T” and “L” shaped channels and corresponding accommodating extensions for securing several components to one another.
[0030] These, as well as other advantages of the preferred embodiments and the present invention will be more apparent from the following description and drawings. It is understood that changes in the specific structure shown and described may be made within the scope of the claims, without departing from the spirit of the invention.
[0031] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The novel features of this invention, as well as the invention itself and the preferred embodiments, both as to structure and operation, will be best understood from the accompanying drawings, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
[0033] [0033]FIG. 1 is an isometric illustration of a typical prior art cornice.
[0034] [0034]FIG. 2 is an isometric illustration of a typical prior art cornice showing a main front decorative piece and sidepiece.
[0035] [0035]FIG. 3 is a side view of a prior art cornice.
[0036] [0036]FIG. 4 is an isometric view of a cornice according to a preferred embodiment of the present invention having modular, interchangeable components.
[0037] [0037]FIG. 5 is another isometric illustration of a cornice according to a preferred embodiment of the present invention showing only top and bottom modules, decorative base unit, and decorative centerpiece.
[0038] [0038]FIG. 6 is an isometric view of separate components of a cornice according to a preferred embodiment of the present invention.
[0039] [0039]FIG. 7 is partial isometric view of a cornice according to a preferred embodiment of the present invention that has been assembled according to an exemplary embodiment.
[0040] [0040]FIG. 8 is a cross sectional view taken along sectional line 8 - 8 of FIG. 7.
[0041] [0041]FIGS. 9A to 9 D show similar cross sectional views of assembled cornices illustrating different coupling methods used within the preferred embodiments and methodologies of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] [0042]FIG. 4 illustrates a cornice 50 according to a first preferred embodiment of the present invention, comprised of modular, interchangeable components made from separate blocks of rigid material whose dimensions are proportionate with the dimensions of each module, rather than largest dimensions of the entire cornice. In the preferred embodiment of the present invention, the rigid material is wood.
[0043] Each modular component of cornice 50 may be of any design, form, and size, and is interchangeable. The illustrated top 34 or bottom 32 decorative modules may be interchanged or be replaced by other pieces, each with different designs. The cornice 50 could have one of only a top 34 , or a bottom 32 piece. Further illustrated in FIG. 4 is an insertable decorative centerpiece module 31 that can easily be replaced by another insertable module with a different design, as is illustrated in FIG. 5. The cornice 50 of FIG. 5 is comprised of differently designed top 34 and bottom 32 modules coupled to a base unit 30 .
[0044] [0044]FIG. 6 illustrates the separate components of cornice 50 in relation to one another. The cornice 50 includes two decorative modules 32 , 34 , and an insertable centerpiece module 31 that are secured (or mounted) on a base unit 30 . Any size or design base unit 30 , decorative modules 32 , 34 , or insertable centerpiece module 31 may be used. In addition, cornice 50 may be comprised of only one decorative module instead of the two that are illustrated.
[0045] [0045]FIG. 7 illustrates a partial perspective view for cornice 50 with decorative modules 32 , 34 coupled to its base unit 30 by adhesion (or some other binder). FIG. 8 further illustrates a cross sectional view taken along sectional line 8 - 8 . FIGS. 7 and 8 illustrate the modules 32 , 34 that include optional insert channels 33 , 35 , respectively, for a secure insertion of centerpiece module 3 1 . The insert channels 33 , 35 may be realized as concave raceways of appropriate size that extend throughout the length of each module 32 and 34 to allow center piece 31 to snugly slide onto cornice 50 , covering the exposed base unit 30 . The base 30 , in other useful embodiments, need not extend all the way through the full height of modules 32 , 34 .
[0046] [0046]FIGS. 9A to 9 D show cross sectional views of an assembled cornice 50 , illustrating different coupling methods. Referring to FIG. 9A, modules 32 , 34 may be mounted (or fastened) to base unit 30 through different fastener elements 51 , 53 , including, for example, nails or threaded fasteners such as screws. FIGS. 9B and 9C illustrate an assembled cornice 50 devoid of the use of fastener elements. In these embodiments, the bottom of the modules 32 , 34 throughout their entire length include carved hollow grooves of raceways or channels 52 , 54 in “T” or horizontally flipped “L” shapes. The modules 32 , 34 , are inserted onto the base unit 30 with similarly accommodating extensions 55 , 56 for secure and tight mounting.
[0047] [0047]FIG. 9D illustrates the inverse structure, as compared to the previous embodiment, with respect to the modules and the base units of FIGS. 9B and 9C. In this embodiment, two sections within the top portion of the base unit 30 throughout its entire length are carved into hallow raceways or channels 62 , 64 of “T” or “L” shapes. The modules 32 , 34 with analogous accommodating extensions 63 , 65 are securely and tightly mounted onto the base unit 30 . The modules 32 , 34 are mounted by inserting their extensions 63 , 65 into the matching channels 62 , 64 . In addition, the base unit 30 further includes two curved extension supports 68 , 70 similar to a hook, for insertion of a centerpiece module 3 1 . With this option, alternative modules 32 or 34 need not have the optional insertion channels 33 , 35 .
[0048] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiments have been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations.
[0049] While the particular Decorative Device Comprised of Modular And Interchangeable Components as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
[0050] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements. | A decorative device, such as a cornice, for crowing a variety of architectural structures also having modular and interchangeable components is disclosed. In one embodiment, a cornice comprises a horizontal base unit having a face section, a top and a bottom, and one or more interchangeable decorative modules. A decorative centerpiece for the cornice is also disclosed. Additionally, the disclosure includes novel means for attaching particular components to one another. In the preferred embodiments, the components are wood. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to a digital VTR, and in particular to a digital image reproduction apparatus and method for performing slow-motion reproduction (hereafter abbreviated to slow reproduction) by using a memory.
In a digital VTR, image signals are so recorded on magnetic tape that each field may be divided to a plurality of tracks. When slow reproduction is to be performed by using magnetic tape having image signals thus recorded thereon, image signals reproduced when the magnetic tape is traveling at low speed are written into a memory having a capacity of one field or one frame, and the image signals thus written are then read out.
The operation for writing the reproduced image signals into the memory at the time of slow reproduction will now be described. That is to say, image signals comprise a train of data in unit intervals (hereafter referred to as blocks) such as horizontal intervals. An ID signal comprising data (field ID) representing a field No. to which the block belongs and block No. is added to each block. The reproduced video signals undergo processing, such as error detection and error correction, on a block by block basis. Blocks free from error are written into addresses of the memory corresponding to the ID signals.
Only blocks of the reproduced video signals free from error are thus stored into the memory. Therefore, slow images reproduced and displayed on the basis of image signals read out from this memory become favorable.
By taking slow reproduction with a quarter speed as an example, such slow reproduction of a digital VTR using a frame memory will now be described concretely with reference to FIGS. 3 and 4. However, it is now assumed that each field of the image signals is so recorded on the magnetic tape as to be divided into two tracks. Therefore, image signals of half a field are recorded onto each track. Such a recording apparatus and method is referred to as a two-segment recording apparatus and method. The recording interval of each field is equivalent to an interval during which a rotary drum having a head mounted thereon makes two revolutions.
FIG. 3 shows a track pattern on a magnetic tape in a digital VTR and scanning trace of the reproduction head at the time of slow reproduction.
Assuming now in FIG. 3 that a certain frame of image signals (hereafter referred to as a frame of interest) is frame 0, its immediately preceding frame is referred to as the preceding frame and is represented as frame (-1), whereas its immediately succeeding frame is referred to as the succeeding frame and is represented as frame 1. Further, one frame comprises two fields. The preceding one of the two fields is referred to as field 0, and the succeeding one of the two fields is referred to as field 1.
Image signals of the preceding frame (-1) are recorded beforehand onto tracks T -1 (0. 1) to T -1 (1. 2). The former half of the field 0 of that frame is recorded beforehand onto the track T -1 (0. 1). Its latter half is recorded beforehand onto track T -1 (0. 2). The former half of field 1 of that frame is recorded beforehand onto track T -1 (1. 1), whereas its latter half is recorded beforehand onto track T -1 (1. 2). In the same way, image signals of frame 0 of interest are recorded beforehand onto four tracks T 0 (0. 1) to T 0 (1 2). Field 0 of the frame 0 is recorded beforehand onto two preceding tracks T 0 (0. 1) and T 0 (0. 2), and field 1 of the frame 0 is recorded beforehand onto two succeeding tracks T 0 (1. 1) and T 0 (1. 2). Further, the former half of field 0 of the succeeding frame 1 is recorded beforehand onto track T 1 (0. 1).
In case of slow reproduction, the traveling speed of magnetic tape is different from that of normal recording on reproduction, as described above. Accordingly, the scanning trace of the reproduction head is inclined with respect to the recorded tracks. In some cases, therefore, the scanning trace extends over two adjacent tracks.
FIG. 3 shows scanning traces S 1 , S 3 , S 5 , S 7 and S 9 obtained in slow reproduction with a quarter speed when the reproduction head scans the tracks T 0 (0. 1) to T 0 (1. 2) having image signals of the frame 0 of interest recorded thereon. The scanning trace S 1 is a scanning trace for the frame 0 of interest in the first revolution of the rotary drum. The scanning traces S 3 , S 5 and S 7 are scanning traces respectively in the third, fifth and seventh revolutions. Scanning traces in even-numbered revolutions are omitted for the sake of clarity.
It is now assumed that magnetic tape 16 travels at a speed equivalent to a quarter of that of normal reproduction in a direction indicated by an arrow A. In reproduction of image signals of this frame 0 of interest, the former half of the scanning trace S 1 caused by the first revolution of the rotary drum lies upon the track T 0 (0. 1) whereas the latter half of the scanning trace S 1 lies upon the track T -1 (1. 2). As the second revolution, the third revolution and so on are made, the scanning trace moves successively to the upper right on the magnetic tape 16 as represented by S 3 , S 5 , S 7 , S 9 , --- as a result of traveling of the magnetic tape 16 in the direction indicated by the arrow A. In the first revolution of the rotary drum, therefore, the track T 0 (0. 1) of the frame 0 of interest and a shaded region of the last track T -1 (1. 2) of the preceding frame (-1) are scanned for reproduction. As the second revolution and then the third revolution are made thereafter, a portion of the track T -1 (1. 2) reproduced and scanned successively decreases. In the fourth revolution, the track T -1 (1. 2) is not scanned for reproduction. Instead, the tracks T 0 (0. 1) and T 0 (0. 2) are scanned for reproduction. Further, commencing with the eighth revolution, the track T 0 (1. 1) having the former half of the preceding field 0 in the frame 0 of interest recorded thereon is scanned for reproduction. Sixteen revolutions of the rotary drum results in reproduction of one frame.
In the former half of the scanning trace S 1 , therefore, image signals are reproduced from the track T 0 (0. 1). In the latter half of the scanning trace S 1 , image signals are reproduced from the track T -1 (1. 2). As the scanning trace advances from S 1 successively to S 2 , S 3 and so on, however, the interval during which image signals are reproduced from the track T -1 (1. 2) becomes shorter. Commencing with scanning trace S 4 , the track T 0 (0. 2) is scanned for reproduction instead. In the scanning traces S 1 to S 4 , the whole of the track T 0 (0. 1) is scanned for reproduction. In scanning traces S 5 to S 8 , the whole of the track T 0 (0. 2) is scanned for reproduction. Commencing with the scanning trace S 8 , the track T 0 (1 1) is scanned for reproduction.
In case of slow reproduction with a quarter speed, image signals of one field are thus reproduced by performing scanning for reproduction eight times. Image signals of one frame are reproduced by performing scanning for reproduction sixteen times.
With regard to slow reproduction shown in FIG. 3, writing digital reproduced image signals into the frame memory will now be described by referring to FIGS. 4A to 4E.
FIGS. 4A to 4E show storage contents of the frame memory obtained when the rotary drum has made an odd number of revolutions. In order to indicate from which track shown in FIG. 3 the storage contents have been reproduced, each of the storage contents is provided with a call out given to each track of FIG. 3.
In the frame memory, storage areas of fields 0 and 1 are predetermined. In each field, blocks reproduced from the magnetic tape 16 are stored into their pertinent storage areas in order of reproduction. The storage areas respectively allocated in the frame memory to the fields 0 and 1 are referred to as field 0 storage area and field 1 storage area, respectively.
First of all, the scanning trace which immediately precedes the scanning trace S 1 shown in FIG. 3 and which is not illustrated will now be described. Although not illustrated in FIGS. 4A to 4E, image signals reproduced from the track T -1 (0. 1) are stored into former half of the field 0 storage area of the frame memory, and image signals reproduced from the track T -1 (0. 2) are stored into latter half of the field 0 storage area. Image signals reproduced from the track T -1 (1. 1) are stored into former half of the field 1 storage area, and image signals reproduced from the track T -1 (1. 2) are stored into latter half of the field 1 storage area.
Under such a storage state in the frame memory, the first revolution of the rotary drum in the frame 0 of interest causing the scanning trace S 1 is started. In the nearly former half of the track T 0 (0 1), signal reproduction is thus performed. As shown in FIG. 4A, the resultant image signals are written into an area nearly equivalent to a quarter of the field 0 storage area in the frame memory beginning with the start address of the field 0 storage area. In nearly the latter half of the scanning trace S 1 , signals are reproduced from nearly the latter half (shaded portion) of the track T -1 (1. 2). As shown in FIG. 4A, the resultant reproduced video signals are written into the last portion of the field 1 storage area in the frame memory nearly occupying a quarter of the field 1 storage area. In this portion, image signals having the same contents as those of image signals already stored are written. As a result, its storage contents are not changed.
If with reference to FIG. 3 reproduction scanning along the scanning traces S 2 (not illustrated) and S 3 is performed by the second revolution and the third revolution of the rotary drum, the reproduction area of the track T 0 (0. 1) expands. In the frame memory as well, the storage area of image signals reproduced from the track T 0 (0. 1) expands in the former half of the field 0 storage area as shown in FIG. 4B. Consequently, the reproduction area of the track T -1 (1. 2) of the preceding frame (-1) decreases. The above described writing range in the field 1 storage area of the frame memory decreases.
In the same way, the track T 0 (0. 2) also begins to be scanned for reproduction as a result of travel of the magnetic tape 16. In the fifth revolution of the rotary drum, image signals reproduced from the whole of the track T 0 (0. 1) are stored into the former half of the field 0 storage area in the frame memory, and image signals reproduced from the former half of the track T 0 (0. 2) are stored into an area occupying nearly a quarter of the latter half of the field storage area as shown in FIG. 4C. In the seventh revolution of the rotary drum, the reproduction area in the track T 0 (0 2) expands, and the storage area of image signals reproduced from this track T 0 (0. 2) thus expands in the field 0 storage area of the frame memory as shown in FIG. 4D. In the eighth and ninth revolutions of the rotary drum, image signals reproduced from the whole of the tracks T 0 (0. 1) and T 0 (0. 2) are written into the field 0 storage area of the frame memory, and image signals of the field 1 reproduced from the track T 0 (1. 1) are written into the field 1 storage area of the frame memory as shown in FIG. 4E.
The write address of the reproduced image signals in the frame memory is specified on the basis of the ID signal added to each block.
In the frame memory, the writing operation heretofore described is performed. While this writing operation is performed, however, a reading operation is performed repeatedly.
Reading from the memory is performed alternately in the field 0 storage area and the field 1 storage area. Such slow reproduction image signals in which one frame comprises field 0 and field 1 are thus obtained.
As described above, the interval of two revolutions of the rotary drum is equivalent to one field interval. Therefore, the interval of four revolutions of the rotary drum is equivalent to one frame interval of image signals. In the frame memory in which a writing operation is conducted as shown in FIGS. 4A to 4E, therefore, the rewriting interval of reproduced image signals corresponding to one frame is equivalent to an interval during which the rotary drum makes sixteen revolutions, in case of slow reproduction with a quarter speed. During this interval, therefore, readout of the frame memory is repeated four (=16÷4) times and hence image signals of four frames are obtained. That is to say, in an interval during which image signals of one frame are reproduced from the magnetic tape 16, image signals of four frames are obtained from the frame memory, resulting in slow reproduction with a quarter speed.
In some cases of the above described slow reproduction, however, image signals of another frame are simultaneously and mixedly reproduced. If a change is caused in such cases between frames of image signals representing a moving picture by a moving portion of the moving picture, blurring appears in the reproduced images.
It is now assumed that a certain frame begins to be read out in the storage state shown in FIG. 4A from the frame memory into which image signals have been written, as shown in FIGS. 4a to 4E. Image signals of one frame are then read out in the interval of four revolutions of the rotary drum. In the storage state shown in FIG. 4C, therefore, a subsequent frame begins to be read out. In the storage state shown in FIG. 4E, a further subsequent frame begins to be read out.
As for the interval of eight revolutions of the rotary drum shown in FIGS. 4A to 4D, the however, writing operation to the field 0 storage area of the frame memory is conducted in the interval of the first to third revolutions of the rotary drum. In image signals of the field 0 obtained by readout in this interval, field 0 of the frame 0 of interest reproduced from the magnetic tape 16 and field 0 of the preceding frame (-1) which precedes it by one frame are mixedly present. That is to say, if readout of a certain frame is started in the storage state of FIG. 4A and readout of a subsequent frame is started in the storage state of FIG. 4C, the following operation results. In the storage state of FIG. 4a, image signals reproduced from the track T -1 (0. 1) of the preceding frame (-1) shown in FIG. 3 are mixed into field 0 of image signals read out from the field 0 storage area of the frame memory. In the storage state of FIG. 4C, however, image signals reproduced from the track T 0 (0. 1) of the frame 0 of interest are present on the area, in which image signals reproduced from this track T -1 (0. 1) of the frame memory were stored before, as a result of a rewriting operation.
Assuming now with regard to slow-reproduction images that images reproduced from the track T -1 (0. 1) are displayed in field 0 of a certain frame interval of image signals obtained from the frame memory, images reproduced from the track T 0 (0. 1) are displayed in the same location as that of the foregoing description in the field 0 of a subsequent frame interval.
There is a time lag equivalent to one frame interval (which is 1/30 second in case of an apparatus and a method of NTSC type) between image contents recorded on the track T -1 (0. 1) and image contents recorded on the track T 0 (0. 1). If a moving portion of image causing a lag is included in these image contents, therefore, discrepancy in position and size between images of successive frames displayed on an identical location of the slow-reproduction screen is caused, resulting in blurring. In general, favorable slow-reproduction images are obtained in case of slow reproduction with 1/n times speed (where n is an integer not less than 2) by repeating a frame having identical image contents n times. In the above described case, however, image contents change while the frame is being repeated n times. Discrepancy in position and size is thus caused in displayed images, resulting in blurring.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a digital image reproduction apparatus, and method, solving the above described problems and being capable of preventing blurring in reproduced images and improving the image quality in slow reproduction of a digital VTR.
In order to achieve the above described object, an apparatus according to the present invention comprises a memory having a first storage area corresponding to alternate fields or frames of digital image signals recorded on magnetic tape and a second storage area corresponding to remaining alternate fields or frames, first means for discriminating a field or frame to which signals reproduced from the magnetic tape belongs, second means for selecting either of the alternate fields or frames and the remaining alternate fields or frames on the basis of the discrimination result of the first means, and third means for writing only the reproduced signals belonging to the selected fields or frames into a specified writing area of the memory.
Further, in accordance with the present invention, a storage area, which is included in the first and second storage areas of the above described memory and which is not specified as the writing area by the third means, is used as a reading area.
Since the writing area of the memory is specified by the third means, it has been made clear which of the first and second storage areas of the memory is the writing area. In addition, only reproduced signals belonging to the same field or frame are written into the first or second storage area specified as the writing area. A writing area specification change from the first storage area to the second storage area or from the second storage area to the first storage area is made when reproduced signals corresponding to one field or one frame are written into the above described writing area. Into the first or second storage area, therefore, reproduced image signals of one field or one frame belonging to the same field or frame are written.
In case of reproduction in which the magnetic tape travels at a speed different from that of the recording operation, reproduction scanning is performed over a plurality of tracks. In an interval during which image signals of one field or one frame are reproduced from the above described magnetic tape, therefore, reproduced signals belonging to different fields or frames are mixedly present. In accordance with the present invention, however, only reproduced signals belonging to the selected predetermined field or frame are selected and written into only either of the first and second storage areas of the memory.
Further, it is apparent which of the first and second storage areas of the memory is the writing area as described above. In addition, reproduced image signals of one field or one frame are completely stored in the first or second storage area which is not the writing area. By using this storage area as the reading area, therefore, image signals read out from the memory comprise in the field interval or frame interval, reproduced signals belonging to an identical field or frame on the magnetic tape. It is thus possible to obtain digital image signals which do not cause blurring in the reproduced image. The reading area in the memory can also the specified correctly.
When magnetic tape travels at a speed different from that of the recording operation, the present invention heretofore described makes it possible to write only reproduced signals belonging to a predetermined field or frame selected from the magnetic tape into a memory and write the above described reproduced signals into a storage area of the above described memory corresponding to the above described predetermined field or frame. Into the above described one storage area, the reproduced signals belonging to an identical field or frame are stored. Further, since it is made clear which storage area of the memory is in the writing state, readout can be performed in a storage area for which a writing operation has been surely finished. In each field interval or each frame interval, image signals comprising reproduced signals belonging to an identical field or frame are thus obtained. In this way, it is possible to completely prevent blurring in reproduced images.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of a digital image reproduction apparatus, and method, according to the present invention;
FIGS. 2A to 2D are time charts showing the operation of the embodiment shown in FIG. 1;
FIG. 3 is a schematic diagram showing a track pattern on magnetic tape in a digital VTR and scanning traces in slow reproduction thereof; and
FIGS. 4A to 4E are diagrams showing a temporal change of state of writing signals reproduced from the magnetic tape of FIG. 3 into a frame memory.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will hereafter be described by referring to drawings.
FIG. 1 is a block diagram showing an embodiment of a digital image reproduction apparatus, and method, according to the present invention. Numerals 1 to 5 denote input terminals. Numeral 6 denotes a frame memory, numeral 7 a write address generator, numeral 8 a write control circuit, numeral 9 a field discrimination circuit, numeral 10 a field sorting counter, numeral 11 a write control counter, numeral 12 an exclusive OR counter circuit, numeral 13 a NAND gate, numeral 14 a read address generator, and numeral 15 an output terminal.
With reference to FIG. 1, an image signal S, which has been obtained by applying reproduction processing, such as error detection and correction, to a signal reproduced as shown in FIG. 3, is inputted to the input terminal 1 and supplied to the frame memory 6. Further, this image signal S is divided into blocks (such as horizontal intervals). Each block undergoes error detection and correction, and a field ID is added to each block. Whenever a block which has not undergone error correction is inputted to the input terminal 1, an error flag EF representing this fact is inputted to the input terminal 2. A field ID separated from the reproduced image signal S is inputted to the input terminal 3. The error flag EF is supplied from the input terminal 2 to the write control circuit 8. A write permission signal a generated by the write control circuit 8 becomes "L" (low level) in an interval during which an uncorrectably erroneous block is inputted from the input terminal 1, whereas the write permission signal a becomes "H" (high level) in an interval during which a block free from error or a block which has undergone error correction is inputted from the input terminal 1. This write permission signal a is supplied to the NAND gate 13. When the write permission signal a is "L", the output of the NAND gate 13 is fixed to "H". When this write permission signal a is "H", the NAND gate 13 outputs a chip select signal b which is obtained by applying level inversion to a write gate signal d outputted from the exclusive OR circuit 12.
When an uncorrectably erroneous block is inputted from the input terminal 1, therefore, the error flag EF is inputted from the input terminal 2 and the chip select signal b outputted from the NAND gate 13 is fixed to "H", the frame memory 6 being brought into the write inhibit mode. As a result, only blocks free from error supplied from the input terminal 1 are written into the frame memory 6.
An ID signal including the field ID inputted from the input terminal 3 is supplied to the write address generator 7. A write address Aw indicating the storage location of each block inputted from the input terminal 1 on the frame memory 6 is thus generated.
Further, the field ID contained in the ID signal inputted from the input terminal 3 is supplied to the field discrimination circuit 9. It is thus judged which of fields 0 and 1 the block inputted from the input terminal 1 belongs to. A field flag c representing the result of this judgment is generated. FIG. 2A shows an example of this field flag c. The level "H" indicates field 0 and the level "L" indicates field 1. This field flag c is supplied to the exclusive OR circuit 12 and the field sorting counter 10.
In the field sorting counter 10, field flags c are sorted by field interval of the reproduced image signal S inputted from the input terminal 1. For each field interval of sorting, field flags c of fields 0 and 1 are counted, respectively. Field count data e representing counts of fields 0 and 1 are generated and supplied to the write control counter 11.
On the basis of the field count data e, the write control counter 11 generates a write field selection signal f and a read field selection signal g which is related by level inversion to the signal f. In response to this write field selection signal f, the block of one of the fields 0 and 1 supplied from the input terminal 1 having a larger number of field flags is written into the frame memory 6 in each field interval.
FIG. 2B schematically shows field count data e in each field interval with respect to the field flag c shown in FIG. 2A. For brevity of description, it is now assumed that the number of field flags c (i.e., the number of blocks) per field interval is 10. It is a matter of course that this number varies depending upon the reproduction tape speed.
Assuming now that the number of field flags c representing field 0 in a certain field interval is 6 and the number of field flags c representing field 1 in that field interval is 4, the write control counter 11 generates the write field selection signal f in this field interval to write only a block included in blocks supplied from the input terminal 1 and belonging to field 0 into the frame memory 6.
Operation of generating the write field selection signal f in the write control counter 11 will hereafter be described.
In case of slow reproduction, the numbers of field flags of fields 0 and 1 in each field interval are not constant. As shown in FIG. 2B, gradual increase and gradual decrease are repeated with the lapse of field intervals. As for field 0, the number of field flags decreases from 6 successively to 5, 3 and 1. Subsequently, the number of field flags increases from 1 successively to 4, 6 and 9. Further, the number of field flags decreases from 9 to 7. On the contrary, the number of field flags of field 1 first increases, then decreases and then increases. This change is uniquely defined by the reproduction tape speed.
Since the direction of change in the number of field flags c of field 0 differs from that of field 1, superiority of one of fields 0 and 1 over the other in the number of field flags c is inverted only once without fail in an interval having a fixed change direction. In addition, the repetitive period of change in the number of field flags c of fields 0 and 1 is uniquely defined if the reproduction tape speed is defined. Therefore, the time when the superiority relationship in the number of field flags is inverted (hereafter referred to as the inversion point) is spaced from the time when the number of field flags c of fields 0 and 1 changes from the decreasing direction to the increasing direction or vice versa (hereafter referred to as the change point) by a fixed number of fields depending upon the reproduction tape speed. In case of slow reproduction with a quarter speed, an inversion point is two fields behind a change point.
The write control counter 11 generates the write field selection signal f which is inverted in level at this inversion point. In the write control counter 11, therefore, it is judged on the basis of the field count data e whether the number of field flags c of either of fields 0 and 1 (such as field 0) is in the increase direction or in the decrease direction. Change points in the direction are thus detected. This judgment between the increase direction and the decrease direction can be formed by comparing the numbers of field flags c in two consecutive field intervals. A point of time at which as many fields as determined by the reproduction tape speed have progressed from the change point is defined as an inversion point. The write field selection signal f which is inverted in level at this point of time is generated. In case of slow reproduction with a quarter speed, a point of time at which two field intervals have elapsed from this change point is defined as the inversion point. This time from the change point to the inversion point is set by tape speed information V T supplied from the input terminal 4. The point of time of level inversion of the write field selection signal f is set at a boundary between field intervals by a field clock CPF supplied from the input terminal 4.
FIG. 2C shows the write field selection signal f. In the same way as the field flag c of FIG. 2A, "H" represents the writing operation of a block of field 0 whereas "L" represents the writing operation of a block of field 1. It is possible to attain the state where the level of the write field selection signal f correctly represents either of fields 0 and 1 having a larger number of field flags c by comparing the number of field flags c of field 0 with that of field 1 at each change point and amending the level of the write field selection signal f if the level is erroneous on the basis of the result of comparison.
As heretofore described, the point of time of level inversion of the write field selection signal f is predicted on the basis of the change point. Despite the fact that the reproduced image signal S, the error flag EF and the ID signal are inputted at the same time, respectively, at the input terminals 1, 2 and 3, and the number of field flags counted by the field sorting counter 10 in each field interval is processed by the write control counter 11, therefore, it is possible to decide at the time of block input whether a block inputted from the input terminal 1 should be written into the frame memory 6 or not.
Together with the field flag c supplied from the field discrimination circuit 9, the write field selection signal f outputted from the write control counter 11 is supplied to the exclusive OR circuit 12. The write gate signal d outputted from this exclusive OR circuit 12 becomes "H" when the write field selection signal f and the field flag c are at identical levels. The write gate signal d becomes "L" when the write field selection signal f and the field flag c are at different levels. When the write permission signal a supplied from the write control circuit 8 is "H", the write gate signal d is inverted in level by the NAND gate 13 and it is supplied to the frame memory 6 as the chip select signal b.
When this select signal b is "L", a block inputted from the input terminal 1 is written into an address of the frame memory 6, which is specified by the write address signal Aw supplied from the write address generator 7.
When the write field selection signal f is "H" to specify field 0 and the field flag c is "H", therefore, the chip select signal b becomes "L" and only blocks included in blocks inputted from the input terminal 1 and belonging to field 0 are written into the frame memory 6. Further, when the write field selection signal f is "L" to specify the field 1 and the field flag c is "L", the chip select signal b becomes "L" and only blocks inputted from the input terminal 1 and belonging to field 1 are written into the frame memory 6.
As described before, the frame memory 6 comprises the field 0 storage area to which blocks of field 0 are written and the field 1 storage area to which blocks of field 1 are written. In case a block supplied from the input terminal 1 is a block of field 0, the write address generator 7 generates a write address signal Aw specifying the pertinent address of the field 0 storage area of the frame memory 6 on the basis of the field ID supplied from the input terminal 3. In case the input block is a block of field 1, the write address generator 7 generates a write address signal Aw specifying the pertinent address of the field 1 storage area of the frame memory 6.
Further, the write control counter 11 generates the read selection signal g which is related to the write field selection signal f by identical timing and level inversion. The read address generator 14 is supplied with the read clock CPR and a clear signal CR from the input terminal 5 and generates a read address signal Ar. In response to the read field selection signal g, the read address signal Ar specifies an address of either of the field 0 storage area and the field 1 storage area included in the frame memory 6.
That is to say, when the write field selection signal f specifies field 0, the read field selection signal g makes the read address generator 14 generate a read address signal Ar specifying addresses of the field 1 storage area of the frame memory 6 in order. When the write field selection signal f specifies field 1, the read field selection signal g makes the read address generator 14 generate a read address signal Ar specifying address of the field 0 storage area of the frame memory in order.
FIG. 2D shows the read field selection signal g. When this read field selection signal g is "H", the read address generator 14 generates a read address signal Ar of the field 0 storage area of the frame memory 6. When the read field selection signal g is "L", the read address generator 14 generates a read address signal Ar of the field 1 storage area of the frame memory 6.
When a writing operation is being conducted in the field 0 storage area of the frame memory 6, the reading operation is repeatedly conducted in the field 1 storage area. Further, when a writing operation is being conducted in the field 1 storage area, the reading operation is repeatedly conducted in the field 0 storage area. Since the write field selection signal f changes the specification of field 0 and 1 storage areas in the frame memory 6 at inversion points where superiority of one of the fields 0 and 1 over the other in the number of field flags is inverted, only blocks of field 0 or field 1 of the same frame are written into the field 0 storage area or the field 1 storage area of the frame memory 6 which is not selected by the write field selection signal f. When contents of this area are repeatedly read out, therefore, blurring is not caused in reproduced images.
The foregoing will now be described by referring to FIGS. 3 and 4. From the scanning trace S 1 , the scanning intervals of the tracks T 0 (0. 1) and T 0 (0. 2) become longer. Therefore, the write field selection signal f selects the field 0 storage area of the frame memory. In a succeeding interval during which the rotary drum makes eight revolutions, the writing operation is conducted in this field 0 storage area. During this time, the read field selection signal g selects the field 1 storage area, and the reading operation is repeatedly conducted in this storage area. When the rotating drum begins to make the ninth revolution, the writing operation is conducted in the field 1 storage area, on the contrary, and a repetitive reading operation in the field 0 storage area is started.
Although an embodiment of the present invention has heretofore been described, the present invention is not limited to this embodiment alone.
For example, in the above described embodiment, the field sorting counter 10 counts field flags every field. However, the field sorting counter 10 may count field flags every arbitrary interval such as every frame. It is a matter of course that a memory having an optimum capacity according to this count interval is used instead of the frame memory.
Further, although the write field selection signal f and the read field selection signal g are formed by decision by majority in the number of field flags in each field interval, another method such as a method whereby the writing operation is not conducted at all during a change in accordance with the mixture ratio of the field flags of a certain specific field may also be used. | The present invention includes reproducing digital image signals recorded on magnetic tape, discriminating a field or frame whereto the signals reproduced from the magnetic tape belong, selecting either of alternate fields or frames of the digital image signals and remaining alternate fields or frames on the basis of result of the discrimination, and writing only the reproduced signals belonging to the selected fields or frames into a specified writing area of the memory. | 7 |
This application is a continuation of application Ser. No. 613,411, filed May 24, 1984, now abandoned.
BACKGROUND
The lamination of thermoplastic films to substrates such as woven fabric is well known. The film provides a protective surface over the fabric, imparts water resistance, weatherability resistance, and the like.
Ordinarily the film is heated until it softens whereupon, in its softened state, it adheres to the fibers in the fabric or to an adhesive coating on the fibers to form a bonded laminate. A disadvantage however occurs in that when the film is heated to the softening point, it sags into the weave interstices and forms an uneven layer over the woven fabric. This is disadvantageous for products where a smooth surface or high light transmission is desirable, and it is disadvantageous for other products where good reflectability of light is desired.
It would be desirable to provide a process for bonding thermoplastic film to woven fabric whereby the film will not sag into the interstices of the woven fabric, yet will result in a strong bond at the points of film-fiber contact.
This invention provides such a process.
SUMMARY OF THE INVENTION
Specifically, this invention provides a process for laminating a thermoplastic film to woven fabric in which the fabric fibers are infrared wave-length absorbing, or are covered with infrared wave-length absorbing material which comprises
a. positioning thermoplastic film which transmits infrared radiation without being substantially heated thereby over and in contact with said woven fabric,
b. subjecting the positioned film and fabric composition to infrared radiation from a radiation source in a manner which maintains the film between the fabric and the radiation source,
c. maintaining the radiation provided in step b until the fibers, or the coating on the fibers, as the case may be, soften at a temperature between the softening temperature of the thermoplastic film and the heat distortion temperature of the film,
d. cooling the film-woven fabric composition while maintaining said contact.
By heating the fibers, or the coating on the fibers, which fibers or coating have a high heat distortion temperature and absorb infrared radiation, and not the film which transmits infrared radiation, the film softens only in those areas in contact with the heated fibers or coating. The softened area then bonds to the fibers or coating. The localized selective heating of only these areas of the film that contact the fibers or coating results in a film surface over the fabric that maintains its integrity, i.e., the film, because it is not heated to its softening point at any other portions, does not sag into the interstices of the weave of the glass fibers. Nor, if it is an oriented film, does it become unoriented in those other portions.
Preferably, the film will be a melt-extrudable tetrafluoroethylene copolymer, and most preferably a transparent one (to provide good light transmission). An advantageous copolymer of this type is a copolymer of 80% to 95% by weight tetrafluoroethylene and 5-20% by weight hexafluoropropylene, which may contain minor amounts of other polymerizable comonomers, these may be prepared as described in Bro et al., U.S. Pat. No. 2,946,763.
Preferably also the woven fabric will have an open weave, as opposed to a tight or closely woven weave, and most preferably will be a glass fabric.
The laminates are useful in applications where fabric protected by the film is used as a roofing or window material.
DETAILED DESCRIPTION OF THE INVENTION
Any woven fabric made from fibers may be used so long as the fiber is constituted to withstand deformation by heat at the distortion temperature of the copolymer used in the film, and so long as the fiber absorbs infrared radiation and becomes heated as a result of such absorption. A preferred fabric is glass fabric, other fabrics include polyesters, polyimides, aramids, and the like.
The thermoplastic film can be any thermoplastic film so long as it is essentially transparent to, i.e., pervious to or unaffected by, infrared radiation and does not become substantially heated upon being subjected to infrared radiation. Vinyl and condensation polymers can be used, such as polyethylene, polyethylene terephthalate, polyvinyl fluoride, polychlorotrifluoroalkylene and the like. Preferably, the film will be a melt-processible copolymer of tetrafluoroethylene and an ethylenically unsaturated fluorinated comonomer, such as, a perfluoroalkyl trifluoroethylene, perfluoroalkoxy trifluoroethylene or perfluoroalkyl ethylene. The copolymers ordinarily have melt viscosities below 10 poise as measured in U.S. Pat. No. 4,380,018, Khan et al. at column 4, lines 38-52. The film may be an oriented film or an as cast film.
A high temperature heat source of 400° F.-6000° F. (204° C.-3316° C.) and/or a peak electromagnetic wavelength of between 0.25 to 10 m may be used as the infrared source. The exact peak range desired will depend on the film. For example, for tetrafluoroethylene/hexafluoropropylene copolymers the peak range should be 0.6 to 3.7 m. Unwanted wavelengths may be filtered out. For most films, infrared laser systems and/or thermal radiation high temperature radiant heaters can be used, as well as any other efficient source which will emit a narrow range of wavelengths that are highly transmitted through the film and are absorbed by the woven fabric.
Several means can be used to maintain the film in contact with the fabric. For example, a vacuum can be applied to one side of the film/fabric construction, or pressure, as from a transparent fluid such as air, can be used. Additionally the pressure induced from the tension of the film on the outer layer of a lamination roll can be used. Use of tension avoids wrinkles in the film.
External cooling may be used to control the temperature of the film. This keeps the heated portions of the film localized to the contact points with the fabric. A cool transparent fluid, such as air, may be directed onto the film.
The process can be used for batch and/or continuous bonding. The process can be used for bonding as cast and oriented films. By achieving suitable bonding of film on both sides of fabric, a product having dead air space can be obtained for use as an improved thermal insulation. In the case of thin oriented films higher heating rates and shorter times are employed to achieve melt bonding with minimum loss of orientation. This can be done by preheating, the use of high flux density of focused and/or parallel radiation, by improving the surface absorptivity of the glass fabric, and by reducing heat loss due to conduction in the fabric by using a suitable coating composition for insulation at the junction surfaces. In addition the surface of the film can be cooled by a transparent fluid by convection and/or by a transparent body by conduction to control penetration and minimize loss of orientation.
The film covered fabric prepared by the process of this invention can be used in applications such as architectural constructions, e.g., roofing, in polymeric heat exchangers, in packaging, in laminations, and in electronic, automotive, or toy applications.
An advantage of the process of this invention is that films remain flat over the substrate surface without wrinkling, forming pin holes or protruding into the weave interstices.
EXAMPLES
In the Examples, the thermal radiant source used was a GE Quartz Infrared Lamp type QH 1200 T3/CL 144V having a tungsten filament as an emitter in Argon atmosphere. The emitter operated at approximately 4000° F. (2204° C.) at rated and 5400° F. (2982° C.) at twice rated voltage, with 1.1 and 0.85 m spectral energy peak respectively. Specifically, the experiments were conducted using parallel radiation source type RI 5305-5A and/or focused radiation source type RI 5193-5, where RI stands for Research Incorporated.
The film used in the Examples was a film of a copolymer of tetrafluoroethylene and hexafluoropropylene (88/12).
The fabric used in the Examples was a woven glass fabric having leno weave style 1590 (5 windows per inch) in which the fabric fibers were coated with a coating of silicone lubricant, ET-4327, polytetrafluoroethylene (Du Pont T-3313) and a topcoat of the copolymer described in the preceding paragraph.
EXAMPLE 1
Lamination was carried by placing a 5 mil cast film over and in contact with the woven glass fabric and passing the layered composite between the radiant energy source described above and an aluminum radiant energy reflector. To aid in maintaining contact between the film and fibers a vacuum was applied to the side of the composite adjacent the reflector.
Lamination of film onto one side of the coated glass fabric was made at the following conditions:
Lamp Volts: 130.
Vacuum in cm H 2 O: 2.54 cm.
Surface cooling: none.
Speed, in/min: 7.85-9.42 (0.332-0.339 cm/sec).
Two parallel radiation sources were used; which were RI 5305-5A.
Solar transmission (measured by ASTM E-424) gave a maximum of 72.5% and thermal conductivity was 0.412 W/m 2 K (about half that of glass) as measured by ASTM C177.
To test for leaks and delamination, a 7.62 cm diameter laminated fabric sample was clamped between two 1/4" (0.635 cm) neoprene gaskets such that air pressure could be applied on the fabric side. When testing for leaks due to pin holes, an ˜1/2" (1.3 cm) water layer on the film side was used to monitor for air bubbles at 36" (91.44 cm) of water pressure. When testing for delamination, the air pressure was increased to ˜35 psi (2.5 kg/cm 2 ) and the sample was examined for film fabric bond delamination. No leaks or delamination were observed.
EXAMPLE 2
Using the procedure of Example I, except adding an air surface coolant, lamination of 5 mil (0.0127 cm) cast film onto one side of the coated glass fabric was made at the following conditions:
Lamp Volts: 240.
Vacuum in cm H 2 O: 15.
Surface cooling air knife pressure psi: 20 (0.14 MPa) and down stream of source.
Speed in/min: 6 (0.254 cm/sec).
One focused radiation source RI 5193-5 was used. The sample has no pin holes at an air pressure equivalent to 36" H 2 O (91.44 cm). It began to leak at 15 psi (0.05 kg/cm 2 ) testing pressure but no delamination occurred up to 35 psi (2.46 kg/cm 2 ).
EXAMPLE 3
Using the procedure of Example 2, lamination of two 5 mil (0.0127 cm) cast films on each fabric side provided a dead air space, for thermal insulation. Lamination was made at the following conditions:
Lamp Volts: 240.
Vacuum cm H 2 O: 6-8 (15.2-20.3 cm).
Cooling air Pressure psi: 8 (0.56 kg/cm 2 ).
Speed in/min: 10-12 (5-6 cm/sec).
The infrared radiation source consisted of RI 5306-5A for pre-heating followed by RI 5193-5 for fusing.
Solar transmission (ASTM E-424) gave a maximum of 72.6% and thermal conductivity was 0.075 W/m 2 K, about 10 times lower than glass. There were no pinholes and/or delamination.
EXAMPLE 4
Lamination of single and double layer film structures were made on a continuous lamination process. In continuous lamination, a roll of the film(s) and a roll of the fabric converge and are held in contact, as the composite is passed over a reflector roll while being subjected to the radiant energy source. The conditions were as follow:
______________________________________ Single Double______________________________________Lamp Volts:RI 5305-5A 140 140RI 5193-5 240 240Cooling air pressure 0.703 0.703Kg/cm.sup.2Speed cm/sec 0.508 0.423Reflector roll temp., °C. 84° C. 84° C.______________________________________
The same film and fabric were used as before. There was no need to use vacuum to ensure contact between film and fabric. Tension of outer film on the lamination roll is suitable to achieve good bonding. There were no pinholes or delamination.
EXAMPLE 5
Using the procedure of Example 2, lamination by bonding of 5 mil (1.30 μm) oriented film (stretch ratio 3.5×) onto one side of glass fabric coated with a copolymer of tetrafluoroethylene and hexafluoropropylene (1.22 Sp.Gr.) containing 2 wt % carbon black, as in Example 4 was made at the following conditions:
______________________________________ Example Example Example 5a 5b 5c______________________________________Topcoat % carbon black 2% 5% 8%RI 5193-5 lamp volts 240 240 240Speed cm/sec 1.02 1.27 1.52Cooling air pressure 2.39 2.39 2.39Kg/cm.sup.2Vacuum in cm H.sub.2 O 50.8 50.8 50.8______________________________________
All samples had good bonding and were free of pin holes. | Lamination of film to woven fiber is achieved by localized infrared heating to heat directly onto the fibers, which in turn cause the covering film to soften and bond only in the area contacting the fibers. | 1 |
BACKGROUND OF THE INVENTION
There are many instances in the design and construction of conveying equipment and the like in which it is desirable to provide a rail system not only to guide articles being carried on a conveyor but also to prevent the articles from contacting other parts of the machinery. Such contact and rubbing could cause wear or damage both to the articles and to the parts of the machinery. This is particularly true in the food industry in which food elements are being moved along a path defined by a conveyor, but in which it is also desirable to protect against wear and at the same time to be completely sanitary. Such a system must not, of course, be capable of permitting the accumulation of food particles or bacteria. At the same time, the equipment must be capable of being cleaned with strong chemical detergents and antiseptic materials. While such systems have been developed in the past, they have lacked some necessary elements, thus rendering them less than optimum in performance. Many of the systems are very complicated and expensive. Most of them are not capable of being adapted to curved paths without the bending being accomplished on heavy machinery; this means that they were not capable of being adapted to the curved path at the installation site. These and other difficulties experienced with the prior art devices have been obviated in a novel manner by the present invention.
It is, therefore, an outstanding object of the invention to provide a guide rail system which can be readily adapted to fit a curved path at the installation site.
Another object of this invention is the provision of a guide rail which can be formed manually and without the use of heavy machinery.
A further object of the present invention is the provision of a guide rail system in which the important elements are readily replaceable in case of damage or deterioration.
It is another object of the instant invention to provide a guide rail system in which the elements are formed with materials and have surfaces which are readily maintained in a sanitary condition.
A still further object of the invention is the provision of a guide rail which can be cleaned with strong chemicals without deterioration.
It is a further object of the invention to provide a guide rail system which is simple in construction, which is inexpensive to manufacture, and which is capable of a long life of useful service with a minimum of maintenance.
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
In general, the present invention consists of a guide rail system having a bracket which is adapted to be attached adjacent a path, having a clip attached to the bracket, and having a rail supported on the clip. The rail consists of a metal core around which is formed a sheath of polymer material, the sheath having a generally cylindrical surface facing the said path.
More specifically, the rail has a cross-sectional shape consisting of a closed figure having a semi-circular portion and a straight line portion directly opposite the semi-circular portion, each end of the semi-circular portion being connected to an end of the straight line portion by a long concave curved portion and a short convex curved portion.
BRIEF DESCRIPTION OF THE DRAWINGS
The character of the invention, however, may be best understood by reference to one of the structural forms, as illustrated by the accompanying drawings, in which:
FIG. 1 is a perspective view of a guide rail system incorporating the principles of the present invention,
FIG. 2 is a front elevational view of a guide rail which is an important element of the system,
FIG. 3 is a vertical sectional view of the guide rail taken on the line III--III of FIG. 2,
FIG. 4 is a side elevational view of a bracket used in the system,
FIG. 5 is a front elevational view of the bracket, and
FIG. 6 is a perspective view of a clip used in the system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, wherein are best shown in the general features of the invention, it can be seen that the guide rail system, indicated generally by the reference numeral 10, is provided with a bracket 11 which is adapted to be mounted adjacent a path 12. The path 12 in general is intended to designate the upper horizontal surface of a conveyor, which conveyor may be of the belt type, link type, or similar construction. A clip 13 is attached to the bracket 11 and holds a rail 14. The rail consists of a metal core 15 around which is formed a sheath 16 made of a polymer material, the sheath having a generally cylindrical surface 17 which faces in the general direction of the path.
Referring to FIGS. 2 and 3, it can be seen that the guide rail 14 is substantially elongated and has a cross-sectional shape indicated in FIG. 3 as being a closed geometric figure. This figure has a semi-circular portion 18 (which defines the surface 17 mentioned above) and located directly opposite the semi-circular portion 18 is a straight line portion 19, these two portions lying on opposite sides of the core 15. The upper end of the semi-circular portion 18 is connected to the upper end of the straight line portion 19 by a long concave curved portion 21 and, a short convex curved portion 22. Similarly, the bottom end of the semi-circular portion 18 is connected to the bottom end of the straight line portion 19 by a long concave curved portion 23 and a short convex curved portion 24. In the preferred embodiment, the core 15 of the rail 14 is formed of stainless steel while the sheath 16 is formed of high-density polyethylene.
In FIGS. 4 and 5, it can be seen that the bracket 11 consists of a lower L-shaped element 27 and an upper L-shaped element 28. The two elements are held together by a clamping knob 29. The lower element 27 is provided with a slot 31 which permits it to be attached to a base element adjacent the path 12, while the upper element 28 is provided with a slot 32 which permits the clip 13 to be attached to it.
FIG. 6 shows that the clip 13 is a unitary plastic molded element having upper and lower hooks 25 and 26 which are adapted to embrace the rail 14. More specifically, the hook 25 rests on the convex curve portion 22 and extends downwardly into the concaved portion 21 while the hook 26 rests on the convex curved portion 24 and extends into the concave curve portion 23.
The operation and advantages of the present invention will now be readily understood in view of the above description. In mounting the system adjacent the path 12, a series of the brackets 11 is fastened to base elements of the machinery defining the path and a clip 13 is provided on each of the brackets with the hooks 25 and 26 extending toward the path 12. The rail 14 is then snapped into the clips. If the path is curved at any portion, it is only necessary to manually bend the rail. This is due to the fact that the core 15 is stainless steel which is a malleable metal element in addition to being strong and free of corrosion. Once the rail has been bent, it does not spring back. Furthermore, the feature of the cross-sectional shape, including the straight line portion 19, allows the rail to be readily manually bent into a long curve in which the straight line portions remain vertical and parallel to the axis of curvature. In that bent condition, it is possible to readily snap the rail into a series of clips 13. In that condition, the cylindrical surface 17 facing toward the path 12 provides a rigid guide surface which not only will not scratch articles moving along the path, but also will not itself be substantially worn by contact with such articles. In addition, the rail 14 can be readily cleaned even with very strong chemical cleaners. It can be seen that the system contains no crevices for bacteria buildup and nevertheless is strong and durable. No machine is needed when installing radius corners and bends. From its very nature, the elements of the system are inexpensive and are readily replaced in case individual parts are damaged.
It is obvious that 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. | System for guiding articles along a path, consisting of a rail with a metal core and a sheath of polymer material surrounding it, the sheath being formed to provide a generally cylindrical surface facing toward the path and to provide an opposite surface adapted to be used in clamping the rail in a selected position. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to a wire cut electric discharge machine in which an electric discharge machining operation is carried out with a machining solution applied between the wire electrode and the workpiece, and more particularly to the control of the specific resistance of the machining solution.
FIG. 3 outlines the arrangement of a conventional wire cut electric discharge machine. In FIG. 3, reference numeral 1 designates a memory for storing various data concerning a wire cut electric discharge machining operation; 2, a paper tape input/output unit for punching a paper tape and reading the data punched in a paper tape; 3, a CRT (cathode ray tube) for displaying a variety of pieces of data; 4, a keyboard for inputting data and instructions; 5, an input/output unit for transmitting data to and receiving data from a flexible disk 6 which stores data provided through the input/output unit 5; and 7, arithmetic means for processing the data which are transferred from the flexible disk 6, through the paper tape input/output unit 2, the keyboard 4 and the input/output unit 5, and executing the operations shown in FIG. 4, a flow chart (the arithmetic means 7 is hereinafter referred to as a "CPU", when applicable). The components 1 through 7 form a numerical control device.
Further in FIG. 3, reference numeral 9 designates a specific resistance detecting unit for detecting the specific resistance of a machining solution; 10, a specific resistance control unit operating to maintain the specific resistance of a machining solution constant; 11, a specific resistance meter for indicating the specific resistance of a machining solution; 12, a data transmitting bus; 15, a wire electrode; 16, wire guides for supporting the wire electrode 15; 17, a nozzle for jetting a machining solution; 19, a machining solution used for machining; 20, a filter for a machining solution; 21, a machining solution passed through the filter 20; 22, a pump for pumping the machining solution out of a machining solution vessel 24; and 30, a wire cut electric discharge machine body.
The operation of the conventional wire cut electric discharge machine thus constructed will be described with reference to the flow chart of FIG. 4.
Prior to analysis of a numerical control program (hereinafter referred to as "an NC program", when applicable) inputted by the paper tape input/output unit 2 or inputted by the input/output unit 5 using the flexible disk 6, the CPU 7 operates to initialize the memory 1 which is used to store specific resistance specifying codes (Step S41). After the initialization of the memory 1, the CPU 7 reads the NC program from the input/output unit 5 or the paper tape input/output unit 2 (Step S42), and analyzes it line by line beginning from the first line thereby to determine whether it includes an error or not, and whether it includes codes for driving the electric discharge machine body or a specific resistance specifying code (Step S43). When an error is included, the CPU displays an error message on the CRT, to suspend the analysis (Step S44). When a specific resistance specifying code is encountered, then the CPU 7 operates to store the specific resistance thus specified in the memory 1 which has been initialized in Step S41 (Step S46). The specific resistance stored in Step S46 is applied, as a signal, to the specific resistance control unit 10. Thereafter, the CPU 7 detects the specific resistance with a sensor 18 which is provided for the specific resistance control unit 10 adapted to control the filtered machining solution, and operates to cause the specific resistance meter 11 or the CRT 3 to display the specific resistance of the filtered machining solution 21 (Step S48). Then, the CPU 7 determines whether or not the NC program step has been executed (Step S49). If the execution of the NC program step has not been accomplished yet, then the next NC program step is effected; that is, the M code for driving the electric discharge machine body is utilized, and the pump 22 is driven to jet the filtered machining solution 21 to the wire electrode 15 through the nozzle 17 (Step S50).
As was described above, in the conventional wire cut electric discharge machine, the specific resistance is displayed on the CRT or the specific resistance meter; however, the CPU does not refer to the set value for specific resistance, and the electric discharge machining operation may be started before the set value is reached. In order to overcome the difficulty, the operator must confirm that the specific resistance displayed on the specific resistance meter or the CRT has reached the set value before the machining operation is started.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to eliminate the above-described difficulty accompanying a conventional wire cut electric discharge machine.
More specifically, an object of the invention is to provide a wire cut electric discharge machine in which, the CPU starts an electric discharge machining operation after confirming the specified resistance has reached a specified value, and the specific resistance can be automatically controlled.
The foregoing object and other objects of the invention has been achieved by the provision of a wire cut electric discharge machine which, according to the invention, comprises: machining solution supplying means for jetting a machining solution to a wire electrode, and collecting and filtering the machining solution; specific resistance control means for controlling the machining solution so that the specific resistance of the machining solution filtered by the machining solution supplying means reaches a reference specific resistance provided therefor; specific resistance detecting means for detecting the specific resistance of the machining solution thus filtered, to output a detection signal; memory means for storing the reference specific resistance; input means for inputting a numerical control program including a specific resistance specifying code and a machining procedure for an electric discharge machining operation; and arithmetic means for reading and analyzing the numerical control program, storing as the reference specific resistance in the memory the specific resistance obtained by analyzing the numerical control program concerning the specific resistance specifying code, and starting the processing of the numerical control program concerning the machining procedure after confirming that the specific resistance represented by the detection signal provided by the specific resistance detecting means has reached the reference specific resistance stored in the memory.
In the electric discharge machine, prior to an electric discharge machining operation, the arithmetic means, namely, a CPU operates to initialize the memory adapted to store the reference specific resistance of the machining solution, and upon reception of a numerical control program including a specific resistance specifying code and a machining procedure for the electric discharge machining operation, the CPU reads and analyzes the numerical control program line by line. In the case where the code for a specific resistance is specified, the CPU causes the memory to store the specified specific resistance, and applies the specified specific resistance to the specific resistance specifying means. Thereupon, the specific resistance control means controls the resistance of the filtered machining solution in the machining solution supplying means so that the specific resistance of the filtered machining solution reaches the specified specific resistance. On the other hand, the specific resistance detecting means detects the specific resistance of the machining solution applies it to the CPU. The CPU starts the electric discharge machining operation after ensuring that the specific resistance of the filtered machining solution has reached the specified specific resistance.
The nature, principle and utility of the invention will become more apparent from the following detailed description when read in conjunction with the accompanying drawings, in which like parts are designated by like reference numerals or characters.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an explanatory diagram showing the arrangement of one example of a wire cut electric discharge machine according to this invention;
FIG. 2 is a flow chart for a description of the operation of the electric discharge machine shown in FIG. 1;
FIG. 3 is an explanatory diagram showing the arrangement of one example of a conventional wire cut electric discharge machine; and
FIG. 4 is a flow chart for a description of the operation of the conventional wire cut electric discharge machine shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
One example of a wire cut electric discharge machine according to this invention will be described with reference to FIG. 1. As is apparent from comparison of FIG. 1 with FIG. 3, the wire cut electric discharge machine according to the invention can be obtained by adding a specific resistance specifying unit 25 to the conventional wire cut electric discharge machine shown in FIG. 3. The specific resistance specifying unit 25 is used to specify a specific resistance for a machining solution.
With the wire cut electric discharge machine thus constructed, before an electric discharge machining operation, the machining solution must be jetted through the nozzle 17 or the filtered machining solution must be stirred using the specific resistance control unit 10 until the specific resistance of the machining solution reaches a target value, because the electrolyte contained in the machining solution allows the flow of electric current, and depending on the current the specific resistance of the machining solution is changed; that is, the specific resistance affects the machining performance of the electric discharge machine.
The operation of the wire cut electric discharge machine according to the invention will be described with reference to FIG. 2, a flow chart.
Prior to the analysis of a numerical control program (hereinafter referred to as "an NC program", when applicable) provided by the paper tape input/output unit 2 or by the input/output device 5, the CPU 7 operates to initialize the memory 1 which is used to store specific resistance specifying codes according to the invention (Step S21). After the initialization of an memory 1, the CPU 7 reads the NC program from the input/output unit 5 or the paper tape input/output unit 2, which program includes a specific resistance specifying code and a processing operation (Step S22). The program is analyzed line by line beginning from the first line thereby to determine whether it includes an error and to determine whether it contains an NC code (an M code) for driving the electric discharge machine body or a specific resistance specifying code according to the invention (Step S23). When an error is included, the CPU displays an error message on the CRT, to suspend the analysis (Step S44). When a specific resistance specifying code according to the invention is encountered, then the CPU 6 operates to store the specific resistance thus specified in the memory 1 which has been initialized in Step S21 (Step S26). The specific resistance thus stored is applied, as a signal, to the specific resistance specifying unit 25 (Step S27). In response to the signal, the specific resistance control unit 10 controls the resistance of the filtered machining solution. Thereafter, the CPU 7 detects the specific resistance with the sensor 18 which is provided for the specific resistance control unit 10 adapted to control the filtered machining solution 21, and reads the specific resistance of the present filtered machining solution 21 through the specific resistance detecting unit 9 (Step S28). Then, it is determined whether or not the specific resistance of the filtered machining solution 21 has reached the specific resistance specified by comparing it with the specific resistance stored in the memory 1 in Step S26. When it has reached the specific resistance stored in the memory 1, Step S22 is effected; if not, Step S28 is repeatedly effected; that is, the specific resistance is repeatedly detected until it reaches the specific resistance stored in the memory 1 (Step S29).
When it is determined that the specific resistance of the machining solution has reached the specified specific resistance in Step S29, then the CPU 7 reads the next NC program step (Step S22), and analyzes it (Step S23). In the case of an M code, the CPU 7 operates to cause the pump 22 to pump up the filtered machining solution 21 to jet it to the wire electrode 15 through the nozzle 17, and starts an electric discharge machining operation (S31). Thereafter, it is determined whether or not the execution of the M code of the NC program has been accomplished (Step S30). When it has not been accomplished yet, the CPU 7 reads the next M code of the NC program, and analyzes it. Upon detection of the termination code, the operation is ended.
In the above-described embodiment, the specific resistance specifying unit 25 is employed to specify a specific resistance; however, it should be noted that the invention is not limited thereto or thereby. That is, the provision of the specific resistance specifying unit may be eliminated by causing the CPU to output a signal which specifies a specific resistance for the machining solution.
Furthermore, in the above-described embodiment, the specific resistance detecting unit 9 detects the specific resistance of the filtered machining solution 21 below the specific resistance control unit 10; however, the detection may be carried out before the position where the filtered machining solution 21 is jetted.
While the invention has been described with reference to the wire cut electric discharge machining operation, the technical concept of the invention may be applied to other electric discharging machining operations using a machining solution.
As was described above, in the wire cut electric discharge machine according to the invention, the specific resistance control unit 10 controls the filtered machining solution 21 in the machining solution supplying unit so that the specific resistance of the machining solution reach the reference value stored in the memory, the CPU reads the specific resistance from the specific resistance detecting unit to determine whether or not the specific resistance thus read has reached the reference value stored in the memory, and starts the electric discharge machining operation after ensuring that the specific resistance of the filtered machining solution 21 has reached the reference value. Thus, the electric discharge machining operation can be automated according to the invention. Furthermore, an electric discharge machining operation will never be started until the specific resistance of the filtered machining solution 21 reaches the reference value stored in the memory. Therefore, with the wire cut electric discharge machine of the invention, the workpiece can be machined with high accuracy. | In a wire cut electric discharge machine, a CPU stores a reference specific resistance specified for a machining solution according to a numerical control program, and causes a specific resistance control unit to control the specific resistance of the machining solution, and compares the machining solution's specific resistance thus controlled with the reference specific resistance, so that the CPU starts the electric discharge machining operation after confirming that the specific resistance has reached the reference specific resistance specified. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to actuators. More specifically, the present invention relates to control actuator systems for rolling missiles.
2. Description of Related Art
Future concepts for highly maneuverable tactical missiles require high performance airframes controlled by very high performance control actuator systems (CAS). Missile maneuvering is traditionally controlled using a cruciform arrangement of four aerodynamic control surfaces (e.g., control fins) with four actuator motors and gear trains that independently control the aerodynamic control surfaces. Conventional missile control actuator systems, however, can have very high power requirements, especially for missiles with a rolling airframe.
Rolling airframe missiles are designed to roll or rotate about their longitudinal axes at a desired rate (typically about 5 to 15 revolutions per second), usually to gain various advantages in the design of the missile control system. Small, rolling airframes, however, exacerbate CAS power density requirements, as the control fins must be driven to large amplitudes at the roll frequency of the missile to produce large maneuvers. In contrast with standard non-rolling missiles, rolling airframe missiles require constant movement of the control fins, thus expending energy throughout the flight. The required power increases linearly with roll rate and deflection angle. In order to achieve the high maneuverability desired in new missile designs, conventional control actuator systems would require power densities that are beyond those fielded in current missile systems.
Most prior approaches for reducing the power requirements of a control actuator system in a rolling missile have centered around minimizing hinge moments (due to aerodynamic loads), minimizing inertias at the control surface, and optimizing CAS design parameters. High gear ratio designs require very high CAS motor accelerations and speeds, leading to high current, high voltage motor designs. As the gear ratios are reduced, CAS motor speeds are reduced but CAS torque requirements increase as the control surfaces have more influence (inertia and hinge moments) on the CAS motor. Attempts to minimize hinge moments through hinge line placement are not always realized as the control surface center of pressure moves around with mach number. The typical solution has been to design the CAS to meet the power (torque/speed) requirements, even if excessive, and size the flight battery/power supplies accordingly.
Hence, a need exists in the art for an improved control actuator system for rolling missiles that requires less power than prior approaches.
SUMMARY OF THE INVENTION
The need in the art is addressed by the control actuator system of the present invention. The novel system includes a control surface mounted on a body and adapted to move in a first direction relative to the body, and a first mechanism for storing energy as the control surface moves in the first direction and releasing the stored energy to move the control surface in a second direction opposite the first direction. In an illustrative embodiment, the system is adapted to rotate an aerodynamic control surface of a rolling missile, and the first mechanism is a torsional spring arranged such that rotating the control surface in the first direction winds up the spring and releasing the spring causes the control surface to oscillate back and forth, alternating between the first and second directions. In a preferred embodiment, the spring has a spring constant such that the control surface oscillates at a natural frequency matching a roll rate of the missile. The system may also include a servo motor for providing an initial torque to rotate the control surface in the first direction, and for periodically adding energy to the system such that the control surface continues oscillating to a desired angle and phase.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a three-dimensional view of a rolling airframe missile designed in accordance with an illustrative embodiment of the present teachings.
FIG. 2 is a simplified diagram of a control fin and control actuator system designed in accordance with an illustrative embodiment of the present teachings.
FIG. 3 is a three-dimensional view of a control actuator system designed in accordance with an illustrative embodiment of the present teachings.
FIG. 4 is a simplified block diagram representing a control actuator system designed in accordance with an illustrative embodiment of the present teachings.
FIG. 5 is a three-dimensional view of a control actuator system for four control fins designed in accordance with an illustrative embodiment of the present teachings.
DESCRIPTION OF THE INVENTION
Illustrative embodiments and exemplary applications will now be described with reference to the accompanying drawings to disclose the advantageous teachings of the present invention.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
FIG. 1 is a three-dimensional view of a rolling airframe missile 10 designed in accordance with an illustrative embodiment of the present teachings. The missile 10 includes a missile body (or airframe) 12 and a plurality of control fins 14 for controlling the aerodynamic maneuvering of the missile 10 (four fins 14 A, 14 B, 14 C, and 14 D are shown in the illustrative embodiment of FIG. 1 ). The missile is adapted to roll about its longitudinal axis at a predetermined rate. The missile roll rate may be controlled by the missile launcher and/or by the control fins 14 or by canted tail fins 21 (the illustrative embodiment of FIG. 1 includes six tail fins 21 ).
The missile body 12 houses a seeker 16 , guidance system 18 , and a novel control actuator system 20 . The seeker 14 tracks a designated target and measures the direction to the target. The guidance system 16 uses the seeker measurements to guide the missile 10 toward the target, generating control signals that are used by the actuator system 20 to control the movement of the fins 14 . In the illustrative embodiment, the missile 10 includes four control fins 14 located in the middle of the missile 10 , spaced equally around the circumference of the missile 10 and arranged in a cross-like configuration. Each control fin 14 is controlled independently by a different actuator motor and gear train of the control actuator system 20 .
In a rolling missile, the control fins 14 are driven at the roll frequency of the missile 10 to produce a maneuver in a single plane. In a standard non-rolling missile, in order to move the missile in a particular direction, the control fins are held at a fixed deflection angle. For example, to move the missile left at an angle of 10°, the top and bottom fins 14 A and 14 C would be rotated to the left at an angle of 10° (i.e., fin 14 A rotated 10° counter-clockwise and fin 14 C rotated 10° clockwise). To perform the same maneuver in a rolling missile 10 , the control fins 12 are moved back and forth (between +10°and −10°) at the roll frequency of the missile 10 , so that when the missile 10 rolls upside-down the fins are pointed left (fin 14 A rotated 10° clockwise and fin 14 C rotated 10° counter-clockwise) and when the missile 10 rolls back to its original orientation (as depicted in FIG. 1 ) the fins are again pointing left (fin 14 A rotated 10° counter-clockwise and fin 14 C rotated 10° clockwise). Thus, for a steady state maneuver, the control fins 14 are moved in a sinusoidal motion to produce the desired airframe motion. It is the acceleration term of this sinusoidal motion that drives the power requirements of a conventional rolling missile control actuator system.
The present invention employs the idea of a spring-mass system to store energy and restore the energy back into the system, greatly reducing the overall power requirements for the CAS and CAS battery in a rolling missile. The moments of inertia of the control fin, gears, and motor act as the “mass” of this system. In accordance with the teachings of the present invention, a torsional spring is added to provide a restoring torque such that the natural frequency of the spring-mass system matches the desired roll rate of the rolling missile. The torsional spring can be attached either to the output shaft (attached to the control surface) or to an adjunct gear.
FIG. 2 is a simplified diagram of a control fin 14 and associated control actuator system 20 designed in accordance with an illustrative embodiment of the present teachings. FIG. 3 is a three-dimensional view of the actuator system 20 designed in accordance with an illustrative embodiment of the present teachings. For simplicity, FIGS. 2 and 3 show an actuator system 20 for controlling only one fin 14 . The system 20 may also be adapted to control additional fins.
The novel control actuator system 20 includes an output fin shaft 22 , servo motor 24 , gear train 26 , and spring 28 . The control fin 14 is attached to the fin shaft 22 such that when the shaft 22 rotates (about the longitudinal axis of the shaft 22 ), the fin 14 also rotates. The shaft 22 is normal to the longitudinal axis of the missile. A servo motor 24 provides a torque to rotate the shaft 22 in response to control signals from the guidance system. The gear train 26 couples the motor to the fin shaft 22 .
In accordance with the present teachings, the control actuator system 20 also includes a torsional spring 28 . One end 30 of the spring 28 is attached to the missile body 12 , or some other component of the missile 12 such that the spring end 30 is fixed and does not rotate with the shaft 22 . The other end 32 of the spring 28 is attached to the fin shaft 22 such that rotating the shaft 22 winds or unwinds the spring 28 . In the illustrative embodiment, the spring 28 is in a neutral position (no tension) when the fin 14 is in line with the missile body 12 . Rotating the fin 14 in a first direction winds the spring 28 , and rotating the fin 14 in the opposite direction unwinds the spring 28 .
The present invention takes advantage of the fact that in a rolling missile 10 , the control fins 14 move in a cyclical fashion, moving back and forth at the roll frequency of the missile 10 . In a conventional actuator system, the servo motor requires a large amount of power to constantly rotate the fins 14 back and forth in this manner. In accordance with the teachings of the present invention, a spring 28 is added to the actuator system 20 to store some of the energy used to rotate the fin 14 in the first direction. The stored energy is then released to rotate the fin 14 back in the opposite direction, causing the fin 14 to oscillate back and forth at the natural frequency of the system. By choosing a spring 28 with an appropriate spring constant, the natural frequency of the system can be made to match the roll frequency of the missile 10 .
An actuator system 20 designed in accordance with the present teachings can therefore control the fins 14 of a rolling missile 10 with reduced power requirements than prior approaches. With this actuator system 20 , it may take a little more energy from the motor 24 to rotate the fin 14 (and wind up the spring 28 ) the first time, but the fin 14 will then continue to oscillate with very little additional energy from the motor 24 (a little energy may need to be added periodically to compensate for friction). The servo motor 24 may include a feedback system adapted to measure the output angle of the fin 14 and add additional torque as needed to keep the fin 14 oscillating to the desired deflection angles.
FIG. 4 is a simplified block diagram representing a control actuator system 20 designed in accordance with an illustrative embodiment of the present teachings. The block diagram shown is a mathematical model of the system 20 , showing the signal flow from an input current I m applied to the servo motor 24 to the resultant rotational angle θ of the fin 14 (where the angle θ is measured with respect to the centerline of the missile 10 ).
In the mathematical model of FIG. 4 , a current I m is input to the motor 24 , which is represented by its motor constant K T , resulting in the motor 24 generating a torque T A . Additional torque contributions due to friction 48 (represented by the friction constant K f ) and the torsional spring 28 (represented by the spring constant K s ) are subtracted from the applied torque T A at a summing node 40 to form the total torque T m in the system. The total torque T m is applied to the overall moment of inertia J m of the system, represented by block 42 , resulting in the angular acceleration {umlaut over (θ)} of the fin 14 . The overall moment of inertia J m includes the moments of inertia of the control fin 14 , shaft 22 , gear train 26 , and motor 24 . Integration of the angular acceleration {umlaut over (θ)} at block 44 results in the rotational rate {dot over (θ)} of the fin 14 . The torque contribution due to friction 48 is a function of the rotational rate {dot over (θ)}. Integration of the rotational rate {dot over (θ)} at block 46 results in the output angle θ of the fin 14 . The torque contribution due to the spring 28 is a function of the angle θ.
The dotted line in FIG. 4 represents the addition of the torsional spring 28 in accordance with the present teachings. The system without the block 28 representing the torsional spring will be referred to as the “baseline design”. The transfer function of the system of the baseline design can be written as:
θ
I
m
Baseline
=
K
T
J
m
s
·
(
s
+
K
f
J
m
)
[
1
]
The transfer function of the system 20 with the added torsional spring 28 can be written as:
θ
I
m
Spring
=
K
T
J
m
s
2
+
K
f
J
m
s
+
K
S
J
m
[
2
]
The ratio of the motor currents in the system 20 of the present invention (with the torsional spring 28 ) relative to the baseline design can therefore be found by dividing Eqn. 2 into Eqn. 1:
θ
I
m
Baseline
θ
I
m
Spring
=
K
T
J
m
s
·
(
s
+
K
f
J
m
)
K
T
J
m
s
2
+
K
f
J
m
s
+
K
S
J
m
I
m_Sprin
g
I
m_Baseline
=
s
2
+
K
f
J
m
s
+
K
S
J
m
s
·
(
s
+
K
f
J
m
)
[
3
]
In accordance with the present teachings, the spring constant, K S , is chosen to set the natural frequency of the system 20 to the desired operating frequency of the system 20 . In the case of a rolling airframe missile 10 , the operating frequency is the roll frequency of the airframe, denoted ω roll . The natural frequency of the torsional-spring-mass system is given by:
ω
natural
=
K
S
J
m
=
ω
roll
[
4
]
With this condition set, the transfer function in Eqn. 3 can be evaluated at the operating frequency, s=jω roll , resulting in:
I
m_Spring
I
m_Baseline
s
=
j
ω
roll
=
-
K
S
J
m
+
K
f
J
m
s
+
K
S
J
m
s
·
(
s
+
K
f
J
m
)
I
m_Spring
I
m_Baseline
s
=
j
ω
roll
=
K
f
J
m
s
s
·
(
s
+
K
f
J
m
)
I
m_Spring
I
m_Baseline
s
=
jω
roll
=
K
f
J
m
j
K
S
J
m
+
K
f
J
m
[
5
]
The magnitude of the function can be taken as:
I
m_Spring
I
m_Baseline
s
=
j
ω
roll
=
K
f
J
m
j
K
S
J
m
+
K
f
J
m
=
K
f
J
m
K
S
J
m
+
(
K
f
J
m
)
2
[
6
]
The power dissipated in the servo motor 24 is proportional to the square of the motor current I m . Therefore, the ratio of power dissipated in the torsional-spring-mass design of the present invention versus the baseline design can be expressed as:
Power
Spring
Power
Baseline
=
[
K
f
J
m
K
S
J
m
+
(
K
f
J
m
)
2
]
2
Power
Spring
Power
Baseline
=
(
K
f
J
m
)
2
K
S
J
m
+
(
K
f
J
m
)
2
Power
Spring
Power
Baseline
=
1
K
S
J
m
K
f
2
+
1
[
7
]
The term K S J m /K f 2 is typically greater than one. Therefore, a torsional-spring-mass system designed in accordance with the present teachings should consume less power than the baseline system.
As a numerical example, consider a system with the following parameters:
K T =0.028Nm/A
J m =284 e −6 Nm-s 2
K f =0.0089Nm-s
ω roll =2π10rad/s
To satisfy the condition that the natural frequency of the system is equal to the roll frequency of the airframe, the spring constant K S is chosen to be:
K
S
J
m
=
ω
roll
K
S
=
J
m
·
ω
roll
2
K
S
=
(
284
ⅇ
-
6
)
·
(
2
π
·
10
)
2
Nm
/
rad
K
S
=
1.12
Nm
/
rad
Plugging these values into Eqn. 7 gives the result that the power dissipation in the actuator system 20 with the addition of the torsional spring 28 relative to the baseline design is:
Power
Spring
Power
Baseline
=
1
K
S
J
m
K
f
2
+
1
Power
Spring
Power
Baseline
=
1
(
1.12
)
(
284
ⅇ
-
6
)
0.0089
2
+
1
Power
Spring
Power
Baseline
=
0.2
Thus, in the numerical example, the addition of a torsional spring 28 (with an appropriate spring constant K S ) to the control actuator system 20 should reduce the power dissipation by 80%.
FIGS. 2-4 showed an actuator system 20 for controlling only one fin 14 . In the illustrative embodiment of FIG. 1 , the missile 10 includes four fins 14 A- 14 D. FIG. 5 is a three-dimensional view of a control actuator system 20 for four control fins designed in accordance with an illustrative embodiment of the present teachings. In this embodiment, each fin 14 A- 14 D is controlled independently by a separate actuator 20 A- 20 D, respectively. Each individual actuator 20 A- 20 D includes a servo motor 24 , gear train 26 , fin shaft 22 , and torsional spring 28 , as shown in FIGS. 2 and 3 . The actuator system 20 may also include electronics 50 for providing the drive currents I m for the servo motors 24 .
Alternatively, a single actuator (as shown in FIG. 3 ) may be used to control multiple fins simultaneously. For example, a missile having only two control fins may include two separate actuators for independently controlling the two fins, or it may include only one actuator for rotating one fin shaft that is coupled to both fins (in this embodiment, the two fins would move together in unison). Other implementations may also be used without departing from the scope of the present teachings.
Thus, the present invention has been described herein with reference to a particular embodiment for a particular application. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof. For example, while the invention has been described with reference to a rolling missile, the present teachings may also be applied to other applications such as a rocket or other air or space vehicle or projectile, a torpedo or other watercraft, or a high speed ground vehicle.
It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention. | A control actuator system. The novel system includes a control surface mounted on a body and adapted to move in a first direction relative to the body, and a first mechanism for storing energy as the control surface moves in the first direction and releasing the stored energy to move the control surface in a second direction opposite the first direction. In an illustrative embodiment, the system is adapted to rotate an aerodynamic control surface of a rolling missile, and the first mechanism is a torsional spring arranged such that rotating the control surface in the first direction winds up the spring and releasing the spring causes the control surface to oscillate back and forth, alternating between the first and second directions. In a preferred embodiment, the spring has a spring constant such that the control surface oscillates at a natural frequency matching a roll rate of the missile. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates generally to the field of fuel delivery devices, and more particularly, is directed to a system and method for effecting either automatic or manual control of a fuel delivery system for delivering a variable quantity of fuel to the engine of a power delivery apparatus.
With the present emphasis in the automotive industry toward improving fuel economy and reducing exhaust emissions, there has been much research and development directed toward providing automatic systems for controlling the operation of a motor vehicle. Some of the research and development has focussed on systems for controlling the fuel delivered to the engine of the vehicle. One such system is disclosed in U.S. Pat. No. 4,424,785, issued in the name of Ishida et al. In this system, various parameters such as the degree of movement of the accelerator pedal, air flow within the engine intake bore and throttle valve position are provided to a control unit which compares these parameters with pre-programmed values to provide an optimum throttle valve setting for the engine. Should the control unit fail, however, the throttle cannot be controlled and the vehicle can not be run. Ishida recognized this deficiency and discloses an auxiliary control unit which assumes control over the throttle when the main control unit is out of order. When the main unit malfunctions, the auxiliary unit is immediately activated. The auxiliary unit, however, provides only limited throttle control, sufficient only to drive the vehicle at low speed to a service station to effect repair of the main unit.
While the Ishida system represents an improvement over such systems known in the prior art, his system is also deficient. For example, in Ishida, the auxiliary control unit immediately assumes control of the throttle valve when the main unit malfunctions. No provisions are provided for returning the throttle valve to a predetermined position or ascertaining the position of the throttle valve so that control can be smoothly passed to the auxiliary unit. Thus, the vehicle may lurch forward or stall until the throttle valve setting matches the auxiliary control unit demand. Moreover, in the Ishida system, the auxiliary control unit provides only limited throttle operation. Thus, the vehicle may be operated only at low speeds until the main unit is repaired. Restricting the vehicle to low speed operation can be dangerous in some situations, as for example freeway driving. It can also be dangerous during routine city driving as well as traffic conditions often demand rapid acceleration. Thus, while Ishida represents an improvement over prior fuel delivery control systems, it is not the ideal system.
SUMMARY OF THE INVENTION
It is the overall object of the present invention to provide a system and method for controlling the operation of a fuel delivery system which can be switched between manual and automatic control.
It is a specific object of the present invention to provide a system and method for controlling the operation of a fuel delivery system for a vehicle which can be smoothly switched between automatic and full manual control without causing the vehicle to lurch forward or stall.
It is another specific object of the present invention to provide a system and method for controlling the operation of a fuel delivery system for a vehicle which, when under manual control, provides full operation of the vehicle.
It is a further specific object of the present invention to provide a system for controlling the operation of a fuel delivery system for a vehicle which does not impair the safety of the vehicle driver or hamper the operation of the vehicle.
The present invention relates to a system for automatically or manually controlling the operation of a fuel delivery system for a vehicle, as for example, a throttle valve. The system comprises a control unit which receives a signal indicating accelerator pedal position and a signal indicating the position of the throttle valve. These signals are processed to provide a control signal to a DC motor which automatically sets the throttle position for optimum performance of the venicle, as for example, to maintain the vehicle along its ideal operating line. The control unit also provides an output signal which controls a clutch. The clutch connects the accelerator pedal directly to the throttle valve when manual control is desired. During manual control, the vehicle driver has full control of the vehicle. Changing control from automatic to manual, however, does not occur until the throttle valve is moved either to a predetermined position or is positioned to match what is commanded by the accelerator pedal. Thus, the vehicle is prevented from lurching forward or stalling when control is shifted from automatic to manual.
In accordance with the present invention, control of the throttle valve may be selected by the vehicle driver for automatic or manual control. It is anticipated that the throttle valve will normally be controlled by the automatic control unit until the unit malfunctions or some other fault is detected. Upon a malfunction or detection of a fault, the unit can be switched to manual control either at the command of the vehicle operator or as a result of the malfunction being detected by the automatic control unit itself and effecting a switch-over to manual control.
It is also anticipated that the control system of the present invention may be used in conjunction with a system for controlling the operation of a continuously variable transmission as disclosed in applicant's pending and commonly assigned application Ser. Nos. 380,922 and 380,923 filed May 21, 1982, now U.S. Pat. Nos. 4,459,878 and 4,458,560, and which are incorporated herein by reference. At high transmission ratios, it is desirable to manually control the throttle valve position while at low transmission ratios, automatic control is preferred.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the system for controlling the fuel delivery system of an engine in accordance with the present invention.
FIG. 2 is a flow chart illustrating a computer subroutine used to generate pulses for driving a DC stepper motor in accordance with the present invention.
FIG. 3 is a flow chart illustrating a computer subroutine used for switching from automatic control to manual control in accordance with the present invention.
FIG. 4 is a flow chart illustrating a computer subroutine used for switching from manual control to automatic control in accordance with the present invention where the throttle valve is driven by a DC motor.
FIG. 5 is a flow chart illustrating a computer subroutine used for switching from manual control to automatic control in accordance with the present invention where the throttle valve is controlled by a stepper motor.
FIG. 6 illustrates an example of a logic sequencer used to drive the phase drivers for a stepper motor.
FIG. 7 illustrates the waveforms for the step input and phase outputs for the logic sequencer shown in FIG. 6.
FIG. 8 illustrates an example of another logic sequencer which may be used to drive the phase drivers for a stepper motor.
FIG. 9 is a block diagram and partial schematic showing the logic sequencer of FIG. 6 or FIG. 8 and the phase drivers for a stepper motor.
FIG. 10 is a schematic diagram of a partial control unit in accordance with the present invention and an analog converter for driving a DC motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention comprises a number of interrelated elements, all of which are shown in at least some detail in FIG. 1. With reference to FIG. 1, the system in accordance with the present invention comprises control unit 1 powered by battery 6. Control unit 1 may comprise a micro-processor or may be formed with discrete components. Battery 6 may be specifically dedicated to control unit 1 or may be the main storage battery for the host vehicle. Accelerator pedal position signal α is provided to control unit 1 from accelerator pedal 2. Signal α may be generated from potentiometer 3 forming part of a voltage divider network. Signal φ is also provided to control unit 1 and indicates the position of throttle valve 4. Signal φ may be generated by potentiometer 5 also forming part of a voltage divider network. Signals α and φ are processed by control unit 1 to provide an output signal for controlling stepper motor 7. When control unit 1 comprises a micro-processor, the signal pulses for driving stepper motor 7 may be generated by the subroutine shown in FIG. 2, as discussed below.
Stepper motor 7 is coupled to throttle valve 4 and sets throttle valve 4 to the position commanded by control unit 1. Alternatively, stepper motor 7 may be replaced by DC motor 8 which can be driven by control unit 1 through analog converter 9.
During normal operation, control unit 1 controls the operation of throttle valve 4 by issuing commands to stepper motor 7 based upon signals α and φ. When control unit 1 comprises a microprocessor, various subroutines may be used to process these signals to provide the ideal throttle setting for optimum vehicle performance, e.g., maximum fuel efficiency and minimum exhaust emissions. When manual control is desired, throttle valve 4 may be operated by accelerator pedal 2 through clutch 11. Thus, when a malfunction is detected in control unit 1 or any place in the system, throttle valve 4 may be manually operated by accelerator pedal 2. In the manual mode, full operation of the vehicle is available to the driver. Thus, the vehicle is not limited to low speed operation, as are such systems known in the prior art.
The control system in accordance with the present invention may also be used in conjunction with a continuously variable transmission. At high transmission ratios, it is desirable for the throttle valve to be directly controlled by the accelerator pedal when the vehicle is starting up. However, at low transmission ratios where the vehicle has reached operating speed, automatic control of the throttle is preferred. Thus, control unit 1 may be programmed to detect the transmission ratio in a continuously variable transmission and switch to the optimum control mode for the throttle.
Where stepper motor 7 is used to operate throttle valve 4, as opposed to DC motor 8, and control unit 1 comprises a microprocessor, the micro-processor may be programmed to generate the appropriate pulses for controlling the stepper motor. With reference to FIG. 2, a flow chart is provided which illustrates the operation of a computer subroutine which may be used to generate the appropriate pulses. During step 20, N, j and i are initialized to zero. These valves are used as counters during execution of the subroutine. In step 21, the required number of pulses is calculated and assigned to variable N s in step 22. The subroutine then proceeds to step 23 where the pulse is turned on. The subroutine then enters the wait loop shown in step 24 for the duration of the on-pulse width. The pulse is then turned off in step 25 and a second wait loop is entered in step 26. The wait loop in step 26 establishes the off-pulse width. After the wait loop in step 26 is completed, the subroutine enters step 27 where counter N is advanced to indicate that another pulse has been completed. The subroutine then enters step 28 where counter N is compared to N s which indicates the total number of pulses required. If N is less than N s , the subroutine loops back to generate another pulse. If N is equal to or greater than N s , then the subroutine is completed.
With reference to FIG. 3, the operation of switching from automatic control of throttle valve 4 to manual control by accelerator pedal 2 will be described. When it is desired to switch from automatic to manual control, clutch 11 is engaged as indicated in step 30 and the power to stepper motor 7 or DC motor 8 is removed as indicated in step 31. When the motor is deenergized, throttle valve 4 is urged toward a closed position by the action of spring 10 (see FIG. 1). Because the electrical power has been removed from the motor, its shaft, which is connected to throttle valve 4, freely turns as throttle valve 4 moves toward a closed position. Accelerator pedal position signal α is compared to throttle position signal φ in step 32. If signal α equals signal φ, the subroutine is completed and a return is executed indicating that the switch from automatic to manual control is complete. If signal α does not equal signal φ, the subroutine proceeds to step 33 where signal α is compared to zero. Zero indicates that the accelerator pedal is no longer depressed. If α does not equal zero, the subroutine loops back to step 32. However, if α equals zero, the subroutine proceeds to step 34 where clutch 11 is disengaged. The subroutine then enters the wait loop shown in step 35. The wait loop is provided to insure that throttle valve 4 returns to the closed position by the operation of spring 10 before clutch 11 is engaged in step 36, i.e., φ equals zero. The subroutine then executes a return indicating that the switch from automatic to manual control is complete.
In the above-described subroutine, switching from the automatic mode to the manual mode is not completed until the state of the fuel delivery system as indicated by φ corresponds to an actual output power or torque which is substantially equal to the desired output power or torque commanded by accelerator pedal 2 as indicated by α. This is the logic decision performed in step 32 of the subroutine. Where φ=α, i.e., φ corresponds to an actual output power or torques which is equal to the desired output power of torque commanded by α, the switch from automatic to manual is complete and the return from the subroutine in step 37 is executed. Also when α=0 in step 33, i.e., accelerator pedal 2 is not depressed or desired output power is zero, and φ=0 at the end of step 35, i.e., actual output power is zero, the switch from automatic to manual is complete and the return from the subroutine in step 37 is executed.
With reference to FIG. 4, the operation of switching from manual to automatic control when throttle valve 4 is driven by a DC motor will be described. As shown in step 40, electrical power is provided to the DC motor. The subroutine then proceeds to step 41 where clutch 11 is disengaged. The subroutine then executes the return shown in step 42 indicating that the switch from manual to automatic control is complete.
FIG. 5 illustrates a flow chart for a computer subroutine when switching from manual to automatic control where throttle valve 4 is driven by a stepper motor. As shown in step 50, clutch 11 is first disengaged. The subroutine then enters the wait loop shown in step 51 before electrical power is provided to the stepper motor in step 52.
FIG. 9 illustrates an interface which may be used between control unit 1 and stepper motor 7. The interface comprises logic sequencer 61 for receiving control signals from unit 1 and phase drivers 62-65 which drive the stepper motor. FIGS. 6 and 8 illustrate two embodiments of a logic sequencer which may comprise logic sequencer 61, and FIG. 7 illustrates the various signals associated with the logic sequencer.
FIG. 10 is a schematic diagram illustrating a simplified control unit 1 using discrete components and analog converter 9 used to drive DC motor 8.
Obviously, many modifications and variations of the abovedescribed preferred embodiments will become apparent to those skilled in the art from a reading of this disclosure. It should be realized that the invention is not limited to the particular system disclosed, but its scope is intended to be governed only by the scope of the appended claims. | What is disclosed is a system and method for effecting either automatic or manual control of a fuel delivery system for delivering a variable quantity of fuel to the engine of a power delivery system. Switching between automatic control and manual control does not occur until a smooth transition between control modes is assured. This is accomplished by ensuring that the pre-switching state of the fuel delivery means corresponds to an actual output power or torque which is substantially equal to the desired ouptut power or torque commanded by the manual control. | 5 |
The present invention concerns a novel method for mechanical disintegration of elastic materials and in particular vulcanised rubber, an intermediate composite body used in said method and the powder produced by said method.
BACKGROUND OF THE INVENTION
Both environmental and economic considerations make the reuse of materials an important issue. Different waste materials are sorted, subjected to various treatments and used as raw materials for the manufacture of new products. In many cases the properties of the waste makes it difficult to process the material into a form suitable for reuse. Such properties can be the physical properties of the waste, such as its elasticity. One example of such materials is vulcanised rubber, the material of car tyres, conveyor bands, rubber mats, etc.
Worn out tyres are associated with special problems, both regarding recycling and disposal on waste disposal or landfill sites. In addition to containing a rubber matrix comprising natural and/or synthetic rubber, modern tyres also contain carbon black, plasticizers, cross-linking agents, anti-oxidants, anti-ozone agents and other performance improving additives plus a reinforcement structure, consisting of metal wire or fibres.
In additional to taking up a great deal of space on waste disposal sites, the dumping of tyres cause several other problems as well. The shape of the tyres cause it to slowly but surely migrate up to the surface of the disposal site and thereby disrupt the degradation process. Tyres also resist degradation as they are manufactured to resist both thermal and biological degradation, as well as mechanical wear. Furthermore, tyres resist ultraviolet radiation, ozone and other oxidants, as well as water and ice. Fires is used tyre depots or waste dumps containing tyres are problematic, as they have proven to very difficult to extinguish. In addition, such fires release toxic substances both in the smoke and in the water used to extinguish the fire.
The reuse of vulcanised rubber—a large source of which is used tyres—has posed several problems, in particular how to turn rubber waste into usable raw material for new products. As a result, only a lesser amount of the rubber waste is reused and thus the main part has to be burned, used as landfill or dumped together with municipal waste. The recycling of rubber has so far been focused on relatively uncomplicated applications, such as blasting mats, as an additive in asphalt or in the production of low vibration flooring.
Sheared or shredded rubber fragments can also be used as such, for purposes as improving soil, as filling material for building work, e.g. in road construction for recreation and trotting tracts, etc. Mixing in with compost has also been suggested.
U.S. Pat. No. 4,386,182 states, that the particulate vulcanised rubber for use in manufacturing thermoplastic electrostatic compositions should have a mean particle size of below 1.5 mm. According to another document, U.S. Pat. No. 5,157,082, concerning the manufacture of a thermoplastic composition including particles of vulcanised rubber, the rubber is required to be in the form of ground, small dispersed particles essentially of 1.5 mm number average or below. It is however difficult to achieve this degree of disintegration in industrial applications. The mechanical disintegration or grinding of vulcanised rubber to a particle size of 1.5 mm and below is made very difficult by the elastic properties of the material and the considerable development of heat during the mechanical treatment. Further, the elevated temperatures increases the elasticity of the rubber.
PRIOR ART
The presently applied solution to the above problem of disintegrating an elastic material to a homogeneous and fine particle size is the so-called cryogenic method. According to this method, rubber articles or rough rubber fragments are cooled to about minus 80° C. with liquid nitrogen. At that temperature, the rubber becomes brittle and can be crushed mechanically, typically in a hammer mill. The thus produced particulate rubber is then sieved in shaking sieves and sorted in the desired particle size fractions. The rubber powder is usually sorted in fractions from about 0 to 0.2 mm until 1 to 4 mm. In practice, however, the most desired fractions i.e. those below 1.5 mm, only constitute a lesser part of the total amount of particulate rubber. The above method is further relatively cost intensive, as the processing of 1 kg rubber requires about 0.5 kg nitrogen.
Further, WO 98/20067, by the present inventor, discloses a process for production of a material composition where recycled particulate vulcanised rubber constitutes the main component. The description discloses a process and composition, characterised by the use of expandable microspheres. The expandable microspheres are added in an amount of about 2 to 30 percent per weight of the composition.
Thus there still exists a need for new methods of treating elastic waste and in particular vulcanised rubber, in order to turn it into useful raw material and make possible its efficient reuse.
SUMMARY OF THE INVENTION
The present inventor has surprisingly found, that the above problems are solved by a method according to the attached claims. In summary, the problems are overcome by first forming a composite body, consisting mainly of vulcanised rubber waste and a lesser amount of a thermoplastic material as a binder, and then subjecting this composite body to mechanical treatment. A homogeneous, fine particulate powder is produced, more easily and at a lower cost than by the prior art methods.
DESCRIPTION
The present invention concerns a method for disintegration of elastic materials. The term “disintegration” is meant to comprise any conceivable method for mechanically producing a particulate matter or powder, such as grinding. The term “elastic material ” in this context comprises all materials, the elastic properties of which make them difficult to disintegrate. The term “rubber” in this context means all vulcanised elastomer mixtures of natural or synthetic origin and is used as one example of elastic materials.
Relatively large pieces or shreds of vulcanised rubber are easily produced according to well known methods, e.g. by cutting or shredding. According to the present method, such shredded rubber is mixed with a thermoplastic material in particulate form. This mixture is then placed in a closable mould or cast and heavily compressed, preferably to about half of its original volume in order to expel possible air trapped in the mixture. The closed mould is then heated to the softening point of the thermoplastic material or to a temperature of about 150° C. to 200° C. Due to the influence of temperature and pressure, the thermoplastic material efficiently binds the rubber particles to a composite body, which retains its shape upon cooling and removing from the mould.
Importantly, the amount of rubber in the mixture can be varied according to the desired rubber content of the end product, the fine particulate rubber powder. The inventive method allows the user a high degree of liberty in choosing the composition of the mixture. Preferably the amount of rubber is the highest amount which still renders a composite body having the necessary mechanical strength. According to one embodiment of the invention, the amount of rubber is in the interval of about 50 to about 80% by weight of the total mixture, preferably about 80%. The amount of rubber is naturally dependent not only on the desired properties of the end product, but also on the binding properties achieved with the thermoplastic material and shred size used in each case. Importantly, the composition of the end product can be decided already in the selection of the raw materials (elastic material and binder), and their reciprocal amounts.
Depending on the choice of thermoplastic material and the amount of rubber, the particle size can be varied within 1.5 to 20 mm and a thickness of about 1 to 3 mm.
Preferably, the shredded rubber used in the present process is rubber having a particle size of about 5 to 10 mm and a thickness of about 3 mm. This is a frequently encountered and easily available residual product or waste, e.g. from the retreading of tyres.
The thermoplastic material sued according to the present invention is preferably chosen among the following plastics: EVA, PE, PP, EPM, an equivalent material or a mixture of any of said plastics. The thermoplastic can be either fresh or recycled, and it is used in the form of a powder or granulate. When selecting the type of thermoplastic material and its amount, consideration should be given to the intended use of the powder produced. If the powder is intended for further processing, such as die casting, compression, extrusion or injection moulding, the type and amount of thermoplastic material is naturally chosen with consideration of this further processing or end use. By proper selection of the raw material, the composition and quality of the end product is thus secured. Preferably the thermoplastic is EVA.
When the cooled composite body is removed from the mould, it can be handled as desired, e.g. stored, transported, sold, etc. before it is subjected to the mechanical treatment.
The shape of the mould and thus the composite body is chosen as to produce a body suited for further handling and in particular the mechanical treatment. Preferably the composite body has an elongate shape, e.g. a bar having a circular, rectangular or square cross section. Another shape of the composite body is a cylindrical body with the shape and dimensions of an ordinary vehicle tyre, for the purpose to fit into existing machines used in tyre retreading plants.
According to the invention, the composite body is subjected to mechanical treatment and pulverised by fast rotating cutting tools with a multitude of cutting teeth. The cutting tool can be a similar tool as those used for removing the tread surface on tyres before retreading. These frequently have saw-toothed blades or elements, attached in screw type grooves. It is obvious, that several other tools or configuration of tools can be applicable, provided that the desired particulate rubber powder is produced.
According to one embodiment of the invention, the composite body is subjected to mechanical treatment in machines specially designed for this purpose or in presently known machines, used in tyre retreading plants for removing the tread layer from used tyres, and pulverised by fast rotating cutting tools with a multitude of cutting teeth.
The particle size and the size distribution of the end product is controlled by proper choice of the tooth size of the cutting tool and the proper adjustment of the rotational speed of the cutting tool and/or the force, with which the composite body or the cutting tool are fed against each other. This has shown to be a very reliable way to control the particle size.
During the mechanical treatment, the cutting tool and/or the composite body is preferably cooled by a cooling medium, e.g. water or air.
The present process, in addition to solving the problems of the prior art methods, also opens up new possibilities. Being a considerably more cost efficient method of producing rubber powder of a homogeneous and comparatively fine particle size, the inventive method opens up for novel uses of waste rubber. The powder produced by the inventive method is easily adapted to the intended use, without further treatment or even without the subsequent addition of further components, as the properties of the product are influenced by the type and amount of thermoplastic material.
The present method is not limited to the treatment of vulcanised rubber or vulcanised rubber from car tyres or tyres from other vehicles, but also applicable to used conveyor belts, rubber mats, etc. As described earlier, the method gives the possibility to disintegrate elastic material of any origin without resorting to expensive cryothermic processing.
The powder produced by the inventive method is suitable for the production of various resilient, sound or vibration damping or heat insulting materials and in particular large volume products. A non-exhaustive list of products includes road and playground mats, sound barriers, fences or other barriers for noise control, mats for railway crossings, vibration or sound damping layer, insulating material etc. For the production of objects, where it is important that the material fills the mould cavities completely, the powder can be mixed with expandable microspheres, as described in WO 98/20067 by the sample inventor.
EXAMPLE
Rubber particles (8 kg) having a particle size of about 5 to 10 mm and thickness of about 3 mm were obtained from a retreading plant. EVA powder (2 kg) was obtained from Exxon Chemicals Co. The material was thoroughly mixed in a weight ratio of 80:20 and then compressed in a mould to removed air trapped in the mixture. The sealed mould was heated in a thermostatically controlled oven, at 150° C. for about 30 minutes. After cooling, the composite bodies were removed from the form.
The composite body was then subjected to mechanical grinding, using a conventional tool for removing the tread layer from used tyres. By adjusting the grinding parameters, a powder having a particle size of about 0.2 to 0.5 mm was produced. This powder was then used for the manufacture of sound barrier mats.
The above process was repeated using PE or polyethylene (2 kg) instead of EVA, also resulting in a highly satisfactory end product.
Although the invention has been described with regard to its preferred embodiments, which constitute the best mode presently known to the inventors it should be understood that various changes and modifications as would be obvious to one having the ordinary skill in this art may be made without departing from the scope of the invention which is set forth in the claims appended hereto. | A homogeneous powder mainly consisting of an elastic material, such as vulcanised rubber, is produced by first forming a composite body of larger particles of the elastic material, bound together by a thermoplastic material. The composite body is then subjected to mechanical treatment, e.g. grinding, producing a homogeneous powder having a particle size of less than 1.5 mm and consisting of up to about 80% by weigh of vulcanised rubber. | 1 |
This is a continuation of abandoned application Ser. No. 09/873,004, filed Jun. 1. 2001.
FIELD OF THE INVENTION
The present invention is directed to an intake and plucking arrangement, having a rotating intake device and an additional conveying element driven by a first stalk roll for directing standing plants into a plucking slot.
BACKGROUND OF THE INVENTION
DE 197 34 747 A describes a corn harvesting implement for attachment to a self-propelled harvesting machine that mows plants standing on a field independent of rows and plucks the ears of corn from the plants. For grasping and mowing of the plants independent of rows, the implement is equipped with a mower head with a rotating drum provided on its outer circumference with recesses and a knife rotating below it, as is known practice from corn heads. The plants are conducted to conventional plucking assemblies attached downstream of the mower head. Clean-up disks or points of the plucking rolls penetrating into the operating area of the mower head are provided, in order to remove the plants that are to be processed from the mower head and to conduct them to the plucking assembly. The ears of corn that have been removed from the plants are transported away by two chain conveyors arranged above the plucking slot. The disadvantage here is seen in the fact that the transition of overripe and soft stalks into the plucking assembly may prove to be problematic.
SUMMARY OF THE INVENTION
It is an object of the present invention of making available an improved intake and plucking arrangement for a crop harvesting arrangement.
The present intake and plucking arrangement comprises a rotatable intake device that grasps parts of the standing plants and directs them into a plucking slot. The intake device is preferably provided with a relatively broad operating width; it thereby operates independent of rows. In addition to the intake device, a driven conveying element is arranged upstream and above the intake end of the plucking slot. The plants transported by the intake device to the intake end of the plucking slot come into contact with the conveying element, before they have reached the plucking slot. The conveying element conveys the plants, in conjunction with the intake device, into the plucking slot. Preferably the direction of conveying of the conveying element and the longitudinal direction of the plucking slot are parallel, so that the conveying element can introduce the plants into the plucking slot without any problems.
The conveying element facilitates the introduction of the plants into the plucking slot. This is especially important respecting plants having soft stalks as the conveying element provides additional support and conveying action to the plants. Due to the supporting effect of the conveying element, a buckling or squashing of the plants between the intake device and the edge of the plucking slot need not be feared.
The conveying element is preferably a screw conveyor that extends over a region (with respect to the direction of movement of the plants) upstream of the plucking slot and over at least a portion of the length of the plucking slot. It would be conceivable to let it extend over the entire length of the plucking slot in order to transport the plants along the length of the plucking slot, however, this is not absolutely necessary, since the transport of the plants over the length of the plucking slot can be performed by the intake device. For reasons of cost and weight, a relatively short screw conveyor is therefore preferred, that covers only the intake end of the plucking slot and a region (as seen in the direction of movement of the plant) ahead and behind it. In place of a screw conveyor, a chain conveyor with drivers of the type used on corn pickers, but shortened in comparison and offset opposite to the direction of movement of the plants (that is, upstream) could be applied to the grasping and introduction of the plants into the plucking slot.
An obvious solution is to arrange the conveying element on the side of the plucking slot that is opposite to the intake device. If the plants move outward relative to the intake device, they come into contact with the conveying element. Then the conveying element conducts them into the plucking slot.
To drive the conveying element, a gearbox can be used that makes a drive connection between a driven stalk roll of the plucking device and the conveying element. It is advantageous that the gearbox be arranged on the upstream side of the stalk roll and the conveying element. As a rule, this side is located in front in the forward direction of operation of the intake and plucking arrangement.
It would be conceivable to support the conveying element at both ends on a stationary element (directly or indirectly). As a rule, however, it is sufficient to support it at only one end and to support it in bearings. Here the concern is appropriately the end of the conveying element facing the gearbox.
In a preferred embodiment the conveying element is arranged above the intake device, in particular, directly above it. This leads to the result that the plants do not bend significantly between the conveying element and the intake device, which would make the introduction into the plucking slot more difficult.
In order to further improve the introduction of the plants into the plucking slot it is proposed that the plucking device be equipped with a stalk roll that is provided with a region arranged upstream in the direction of movement of the plants in which a screw conveyor is arranged, which also transports the plants that come into contact with it into the plucking slot. The conveying element is arranged above the screw conveyor. As a result, a plant is conducted into the plucking slot by the screw conveyor of the stalk roll, by the conveying element and by the intake device. Therefore the plant is supported at three points so that a buckling even of soft plants need not be feared. As a rule, the conveying speed of the conveying arrangement, of the screw conveyor and of the intake device coincide, so that the plant is conveyed in a vertical position and is not bent due to differing conveying speeds.
The screw conveyor in the upstream region of the plucking roll and the conveying element are preferably located directly above one another. At this location the plucking rolls begin to act upon the plants and to draw them in downward.
The intake device can also be utilized to transport the plants over the effective length of the plucking device, that is, that part of the length of the plucking device in which the plucking device processes the plant, that is, draws it in and separates the useful components from the remainder of the plant.
The intake device can rotate about an approximately vertical axis and be equipped with radially extending fingers that are used to grasp and transport parts of the plants, particularly stalks.
The fingers of the intake device are preferably provided with leading surfaces with rejecting conveying performance, that is, they have a trailing configuration. This conveying performance can be attained by a curvature of the fingers of the intake device that is trailing, opposite to the direction of rotation. Thereby this results in the stalks of the plants being forced outward by the intake device and prevents the stalk from being drawn inward aggressively and becoming clamped between the edge of the sheet metal stripper plate and the finger.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of an intake and plucking arrangement of a crop harvesting arrangement.
FIG. 2 is a side view of the intake and plucking arrangement of FIG. 1 .
FIG. 3 is a front view of the intake and plucking arrangement of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows an intake and plucking arrangement 10 of a crop harvesting arrangement. Typically, a full crop harvesting arrangement is provided with a multitude of intake and plucking arrangements 10 . However, it is conceivable that a crop harvesting arrangement could be provided with only a single intake and plucking arrangement 10 . If several intake and plucking arrangements 10 are applied, they may be configured identically or symmetrically about the longitudinal center plane of the crop harvesting arrangement.
The intake and plucking arrangement 10 is provided with an upper intake device 12 , that is used for grasping and drawing in the plants that are to be harvested, a rotating chopper knife 14 , a first stalk roll 16 , a second stalk roll 18 and a sheet metal stripper plate 20 having a plucking slot 22 formed therein. Both stalk rolls 16 and 18 are located below the plucking slot 22 .
The upper intake device 12 is arranged so as to rotate about a vertical axis and is rotated by a drive, not shown. The upper intake device is driven in a clockwise direction when viewing FIG 1 . The intake device 12 is arranged above the sheet metal stripper plate 20 and has an axis of rotation that is inclined slightly to the front. Line B in FIG. 1 corresponds to the surface of the ground. In its basic configuration the intake device 12 comprises a central disk 24 with radially extending fingers 26 distributed around its circumference. The fingers 26 are also curved in the plane of the disk 24 opposite to the direction of rotation, in a trailing configuration. Therefore the fingers 26 have a rejecting conveying performance. Alternatively or in addition to the curvature of the fingers 26 , a controlled, radial or azimuth-like movement of the fingers 26 relative to the disk 24 would be possible, as is known from harvesting reels or screw conveyors of mower heads, and can be attained by an eccentric drive, in order to attain a rejecting conveying performance.
As can be seen in FIG. 1 , the intake and plucking arrangement 10 is further provided with stalk dividers 28 and 30 that are arranged ahead of the intake devices 12 and 16 in the direction of forward movement V of the crop harvesting arrangement. Intake devices 12 of the intake and plucking arrangement 10 direct or bend the stalks of plants 32 into the intake 23 of the plucking slot 22 as the crop harvesting arrangement moves in the forward direction V across a field. As illustrated in FIG. 2 , the leading edge of the sheet metal stripper plate 20 in the forward operating direction is curved in such a way that the stalks of the plants 32 are directed into the operating region of the intake device 12 . The operating region of the intake device 12 is so large that the intake and plucking arrangement 10 interacting with the curved leading edge of the sheet metal stripper plate 20 , and/or the stalk dividers 28 and 30 , allows the intake and plucking arrangement 10 to operate independently of rows. Hence the operating width of the intake and plucking arrangement corresponds to the sideways distance between the points of the stalk dividers 28 and 30 .
As shown in FIG. 1 , the stalk of a standing plant 32 comes into contact with a finger 26 of the intake device 12 (independent of its sideways position). The stalk of the standing plant 32 is directed by the finger 26 towards the plucking slot 22 . If necessary the finger 26 is assisted by the stalk dividers 28 and 30 and/or the leading edge of the sheet metal stripper plate 20 . The stalk is carried along by the leading surface of the finger 26 and is forced outwardly because of the trailing configuration of the finger 26 . In this way the stalk of the plant 32 is directed by the finger 26 into the plucking slot 22 . The plucking slot 22 extends approximately parallel to the forward operating direction V and is formed into the sheet metal stripper plate 20 between the first plucking roll 16 and the intake device 12 .
The first stalk roll 16 is arranged on the side of the plucking slot 22 away from the intake device 12 and is inclined slightly to the front and downward when viewed from the side. The first stalk roll 16 is oriented parallel to the forward direction of operation V when viewed from the top. In the vertical direction the first stalk roll 16 is arranged underneath the sheet metal stripper plate 20 . In the forward region of the first stalk roll 16 , located upstream relative to the direction of movement of the plants 32 , a screw conveyor 34 is located that draws in the stalk of the plant 32 into the plucking slot 22 , interacting with the intake device 12 . The inlet end 23 of the plucking slot 22 is located ahead of the axis of rotation of the intake device 12 . The plucking gap 22 initially narrows and then has takes on a constant gap over the length of the plucking slot 22 . The rearmost end region of the plucking slot 22 is curved in the direction towards the axis of rotation for the intake device 12 .
When the plant 32 enters the plucking slot 22 , the fingers 26 form an acute angle with the edge of the plucking gap 22 (that is shown at the bottom in FIG. 1 ). By reason of this acute angle between the edge of the plucking gap 22 and the fingers 26 , the stalk of the plant 32 can be squashed, particularly if the stalks of the corn plants are strongly overripe and therefore soft. In this case, the plant 32 is not transported further and the intake and plucking arrangement 10 becomes jammed.
To solve this problem a conveying element 52 in the form of a screw conveyor is arranged above the inlet end 23 of the plucking slot 22 and above the intake device 12 . The longitudinal direction and the direction of conveying of the conveying element 52 extends parallel to the first stalk roll 16 . The conveying element 52 has approximately one-third the length of the first stalk roll 16 and is brought into rotation by a gearbox 54 which establishes a drive connection with the forward end face of the first stalk roll 16 . Hence the first stalk roll 16 transmits the driving torque from the shaft 46 to the conveying element 52 . The housing of the gearbox 54 is fastened to the sheet metal stripper plate 20 . The conveying element 52 is supported in bearings only on its forward end face, as seen in the forward operating direction V, on the gearbox 54 , but it is not supported or provided with bearings on its rear end face.
The stalk of a plant 32 grasped by the finger 26 of the intake device 12 is pressed against the conveying element 52 . The conveying speed of the conveying element 52 conforms to the conveying speed of the screw conveyor 34 and the intake device 12 , so that the plant 32 is conducted synchronously into the plucking slot 22 by the screw conveyors 34 and 52 and the intake device 12 . The conveying element 52 provides support and conveying above the finger 26 of the intake device 12 . Due to the interaction of the two screw conveyors and the finger 26 the plant 32 is held securely and conducted in a straight line into the plucking slot 22 and between the stalk rolls 16 and 18 . The plant is supported at three points so that a buckling or squashing is not to be feared. In addition, due to the action of the conveying element 52 , the intake performance of the intake and plucking arrangement 10 has become considerably more aggressive.
The screw conveyor 34 , the conveying element 52 and the intake device 12 direct the stalk of the standing plant 32 into the operating region of the second stalk roll 18 . The forward point of the second stalk roll 18 lies ahead of the axis of rotation of the intake device 12 . The second stalk roll 18 is parallel to the first stalk roll 16 and is arranged between the latter and the axis of rotation of the intake device 12 . The slot defined between the first stalk roll 16 and the second stalk roll 18 is located vertically underneath the plucking slot 22 . The rear region 36 of the first stalk roll 16 , whose length corresponds to the length of the second stalk roll 18 . Both stalk rolls 16 and 18 are equipped radially extending drivers 38 , which are best illustrated in FIG. 3 . As seen in FIG. 3 , the first stalk roll 16 rotates in clockwise direction and the second stalk roll 18 rotates in counterclockwise direction. The first stalk roll 16 and the rear region 36 of the second plucking roll 18 draw in the stalk of the plant 32 downward. At the same time the sheet metal stripper plate 20 on both sides of the plucking slot 22 is used to strip off useful components of the plant 32 .
The conveying element 52 ends precisely above the forward end of the second stalk roll 18 and the beginning of the rear region 36 of the first stalk roll 16 . As soon as the plant 32 is drawn downwardly by the stalk rolls 16 and 18 , the conveying action by the conveying element 52 and the screw conveyor 34 of the first stalk roll 16 ceases.
During the plucking process the fingers 26 of the intake device 12 provide assurance that the plant 32 is transported over the length of the plucking slot 22 . The rotational speeds of the stalk rolls 16 and 18 and the intake device 12 are preferably designed in such a way that the entire plant 32 has been drawn downwardly into the plucking slot 22 when the end of the plucking slot 22 is reached.
The useful components of the plant 32 , ears of corn, sunflower heads, etc., are separated from the plant 32 by the plucking device. The useful components are conveyed by the intake device 12 into a trough 40 arranged at the rear of the intake and plucking arrangement 10 . A cover 42 on both sides of the plucking slot 22 defines a channel leading to the trough 40 , through which the useful components of the plants 32 are conveyed. The cover 42 partially covers the intake device 12 and the conveying element 52 and due to its shielding effect enhances the performance and operating safety of the intake and plucking arrangement 10 . The trough 40 may be a one-piece unit with the sheet metal stripper plate 20 , or it may be a separate element. A transverse screw conveyor 44 is arranged above the trough 40 and transports the useful components to a harvesting machine (for example, a combine or forage harvester) or to a trailer. A shaft 46 extends beneath the trough 40 and provides a drive for the two stalk rolls 16 and 18 , the chopper knife 14 , the conveying element 52 and the intake device 12 . The shaft 46 is driven by the engine propelling the crop harvesting arrangement. A frame 48 carries the intake and plucking arrangement 10 of the crop harvesting arrangement, all of which are driven by the shaft 46 .
The remainder of the plants 32 , that are transported away downward by the stalk rolls 16 and 18 , reach the operating region of the rotating, four-armed chopper knife 14 and are cut by this into individual pieces. Hence chopped plant remains are deposited on the field. During the chopping, the stalk rolls 16 and 18 hold the plant 32 . The chopper knife 14 rotates about a vertical axis of rotation 50 . The vertical axis 50 is located between the axis of rotation of the intake device 12 and the screw conveyor 44 , as can be seen in FIG. 2 . The chopper knife 14 is driven by the shaft 46 through an angular gearbox 56 . As seen in FIG. 1 , the chopper knife 14 is positioned beneath the stalk rolls 16 and 18 . The direction of rotation of the chopper knife 14 is clockwise, so that the chopped crop is thrown to the side and the rear.
Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. | An intake and plucking arrangement comprises a rotatable intake device that grasps a standing plant and directs it to a plucking gap. The plucking gap is located above parallel first and second stalk rolls that pull the stalk of the plant downwardly so that the plucking gap can separate the useful parts of the plant from the stalk. The upstream end of the first stalk roll is provided with a lower screw conveyor. A conveyor element is drivingly connected to the screw conveyor. The conveying element comprises an upper screw conveyor that is located above the lower screw conveyor. Both screw conveyors are located upstream from and above the inlet end of the plucking slot. The conveying element working in conjunction with the rotatable intake device direct standing plants into the plucking slot. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This Application claims the benefit of priority and is a Continuation application of the prior International Patent Application No. PCT/JP2012/084264, with an international filing date of Dec. 21, 2012, which designated the United States, and is related to the Japanese Patent Application No. 2012-014630, filed Jan. 10, 2012, the entire disclosures of all applications are expressly incorporated by reference in their entirety herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to cooling garment for cooling the body and thereby promote vaporization of the water that is the water retention in the water absorbing material. And, similar cooling cover such cool the head of the people, etc., about the wearable implement.
[0004] 2. Description of Related Art
[0005] Measures the heat of the outdoors in the summer, as heat stroke measures, there is a cool vest, etc. that can be worn by dog animals and the human body.
[0006] Cooling garment that can be provided on the planar water-absorbing material for water retention of moisture in the clothes, and absorbs heat in the heat of vaporization by the evaporation of the water, to cool the body is well known.
[0007] For example, prior art documents, there is a JP 11-172510.
[0008] And immersing the entire surface water such as a container filled with water the water absorbing material of surface shape, and squeeze excess water. And I have put in the pocket of the chest or back pocket of fire-fighting clothing.
[0009] There is an example that describes the adoption of an arrangement for cooling the body and in a high temperature environment of the fire.
[0010] In addition, there is a description example of a cooling garment Vest that in JP 2001-40512, is provided with a fan at the upper end, flowing air by providing a mere air passage space between the inner fabric and outer fabric, air-cooling the human body.
[0011] And outdoor work under the hot weather of summer, incinerators around the fire work like high-temperature environment, I want to get sufficient cooling effect in the upper half of the body of the human body. To do so, in the water absorption of the surface material's built-in pre-sewing, etc., that you cover the entire upper body as much as possible of it is necessary to such clothes Vest.
[0012] And, to a cooling garment high cooling effect this, there is a problem such as (1) to (4) below.
[0013] (1);That in order to soak in water uniformly throughout the water absorption of the material, a large container filled with water is required.
[0014] (2); The operation to narrow twisting the clothes considerable force with both hands is necessary in order to eliminate squeeze any excess water .
[0015] (3); Furthermore , cooling effect time under the hot weather and the like end , it reaches the dry state , again , take off their clothes , and infiltrate water retention in the water providing a large container again , filled with the water , to be worn again there is a hassle that must behave .
[0016] (4); There is a cooling garment incorporating a water-absorbing material. You want to include in this cooling garment electric blower for sending air to air passage between the inner fabric and the middle cloth. In this case,
[0017] Air passage also may give rise to large wind pressure loss places closed is twisted, the electric blower is weak to water, it is difficult to incorporate.
[0018] There is a problem to be solved that.
BRIEF SUMMARY OF THE INVENTION
[0019] In an aspect of the present invention, a wearable implement has a water absorbing material having a planar shape; and a waterproof breathable sheet or cloth having both functions of waterproof and breathable, wherein the water absorbing material is wrapped by the waterproof breathable sheet or cloth at one side or both sides, a gap is formed between the water absorbing material and the waterproof breathable sheet or cloth, a water inlet is provided so that water is filled in the gap from an outside, a waterway is configured by a sewing or an adhesion joint processing of the waterproof breathable sheet or cloth, which wraps the water absorbin material, so that the water flows vertically and horizontally on an entire surface of the water absorbing material, and the water filled from the water inlet is dispersed over the entire surface of the water absorbing material and penetrated into the water absorbing material so as to obtain a cooling effect of heat of vaporization.
[0020] The described cooling garment of the present invention to solve the foregoing problems. The superposed each other by wrapping sandwiched between the inner fabric and the intermediate cloth water absorbent material capable of absorbing water as an example, provided in a planar shape the size of substantially the entire outer surface of the cooling garment, a water several times its own weight and so as to be integrated, it is joined by waterproof seal junction or sewn places partially.
[0021] Then, over the entire surface of the water absorbing material of the surface of the joint is provided with a plurality of dispersion.
[0022] In the state where the worn on the upper body of a human, opening into the water provided in the upper portion of (injection port), cooling garment of the present invention can be inserted by a water bottle or the like.
[0023] Then, over substantially the entire surface of the water absorbing material, from the top, towards the lower direction stepwise, while meandering from side to side, it is possible to form a water channel where water flows.
[0024] Thus, it is possible to supply water by dispersing the water absorbing entire surface.
[0025] In another aspect of the present invention, a portion configured by the sewing or the adhesion joint processing has a width like a character of V in a horizontal direction,
a partition is provided to form a puddle and configure the waterway in a stepped shape downwardly from a top, moisture is replenished widely to an upper side of left and right of the entire surface by the water of the puddle and capillary action of the water absorbing material so as to obtain the cooling effect of heat of vaporization.
[0028] To provide a partition of the water to have a recess and the tilt angle appropriate to the water channel, having a length in the horizontal direction.
[0029] And, of the many puddles of water storage for the temporary is provided on the entire surface of the upper, lower, left and right this cooling garment.
[0030] Then, the capillary action of the fabric and the water absorbing material itself, over time, the water is dispersed in a wide area of the upper portion of the puddle.
[0031] Then, for example, the water absorbing material surface having size corresponding to nearly the entire surface of the upper body front surface of a human, over the entire vertical and horizontal, to provide a partition of the plurality of water with a moderate distance. Thus, over the entire surface of the water absorbing material, and it can distribute the water, it is possible to penetrate water absorption water retention water almost equally.
[0032] By means of the present invention, I resolve to (1), (2) and (3) of the problems to be solved as described above this.
[0033] In another aspect of the present invention, when a plurality of partitions are provided, an interval between the partition is within a range that the moisurure can be raised by the capillary action of the water absorbing material.
[0034] The water absorption exceeds the maximum amount of water absorption by the material whole entire surface is too much water to be inserted from the plastic bottles. Then, it is beyond the folded portion of the sheet or tarpaulins, water would overflowing the cooling garment is considered. This solution due to the fact that in order to prevent this, the provision of the arrival detection part of the water in the lower cooling garment can also be presented.
[0035] In another aspect of the present invention, a sensing location, which is a hollow of the water absorption material, is provided at a lower end of the water absorption material so as to detect that the water inserted from the water inlet reaches the lower end by a human finger.
[0036] In another aspect of the present invention, an inlet is provided for blowing air from a small fan, the waterway configured in the stepped shape is also used as an air passage, the water inlet is also used as an outlet of the air, and the vaporization is promoted at the surface of the water absorbing material by blowing the air from the small fan after the water is penetrated into the water absorbing material.
[0037] To provide a small fan by the motor drive of the battery and the air intake at the bottom of the waterway of the foregoing description of the cooling garment of the present invention.
[0038] After the insertion of water, the water in the puddle by the capillary phenomenon has been absorbed by the water absorption material, due to the small fan is blown.
[0039] To provide a means, such as changing the air passage of the waterway before description, and, to change the exhaust port opening into the water at the top of the cooling garment.
[0040] As a result, while continuing to wear the cooling garment, and was greatly promoted the vaporization of the water absorbing surface, further, since it is increasing the cooling effect, it also solves the problem (4).
[0041] In another aspect of the present invention, a cooling source of a refrigerant, an ice or a Peltier effect thermoelectric cooling element is provided so as to be in contact with the water filled or the water of the puddle.
[0042] According to the cooling garment of the present invention, there is an effect of the functional, such as the following.
[0043] 1; In order to penetrate water retention of water on substantially the entire surface of the water absorbing material of large surface form the cooling garment, a large container filled with water for immersion in water the clothes for each is required.
[0044] In addition, in order to remove excess moisture, strong force to squeeze the clothes in considerable force with both hands is required.
[0045] However, in the present invention, while wearing the cooling garment, it can be easily injection of water in plastic bottles, and the like from the water inlet at the top of the cooling garment.
[0046] Further, it is possible to disperse the water over substantially the entire water absorbing material of the foregoing description, and infiltrating water retention and water evenly. Large container of said also, the power to squeeze even twisting without the need, there is an effect of less powerful men and women of all ages can use with ease.
[0047] 2; Furthermore, the cooling effect of time under the scorching sun, etc. have passed, vaporization of the moisture of the water-absorbing material is the end, if it is even in the dry state, there is no need to take off their clothes again.
[0048] Further, there is no need to provide a large container filled with water.
[0049] Easily, it is possible to replenish the water in plastic bottles, and the like from the opening to put in the water.
[0050] Then, it is possible to reproduce a cooling effect over the entire cooling garment by dispersing water over substantially the entire surface of the water absorbing again infiltrate water retention water evenly.
[0051] The use, in the work, this can be expected to be a breakthrough effect during use, while moving in the sport, it is possible to replenish the water easily even while running, can last a long time in succession cooling effect.
[0052] 3; Also, at this time, it is too put the water from the inlet to put in water, the water overflows from the folded portion of the sheet or tarpaulin cooling garment bottom edge. When wetted with water or the like trousers, it becomes uncomfortable results. Therefore, in a part of the folded portion for example I provided the part has been removed partially cut the water absorbing material that is very thick.
[0053] I reach the detection part of the water. The replenish water in plastic bottles, and the like from the inlet into the water in the upper right hand Thus, fingertips of the left hand, it is possible to detect that you feel the arrival detection portion of the water provided at the lower end, the water reaches the lower end.
[0054] Therefore, I can stop the supply of water. Then, there is an effect that it is possible to prevent the water overflow.
[0055] 4; In addition, there is a waterway of water partition by joining by sewing or the like forming a puddle of the foregoing description.
[0056] When the wind blowing in reverse, since there is provided a small Juan previous description, the intake air by the air duct to the flow of water, the partition has a tilt angle of the blast forward of the wind. Thus, ventilation resistance is a small air passage. That is, after the flowing water to the water channel, water puddles absorbed in the water absorbing material in capillary action, and blowing air from the bottom to the top. Therefore, the waterway is the air passage in order to facilitate the vaporization evenly over the entire surface of the water absorbing material. Therefore, there is no need to construct separate and to construct the air path present invention, a large effect can be achieved at low cost.
[0057] 5; FIG. 12 , 13 , by 14 , describes an example of a cooling cover to cool the head.
[0058] Again, I use the capillary action of the water-absorbing material that covers the surface like the head. to 5˜10 cm interval of about vertical height limit of moisture over go, is provided with a water partition portion extending horizontally, to configure the water reservoir.
[0059] Therefore, the moisture to penetrate into the upward direction of the water reservoir in the capillary action of the water-absorbing material.
[0060] Then, the uniform or the like vertically and horizontally the entire surface of the water absorbing material, since it is made to absorb moisture in the reservoir until the water disappears, it is possible to obtain the cooling effect of the heat of vaporization for a long time.
[0061] In this way, the cooling shroud and cooling garment of the present invention is intended to be usable to people, animals also.
[0062] Therefore, these can be referred to as a cooling wearable implement collectively.
[0063] 6; As can be shown by the example of the cooling wearable implement of description in FIG. 15 , 16 , 17 of the present invention, or the water near the water reservoir is provided with a cold source of the refrigerant such as Peltier effect devices in contact therewith.
[0064] The position change of an operation state of the wearable implement, to mix with the cold water in contact with the cooling source and the water is allowed to flow back to the water, warmed. Therefore, it is possible to infiltrate the water absorbing cooling water uniformly throughout to obtain the cooling effect of evaporation heat further.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 is a schematic front view of the front side of the cooling garment according to an exemplary embodiment of the present invention.
[0066] FIG. 2 is a schematic sectional view of A-A shown in FIG. 1 of the present invention cooling garment.
[0067] FIG. 3 is a diagram showing surrounding area of the water reaching detection portion of the present invention cooling garment lower position.
[0068] FIG. 4A and 4B are a diagram showing a B-B′ cross section shown in FIG. 3 .
[0069] FIG. 5 is a diagram showing a usage state in which the water is inserted to cooling garment of the present invention.
[0070] FIG. 6 shows that it has provided to a rear (the back surface) functions too of cooling garment of the present invention.
[0071] FIG. 7 , an electric battery-powered, such as the air intake by the air insertion duct at the lower end of the cooling garment of the present invention, and it is a diagram showing an example in which the small fan.
[0072] FIG. 8 shows that it is configured as a partition dam water cooling garment of the present invention.
[0073] FIG. 9 is a diagram showing a configuration example of another water partition cooling garment of the present invention.
[0074] FIG. 10 is a diagram showing the C-C′ cross section shown in FIG. 9 .
[0075] FIG. 11 is a diagram showing an example of disposed outside the sheet or tarpaulin.
[0076] FIG. 12 is a diagram showing a use state of the cooling cover to cool the head of the present invention.
[0077] FIG. 13 , Figure shows the structure of a cooling cover of the present invention
[0078] FIG. 14 is a diagram showing the D-D′ section shown in FIG. 13 .
[0079] FIG. 15 shows the cooling cover wearable implement with extended top part of head, it is including a water absorbing material.
[0080] FIG. 16 shows a cross section E-E′ of the cooling cover wearable implement of FIG. 15 , and it was attached to the human with a helmet.
[0081] FIG. 17A and 17B are a diagram showing a use state of the cooling cover wearable implement is attachment.
DETAILED DESCRIPTION OF THE INVENTION
[0082] The following describes the embodiments of the present invention with reference to the drawings.
[0083] FIG. 1 shows schematic front view of the front side of the cooling garment according to an exemplary embodiment of the present invention. FIG. 2 is a schematic sectional view of A-A′ shown in FIG. 1 of the present invention cooling garment.
[0084] Cooling garment 10 of the present embodiment is worn as best upper body of a human body. It is obtained by cooling the upper body, is used to heat stroke measures and heat measures.
[0085] Water absorbing material 11 over the entire surface substantially front side of the cooling garment 10 can be water-absorbing water retention and water several times its own weight is provided on the planar.
[0086] Water absorption material of the planar is or wrap the front and back both sides are sandwiched between the sheet or tarpaulin 13 cloth and intermediate pad 12 .
[0087] Are configured to square periphery is sealed by thermal bonding or sewing them.
[0088] Further, breaking through the outer cloth 22 at the upper portion of the cooling garment 10 is provided with a water inlet port 14 into the opening in the water of the intermediate pad 12 .
[0089] At this time, between the sheets or tarpaulin 13 planar, I provide a slight gap as well as the water- absorbing material 11 of the planar.
[0090] Therefore, as shown FIG. 1 , FIG. 2 , bottle 15 is inserted the water into there from the inlet of the water. It is possible to hydrate the water absorbing material 11 of the planar one.
[0091] The following is one of the object of the present invention.
[0092] Over almost the entire surface of the water absorbing material 11 wide planar, water that has been injected, it flows through the lower direction from the top.
[0093] And, and that the water is dispersed over the entire surface, including to the end of the left and right of the water absorbing material 11 and has been supplied uniformly, in the same manner as the water absorbing water retention.
[0094] Therefore, across the water absorbing material 11 of the surface shape, and for sealing of gluing by chemical adhesive or high-frequency thermal bonding or stitching process at a plurality of locations.
[0095] Connected to places linear sheet or tarpaulin 13 and the intermediate pad 12 Thus, it is bonded, to form the partition 16 in the water having a length in the horizontal direction. The partition 16 of the water has a moderate inclination angle, as shown in FIG. 1 with respect to the horizontal.
[0096] Cause a puddle for holding water 17 , like the so-called rice terraces, at the position of the partition 16 of the water, do both of drainage downward 18 and holding water flowing from the top, the water channel 19 of the continuous stepwise can be configured.
[0097] As described before, this water absorbing material 11 is of a planar wide enough to span the upper body of the people, almost the entire surface.
[0098] The As described in problem to be solved by the present invention, as long soak cooling garment per the present water absorbing whole in a large container filled with water, to disperse uniformly substantially the entire large surface water-absorbing material is caused to water retention and water.
[0099] However, it is not so, and, only having to insert the water inlet port 14 into the water at the upper end of the cooling garment, people while wearing, the lower end from the top over the entire surface of the water absorbing material 11 of this planar direction, and it is distributed to every corner of the entire left of the water absorbing material 11 , the extreme right, including the left and right, it is necessary to supply the water uniformly.
[0100] To do this, as shown in FIG. 1 the partition 16 of the water with said moderate inclination angle, the front such a cooling garment 10 , the entire surface of the water absorbing material 11 is provided by widely dispersed plurality.
[0101] Needs to be configured to produce a water channel 19 of consecutive stepped, the water puddle 17 multiple of the entire water absorbing material 11 .
[0102] This, and water absorption material 11 , intermediate pad 12 suck up the puddle 17 for holding water by capillary action.
[0103] Then, it is possible to replenish moisture wide including a surface vicinity of the water absorbing material 11 in the upward direction water partition 16 , thereby absorbing water retention.
[0104] Since this phenomenon occur with multiple dispersed to upper, lower, left and right end in the water absorbing entire surface, and can be every corner to infiltrate water absorption water retention of water on the entire surface of the water absorbing material 11 with the passage of time
[0105] The capillary action of this case, for example, the balance in the own weight of water and the surface tension in the fiber gap of the water-absorbing material, the amount of moisture transport height and the rise of the water is determined is known.
[0106] In order to state the best cooling effect of the cooling garment 10 of the present invention, experiments were carried out for the selection of the water absorbing material 11 .
[0107] For example, as one case. a water absorbing material 11 comprises a polymer composed mainly of sodium polyacrylate, and direct spinning.
[0108] It is constructed in weight 200 g/m 2 , 2 mm thick, of about 2800 g/m 2 water absorption.
[0109] Increased penetration of moisture by capillary action after 10 minutes,
[0110] It spread a wide surface of approximately 5 cm in height above the water surface direction puddle 17 made by partition 16 of water.
[0111] I penetrated into 8 cm height after 30 minutes thereafter.
[0112] Then, substantially the same even 2-5 hours after, saturated with 10 cm to high, as balanced, limit has been reached.
[0113] Water absorbing material of the present invention is not limited to the direct spinning fibers containing a polymer composed mainly of sodium polyacrylate of the course.
[0114] For example, it may be a cloth towel that has been subjected to a hair implant material widely used in the home, the thick cotton.
[0115] There is an effect of low production cost in this case.
[0116] Further, on the other hand, it is possible that the water absorption amount is large, the height of the water rise by capillarity use a higher water absorbing material, to increase the vertical spacing of the partition 16 in the water. It is possible to uniformly spread the water to cooling garment entire surface by a partition 16 of water in the smaller number. In this case, there is an advantage to be able to make better design of cooling garment.
[0117] Heat, the cooling of the upper body by the heat of vaporization, I want to enough water absorption water retention over the entire surface of the water absorbing material 11 with into 30 minutes nearly as heat stroke measures.
[0118] If you have a 40 cm about height required above and below the water absorbing planar incorporated in the cooling garment 10 of the present invention is provided with a water storage pudlle 17 increased allocates left it at five stages around several vertically.
[0119] It is possible to solve the problem of the present invention in the description before you configure the waterways of continuous stepwise as in FIG. 1 .
[0120] Water absorbing material 11 wide planar, from the water inlet 14 , when you insert the start of the water, then, dispersing the water full top and bottom of the water absorbing material 11 , left and right, until every corner almost, the water absorption evenly after 30 minutes about it is possible to cause water retention.
[0121] It was found that at this time, just most preferable to set the tilt angle and the horizontal length width of the partition 16 in the water as is sucked up by capillary action to the water absorbing material 11 around the water in the water puddle 17 .
[0122] At this time, as the water absorbing material 11 , and containing the polymer, particularly when employing the fibers were direct spinning, its containing polymer particles absorb water, the volume expansion of itself, compressing the gap of the direct spinning fiber, the water absorbing material 11 is an aggregate has been found to be difficult Mora water in the outer direction, the intermediate fabric, it becomes waterproof wall state.
[0123] This would be imaginable from the fact that the bag enclosing a large amount of the polymer particles has been used as sandbags flood disaster is well known.
[0124] Without leaking to the outside through the intermediate pad 12 is consequence, the water collected in the water puddle 17 , all distributed by capillary action upward to the right and left near the water surface of the puddle 17 of the water absorbing material 11 , and is permeated water absorbing water retention. Very good condition.
[0125] Further, by lapse of time thereafter, the vent and the outer, vaporized evaporation is promoted, the surface of the intermediate pad 12 side of the water absorbing material 11 which is water retention sufficiently can be obtained for a long time a cooling effect by it. I have found that good condition very still.
[0126] However, the water channel 19 is complex and stepped in, because it is not visible from the outside, with, in some cases too put a large amount of water inlet port 14 into the water.
[0127] You can become an extra water that can not be in the water absorption of water absorbing material inside, there is a case in which the folded portion 102 of the sheet or tarpaulin cooling garment until it reaches the lower end.
[0128] And configured to the shield water side 103 , but when water or overflows from the upper end of the folded portion 102 occurs. As a means for solving this problem, to provide the ultimate detection portion 101 of the water in the cooling garment bottom edge. Only part of reaching detection portion 101 of the water, except off the water absorbing material that is very thick, which is provided with a cut portion 31 of the water-absorbing material. Front sheet or tarpaulin 13 that part, as reaching the detection portion 101 of water, and make up so that water accumulates the space only by the folded surface.
[0129] As a result, the water from the water inlet port 14 to flow from the top of the water absorbing material 11 in stages, I could places puddle.
[0130] And, when it reaches the lower end, and if put in the cross-sectional direction in the index finger 42 and thumb 41 the arrival detection portion 101 of the water, for the touch of the finger, and, easily, reaching the degree of water can be clearly determined. FIG. 3 is a diagram showing a reaching detection portion near the water present invention lower cooling garment.
[0131] FIGS. 4A and 4B are diagrams showing a B-B′ cross section shown in FIG. 3 .
[0132] And shows a state prior to the touch sensing with a FIG. 4A .
[0133] And shows that FIG. 4B and feel with your thumb and index finger, and have reached the detection of water.
[0134] In FIG. 2 , the middle intermediate pad 12 cloth that breathes, through the outer cloth 22 of cosmetic purposes good breathability, moisture of water absorbing material, shows how to take the heat vaporizes the outside 23 as well.
[0135] The thermally conductive heat 24 mainly by water absorbing material 11 , sheet or waterproof tarpaulin 13 cloth is cool body side 21 .
[0136] In this case, but could not get past drainage to body side 21 , due to moisture evaporation vaporization is not come, and when worn underwear, etc. to side, the underwear is not wet.
[0137] Therefore, the amount of perspiration from the body is relatively small, I is suitable for construction work, such as civil engineering work in the outdoors.
[0138] In contrast, FIG. 11 is a diagram showing an example of disposed outside the sheet or tarpaulin.
[0139] In this case, the vaporization of the moisture of the water absorbing material 11 is performed, for example, in the gap between the body side 21 and an intermediate pad 12 which kept the air permeability.
[0140] 111 shows the flow of the air stream of a state to take the heat from the body in the heat of vaporization. Depending on the sweat and the like material performance of intermediate pad 12 , but the body is cooled in the heat of vaporization, but this case is also exposed to moisture by evaporation vaporization.
[0141] However, for example, so do not mind so much if you are also, do a lot of sweating and have fun with intense various sports of operation to sweating aggressively, without wearing underwear separately, this is, direct the cooling garment it is possible to wear the body and comfortable to use. Thus, examples of the arrangement shown in FIG. 11 is also effective as an embodiment of the present invention.
[0142] At this time, the sheet or tarpaulin 13 also intermediate pad 12 can also configure the cloth having a function that combines the breathable and waterproof, the so-called cloth of waterproof breathable.
[0143] then whether in the FIG. 2 or FIG. 11 case also, it is possible to obtain cooling by heat of vaporization without get wet the body side 21 by water moisture.
[0144] FIG. 5 is a diagram showing a use state wear cooling garment of the present invention, are inserted water.
[0145] For example, in the left hand, and feel with your fingers reaching water detection portion 101 of the cooling garment 10 lower end of the front, the wearer, have confirmed the degree to which the water reaches to the bottom.
[0146] And I shows the use state that is inserted into the water inlet port 14 to put in the water at the top of the cooling garment 10 from plastic bottle 15 with the right hand.
[0147] I did experiment a prototype of the present invention.
[0148] In use, such as the FIG. 5 , the time to reach the water reaches the detection unit amount of water to be inserted from the bottle, the upper portion of the cooling garment, as it is indicated by FIGS. 4A and 4B , it is possible to detect the amount reaches to the lower end of the water to feel the degree of swelling of the detection portion 101 .
[0149] The three conditions, I can recognize the wearer himself learned empirically several times.
[0150] It has been found that this, adjust the water retention capacity of water absorption to water absorbing material 11 as a result, it is possible to adjust the degree of cooling by evaporation heat generation rate by it.
[0151] As a result, it is possible and the presence or absence of the surrounding environment of heat sources such as incinerators, be tailored to the activity of the wearer's temperature at the time of the wearing of the cooling garment of the present invention, around. Innovative effects can be used to be more comfortable is added.
[0152] FIG. 6 shows that it has provided to (the back surface) and a rear functions of cooling garment of the present invention.
[0153] Wearer, for example, put from eater inlet port 14 to put in water bottled water with the right hand.
[0154] Providing a long pipe 61 from the over-the-shoulder of the cooling garment 10 , I have configured to be capable of absorbing water water retention of water to the water-absorbing material 11 of the surface of the cooling garment shown in FIGS. 1 and 2 of the rear (back surface).
[0155] By providing the water reaches the detection portion 101 to the surface after this, it is possible to adjust the insertion amount of the water from above while detecting the arrival of water to the lower left hand as described above.
[0156] FIG. 7 is a diagram showing an example in which a small electric anxiety driven by a battery and the air intake of the air duct inserted into the lower end of the cooling garment of the present invention.
[0157] Puddle 17 inside the cooling garment 10 described with reference to FIGS. 1 and 2 of the foregoing description.
[0158] Be composed water channel 19 by a partition 16 of water each having a moderate inclination angle.
[0159] And a cavity after the water has been inserted, is absorbed into the surface shape by capillary action of the water absorbing material 11 .
[0160] For the air blown from the air intake port 72 by the air duct insertion and small electric fan 71 provided at the lower end, the inclination angle can be constructed the air passage 73 wind pressure loss in the favorable wind direction is small.
[0161] Intake air 74 flowing from the lower end of the cooling garment, the cavity air passage 73 of the gap of the water absorbing material 11 and sheet or tarpaulin 13 by driving the small electric fan 71 .
[0162] I greatly encourage the vaporization of surface water absorbing material 11 over almost the entire surface of the front cooling garment 10 .
[0163] While applying increasing the cooling effect by the evaporation heat, the air is exhausted from the port 14 into the water.
[0164] In cooling garment 10 of the present invention, when it is fitted with a small electric fan 71 at its lower end, the port 14 to put in water will be air exhaust port as this.
[0165] Water channel 19 will air passages 73 wind flows 75 .
[0166] The partition 16 of the water becomes the partition 76 for the wind pressure loss is small, and forming the air passage in a stepwise manner over the entire surface of the water absorbing material.
[0167] It is possible to bring that can be used to serve as, respectively, a good utility cost. 75 in the figure shows the flow of wind through the air passage 73 .
[0168] Thus, the wearer, comfort by the cooling effect is a large difference in the case you promote vaporized by small electric fan 71 , in the case without it.
[0169] It has become possible to wear even in the poor thermal environment of high temperature work site.
[0170] FIG. 8 shows that it is configured as a partition dam water cooling garment.
[0171] Was described in the previous description FIG. 1 , puddle 17 having a suitable inclination angle.
[0172] I illustrates a method for the same action as the partition 16 of the water for this purpose.
[0173] As shown in FIG. 8 is provided with a horizontal water partition 81 which is bonded or sewn, sheets or tarpaulins 13 and the intermediate pad 12 to a plurality of horizontally. Then, like the function with an appropriate height in the horizontal direction, I provide a vertical water partition 82 which is bonded or sewn as well.
[0174] The same effect can be obtained the present invention can be configured as a dam to perform water discharge by overflow and water.
[0175] FIG. 9 is a diagram showing a configuration example of another partition water cooling garment of the present invention.
[0176] FIG. 10 is a view showing a C-C′ cross section.
[0177] Water absorbing material 11 of the surface shape in the present embodiment is configured such that cutouts 91 in the vicinity of the partition of the water. Partitioning of water on volunteers were pre-described described in FIG. 1 , a suitable tilt angle, performing a water discharge by overflow the reservoir of water, a high-frequency and intermediate pad 12 and seat or tarpaulin 13 as shown in FIGS. 9 and 10 . It can also be configured as a sealing joint water portion 92 by a chemical adhesive or thermal bonding. Place in FIG. 10 and FIG. 9 , the water partition by the seal coupling part due to the high frequency heat bonding is in cutout partial 91 surface of water absorbing material 11 . At this time, as described earlier, both the sheet or tarpaulins 13 and intermediate pad 12 if a so-called waterproof breathable fabric, such as a main component such as polytetrafluoroethylene of fluorine resin, the high-frequency thermal bonding It can be and can configure the sealing coupling water portion 92 easily, etc., is obtained in the processing method of the low-cost cooling garment having the cooling effect of evaporation heat.
[0178] Next, I will explain an example of an embodiment of a cooling cover to cool the head of the present invention.
[0179] FIG. 12 is a view showing a use state of the cooling shroud to cool the head of the present invention.
[0180] The head cooling cover (hereinafter, referred to as a cooling cover) are attached hat for protect the head, or helmet 121 by front band 124 .
[0181] Water supply port 122 is provided at the cooling shroud.
[0182] 125 is a plastic bottle you are going to put the water in the interior of the cooling cover wearable implement 123 from the filling
[0183] FIG. 13 is a view a view showing a structure of a cooling cover of the present invention, as viewed from inside the cooling cover wearable implement 123 .
[0184] There is the outer cover 132 of the outer material and the waterproof breathable with an area of enough to hide the cheek, the cover section 133 of the inner and the waterproof breathable material compress as well.
[0185] Then, (in the sandwich) across the water absorbing material 131 planar enough to cover the back of the head or heads, so as create an enclosed space, and a heat fusion bonded seal 134 on four sides around the inner cover portion.
[0186] In addition, in places, cutting out the water absorption material, and held in a vertical direction water-absorbing material, and, for the formation, to provide a point of joining 1310 processing the inner cover portion and the outer cover portion waterways.
[0187] In the top of the outer cover 132 , water supply port 122 is provided at a position where it can irrigation water to the sealed space.
[0188] At this time, at a position resolution of an intermediate position enough longitudinal direction of the water absorbing member 131 (the vertical direction), the water to have a length in the horizontal direction were taken from the water supply port 122 to as accumulated adaptation.
[0189] And to provide a water partitioning adhesive seal portion 135 for being heat-sealed bond V-shape, the inner cover portion 133 and the outer cover 132 , to create a water reservoir water overflow to flow down.
[0190] At this time, it is water absorbing material 131 of the seal portion and keep hollowed out. Accordingly, the water 136 from the water supply water supply port 122 may puddle 137 water partitioning adhesive seal portion 135 for making the water reservoir.
[0191] 138 water which overflowed to create a water reservoir 139 of another beneath.
[0192] Depending on the material density of the water-absorbing material 131 , but the height limit increase of moisture by capillary action of the water-absorbing material which is available at low cost in general is a 7 cm 8 cm from the vertical direction.
[0193] For example, when the height of the longitudinal direction of the water absorbing material 131 of the cooling cover of the present invention (the vertical direction) was set to around 15 cm, to provide the water partitioning adhesive seal portion 135 for making a puddle on the dividing position in between about herf.
[0194] It is possible to use of a capillary phenomenon, uniform, and to supply water for a long time over the entire area of about 8 cm, for example the height of the upper direction from the water partitioning adhesive seal portion 135 of the 131 water absorbing material.
[0195] Further, the entire area of about 7 cm such height downward capillary phenomenon of the water absorbing material 131 from the water reservoir part 139 of another lower, water is supplied uniformly more.
[0196] Thus, the entire surface area of the 15 cm in height of the water absorbing member 131 , uniform, and through the outer cover 132 , to vaporize the water.
[0197] Head side in contact with the inner cover portion 133 with the heat of vaporization can be obtained a cooling effect for a long time.
[0198] FIG. 14 is a diagram showing the D-D′ section shown in FIG. 13 .
[0199] Sign in FIG. 13 and FIG. 14 shows the same thing.
[0200] Water absorbing material 131 is in the vertical plane, the water retention is vertically uniform.
[0201] Humidity-permeable portion of the inner cover 133 and outer cover 132 , made of a waterproof breathable, the vaporized water is heat of vaporization cooling.
[0202] Thus, a back of the head side 140 is radiated to the outside through the cooling cover wearable implement 123 .
[0203] According to experiments, if the moisture permeation amount was used to both outer cover 132 , and inner cover 133 , using a waterproof breathable performance of about 13,500 g/m2/24 hr, ambient temperature at 33° C. to 38° C. environment, from water supply port 122 for example 10° C., if you turn on the cold water of 130 ml, vaporization amount was about a 17 ml per hour.
[0204] The contact temperature of the inner cover part was able to get the heat of vaporization cooling effect of about 6 hours at 20° C. to 28° C.
[0205] In the configuration in general, is sandwiched between cloth through the normal water a water absorbing material, is immersed in water, to use squeeze light, which is cooled duration of about 2 times the same cooling cover with a heat of vaporization cooling was effective to obtain.
[0206] In addition, FIG. 15 is a view of the cooling shroud attachment which extends to the top of the head to be integrated cooling unit including a water absorbing material. Shows a cross section E-E′ of the cooling cover mounting device of FIG. 15 , FIG. 16 is a drawing showing that that attached to a person wearing the helmet.
[0207] FIGS. 17A and 17B are views showing a use state of the cooling cover attachment.
[0208] To be in contact with the water or near the water of the water reservoir 137 is provided with a cooling source 151 of refrigerant ,or such as cooling elements of electronic cooler by the Peltier effect. In this case, it is same effective, if using ice which put in the puddle of the cooling cover
[0209] Outdoor work during the summer, I can be cooled to around 10° C., the ambient atmosphere for example became a high temperature to 30° C., such as water in the water reservoir 137 .
[0210] Therefore, the state shown in FIG. 17B from FIG. 17A , the use state of the mounting the cooling cover wearable implement extending head top 150 .
[0211] For example, the water absorbing material 153 in the integral cooling extension 152 to the top of the head up, the temporary head about water of 137 the water reservoir to flow back by gravity cooling cover wearable implement 150 was extended parietal up to be integrated cooling unit I lowered basis.
[0212] And also, then, I will do attitude behavior of returning.
[0213] Water in the water reservoir 137 , which is the cooling penetrates chilled water-absorbing material 153 of the top of the head as well and the water absorbing material 137 of the top cover.
[0214] Then, the mix with water in the water pool of the other not in contact with the cooler, and returns to the water reservoir 137 to the water warmed is provided with the cooling element.
[0215] Repeating each hour for about 30 minutes, this behavior can always be evenly distributed to the cooling cover wearable implement extending head top 150 overall, the water is cooled by the cooling source 151 . In the figure, 160 indicates a power supply unit which is mounted on the helmet for driving the cooling source 151 of the thermoelectric cooler and the like by the Peltier effect.
[0216] This has the effect that it does not require a pump or requiring a new driving force for circulating the upper and lower cooling water, a pipe mechanism prone to clogging, it is possible to realize the uniform at low cost.
[0217] Similarly, also the cooling garment of the present invention, somewhere in the water reservoir of FIG. 1 , a position, or easy to be the lowest accumulated water, instead of the small electric fan 71 , for example, shown in FIG. 7 , the cooling device by providing a cooling source 151 of the refrigerant, and the like, while the wear, and the operation of lean forward from time to time, the cooling garment, to raise or lower back flow the water in the water reservoir of the cooling garment within the overall, based on the attitude By returning the same manner as described above, it is possible to uniformly, it is possible to allocate the cooling water in the cooling garment whole, to obtain a large cooling effect further heat of vaporization of water cold.
[0218] Although not shown in the figure, when using the refrigerant as a cooling source 151 in the above, the cooling garment 10 and the outer cover 132 , it is preferable to provide a pocket which can hold it.
[0219] Description in the figure is omitted, cooling cover of the present invention is changing the shape is not only available in high-temperature environment or under the scorching sun of the head of the people, and so as to cover in the body and head of horses, such as dogs, It is one that can also be used to heat measures of the summer, it is cooling attachment.
[0220] In particular, compared to the cooling cover of the structure is sandwiched between cloth through a normal water water-absorbing material of said, there is no feeling that I wet the back side which is in contact with the skin, do not wet with water.
[0221] People as well, there is an advantage in effect the animal, dog, horse, etc. does not dislike wearing.
[0222] Similarly, the surface is not exposed to water, electrical insulating properties also relatively good. So there is also an effect that is said to be easy to use for electrical work. In the description of the figure, in the description of the embodiments of the cooling cover wearable implement 123 and the embodiment in cooling garment 10 of the present invention, respectively, In here, the same role material is named same, like the water absorbing material 131 is same name the water absorbing material 11 , and the puddle 137 is same name the puddle 17 etc.
[0223] Are each the same invention, it is intended to simplify the explanation in the each example was given different numbers in accordance with the drawing number.
[0224] Recently, the warming of the earth every year is in progress, much less exhaust heat of air conditioning in the building or the like is released to the outside, so-called heat island current situation is occurring in urban areas.
[0225] Under such circumstances, in particular, outdoors in urban areas, civil engineering under the hot weather of summer, construction work, the equipment maintenance, etc., attention to heat stroke of the worker has been advocated strongly, occupational health safety and it has evolved into a big problem on.
[0226] Until now, the invention for cooling the neck portion or head, of the body was present. However, the present invention of a low cost and, allows the replacement of water in order to continue the cooling effect of evaporation heat, the entire upper body, it is possible to detect the proper amount of replenishment water.
[0227] In addition, the small blower, efficient, low-cost, I can provide a cooling garment for the upper body full broadly, to promote the vaporization, has further enhanced the cooling effect.
[0228] But is to be contribution measures the heat of the, the resolution of occupational health safety over the heat stroke measures, industrial applicability is very large.
[0229] Further, the cooling cover the same invention, in the configuration in general, is sandwiched between cloth through the normal water a water absorbing material, is immersed in water, to use and squeeze gently, and a similar cooling cover with a heat of vaporization cooling I obtained a cooling duration of about 2-fold. In addition, as described above, so also serves as a cooling wearable implement that can be used as a pet such as a dog, even heat stroke measures of domestic animals such as horses, and are of great industrial applicability. | Water absorbing material provided in a planar shape over the substantially entire surface of a front side surface of cooling clothing is layered with an intermediate cloth having air permeability and a waterproof material or sheet, which is waterproof, to be sandwiched and wrapped therewith. By sewing or by sealing and joining the intermediate cloth and waterproof cloth or sheet, waterproof water dividers having length in the horizontal direction are provided at a suitable inclined angle of locations. Water that is inserted from a water inlet in the upper part of the cooling clothing by a PET bottle or the like flows toward the lower part of the cooling clothing between the surface of the water absorbing material and the waterproof cloth, meandering left and right continuously or in a stepwise shape, and making a puddles arise like terraces in prescribed locations here and there. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the manufacture of candle wicks. More particularly, the invention relates to methods for manufacturing candle wicks whereby the characteristics of the wick may be readily and accurately determined.
[0003] 2. Brief Description of the Prior Art
[0004] While the manufacture of candle wicks may seem to the unacquainted a simple low technology art, it is actually quite complex. Candle wick technology has evolved as has the chemical composition of candles. Different types of candles require different types of wicks and some wicks perform better than others in a given candle chemistry.
[0005] Wicks can be organized into various broad groupings based upon how they are manufactured, e.g., twisted, braided, knitted, cored, etc. and how they are shaped, e.g., flat, round, rectangular, square, etc. The twisted wicks usually are the least expensive and the lowest in quality. The flat wicks produce a strong and uniform flame, which generally minimizes the generation of soot. The round wicks are made with copper, fiberglass, cotton, paper, etc. cores. The small sized wick provides a small flame, a slow, lasting burning and a low consumption of paraffin. A large diameter wick produces a larger wax pool with high heating. Metal cored wicks generally have average flame heights and burn with lower flame temperatures. The metal wire makes handling and manufacturing easier due to its superior rigidity. The cotton core wick has features similar to the other metal cored wicks, but are generally more sensitive to the quality of the candle wax composition. They exhibit a higher flame with a higher heating power. The paper cored wick produces an above average flame with a heating power between cotton cored and metal cored wicks. Because paper cored wicks are structurally more rigid, they make handling easier than cotton cored wicks. All of the wicks are available in different thicknesses and may be coated with, e.g., vegetable or paraffin waxes or left uncoated.
[0006] Wicks are also made of braided plies of cotton yarns. Some use hemp or wool. Anything fibrous can be used to make a wick. More plies of yarn in the braid means a bigger wick, having a higher burn rate with a wider melt pool. In addition to the paper, cotton and copper cores mentioned above, hemp and zinc cores are sometimes used.
[0007] The flat braided wicks, also known as “plaited” wicks tend to curl to one side resulting in the tip of the wick lying in the hottest part of the flame. These wicks work well in pillar and taper candles as well as in gel candles. Candles in glass containers generally work better with a cored wick, preferably a metal core such as copper or zinc. The metal core helps keep the wick upright in a deep melt pool.
[0008] In addition to the type of wick, thickness matters as well. All of these characteristics need to be taken into account with respect to the type of candle (e.g. taper, pillar, votive, etc.) as well as the type of wax, dye, and fragrance which make up the candle. Indeed, over one thousand different types of candle wicks are available in the marketplace today.
[0009] Exemplary machinery for manufacturing candle wicks are the “Maypole Braider” series from the Wardwell Braiding Machine Company, Central Falls, R.I.
[0010] Modern candle wicks are categorized according to type and thickness as well as according to rate of combustion, flame height, and pool diameter. Thickness is generally expressed as yards per pound and the rate of combustion is generally expressed as ounces per hour. In addition, wicks may be categorized according to the braiding characteristics, picks per inch, warp threads, core diameter, etc.
[0011] In commercial production, candle wicks are sold on a spool containing hundreds of yards of wick material. The wick itself is usually white with no markings on it. The characteristics of the wick are printed on a label affixed to the spool. Unfortunately, it is possible that a spool of candle wick material is mislabeled. This can have disastrous results. If the wrong wick is used in a candle, it can create not merely an aesthetic issue but a safety issue as well. The wrong wick can cause a candle to become a dangerous article of combustion which results in dangerous, sometimes fatal, fires.
[0012] Because of the many thousands of different wick types and the many different manufacturers, it is impossible to identify a wick accurately by visual examination, even with the aid of a magnifying device. One must rely on the label.
[0013] Attempts have been made to identify wicks by, e.g., printing information on paraffin coated wicks. Wicks have also been striped (like a barber's pole). However, these wicks are considered to be visually and aesthetically unacceptable.
SUMMARY OF THE INVENTION
[0014] It is therefore an object of the invention to provide a visual indication in a candle wick which identifies its properties.
[0015] It is also an object of the invention to provide a visual indication in a candle wick which identifies its properties and which is not prone to error.
[0016] It is another object of the invention to provide methods for including a visual indication in a candle wick which identifies its properties.
[0017] It is yet another object of the invention to provide candle wicks having visual indications which identify their properties.
[0018] It is still another object of the invention to provide these visual indications in an aesthetically acceptable manner.
[0019] In accord with these objects which will be discussed in detail below, the methods according to the invention include inserting a colored yarn or thread into the candle wick during manufacture. The colored portion of the wick is inserted in such a way that the color is not visible on the surface of the wick and can only be seen in a cross section of the wick. According to a presently preferred embodiment, multiple color combinations are used to identify a broad range of different types of wicks. According to an optional method of the invention, the color coding of the wick also identifies the manufacturer as well as the wick characteristics.
[0020] The candle wicks according to the invention are coded at the time of manufacture and therefore maintain the proper coding throughout their chain of custody from the manufacturer to the consumer. The wick identification can be read at any time, even after the candle is consumed. Thus, fire investigations are assisted and product liability evidence is preserved in the case of improperly manufactured candles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic view of a cored round wick according to the invention during the manufacturing process;
[0022] FIG. 2 is a schematic cross section of the wick of FIG. 1 ;
[0023] FIG. 3 is a view similar to FIG. 2 but illustrating a multicolor coding;
[0024] FIG. 4 is a schematic view of a coreless flat wick according to the invention during the manufacturing process;
[0025] FIG. 5 is a schematic cross section of the wick of FIG. 4 ;
[0026] FIG. 6 is a view similar to FIG. 5 but illustrating a multicolor coding;
[0027] FIG. 7 is a schematic view of a knitted wick according to the invention during the manufacturing process;
[0028] FIG. 8 is a schematic cross section of the wick of FIG. 7 ;
[0029] FIG. 9 is a view similar to FIG. 8 but illustrating a multicolor coding;
[0030] FIG. 10 is a schematic view of a square braided wick according to the invention during the manufacturing process;
[0031] FIG. 11 is a schematic cross section of the wick of FIG. 10 ;
[0032] FIG. 12 is a view similar to FIG. 11 but illustrating a multicolor coding; and
[0033] FIG. 13 is a table illustrating an exemplary relationship between color code and wick type.
DETAILED DESCRIPTION
[0034] Turning now to FIGS. 1 and 2 , a first embodiment of a candle wick 10 according to the invention includes a round braided outer part 12 which is made from cotton threads 14 in a braiding machine. The wick 10 is provided with a core 16 within which are placed a core filament 18 (e.g. cotton, paper, copper, zinc, tin, fiberglass, etc.) and a colored identification filament 20 . The colored identification filament is preferably made of a compatible candle wick fiber which is dyed with a colorfast dye which will not fade or change color during combustion or over time. Although FIGS. 1 and 2 show a single monochromatic identification filament, it will be appreciated that a single multi-colored or striped identification filament or multiple filaments of the same and/or different colors may be incorporated into the core of the wick to make visual identification easier.
[0035] FIG. 3 illustrates an alternate first embodiment of a candle wick 10 ′. In this embodiment, filaments 20 , 22 , 24 , and 26 define a multicolored code. As seen in FIG. 3 the filaments are arranged in a substantially circular pattern. One of the filaments can be colored as a key filament from which the others are to be read in clockwise order. Thus, filaments arranged red, green, blue are a different code from filaments arranged blue, red, green, etc. From the foregoing, those skilled in the art will appreciate that a wide range of codes can be constructed using only a few colors arranged in order. For example, using four filaments and six colors, 1,296 codes can be created (6 4 =1,296).
[0036] FIGS. 4 and 5 illustrate a coreless flat wick 110 according to the invention. The wick 110 according to the invention includes a flat braided outer part 112 which is made from cotton threads 114 in a braiding machine. The wick 110 has a central region 116 within which is placed a colored identification filament 120 . The colored identification filament is preferably made of a compatible candle wick fiber which is dyed with a colorfast dye which will not fade or change color during combustion or over time. Although FIGS. 4 and 5 show a single monochromatic identification filament, it will be appreciated that a single multi-colored or striped identification filament or multiple filaments of the same and/or different colors may be incorporated into the central region of the wick to make visual identification easier.
[0037] FIG. 6 illustrates an alternate second embodiment of a candle wick 110 ′. In this embodiment, filaments 120 , 122 , 124 , and 126 define a multicolored code. As seen in FIG. 6 the filaments are arranged in a substantially linear pattern. One of the filaments (e.g. 126 or 122 ) can be colored as a key filament from which the others are to be read left to right or right to left whatever convention is chosen. Thus, filaments arranged red, green, blue are a different code from filaments arranged blue, red, green, etc.
[0038] FIGS. 7 and 8 illustrate a knitted wick 210 according to the invention. The wick 210 according to the invention includes an outer part 212 which is made from cotton threads 214 in a knitting machine. The wick 210 has a central region 216 within which is placed a colored identification filament 220 . The colored identification filament is preferably made of a compatible candle wick fiber which is dyed with a colorfast dye which will not fade or change color during combustion or over time. Although FIGS. 7 and 8 show a single monochromatic identification filament, it will be appreciated that a single multi-colored or striped identification filament or multiple filaments of the same and/or different color may be incorporated into the central region of the wick to make visual identification easier.
[0039] FIG. 9 illustrates an alternate third embodiment of a candle wick 210 ′. In this embodiment, filaments 220 , 222 , 224 , and 226 define a multicolored code. As seen in FIG. 9 the filaments are arranged in a pattern. One of the filaments can be colored as a key filament from which the others are to be read according to a predefined convention.
[0040] FIGS. 10 and 11 illustrate a square braided wick 310 according to the invention. The wick 310 according to the invention includes an outer part 312 which is made from cotton threads 314 in a braiding machine. The wick 310 has a central region 316 within which is placed a colored identification filament 320 . The colored identification filament is preferably made of a compatible candle wick fiber which is dyed with a colorfast dye which will not fade or change color during combustion or over time. Although FIGS. 10 and 11 show a single monochromatic identification filament, it will be appreciated that a single multi-colored or striped identification filament or multiple filaments of the same and/or different color may be incorporated into the central region of the wick to make visual identification easier.
[0041] FIG. 12 illustrates an alternate fourth embodiment of a candle wick 310 ′. In this embodiment, filaments 320 , 322 , 324 , and 326 define a multicolored code. As seen in FIG. 12 the filaments are arranged in a pattern. One of the filaments can be colored as a key filament from which the others are to be read according to a predefined convention.
[0042] The above examples illustrate different candles according to the invention and methods of making them. It will be appreciated that another part of the invention is to relate the color coding to candle type and (optionally) manufacturer. FIG. 13 is an example of how this code relationship can be expressed. The table in FIG. 13 illustrates a five order, four color coding scheme. The colors are red (R), green (G), blue (B) and yellow (Y). An ordered combination of five colors indicates the manufacturer, the wick type, the yield (yards per pound), the rate of combustion (ROC in ounces per hour), the flame height and the pool diameter (both in inches).
[0043] There have been described and illustrated herein several embodiments of candle wicks and methods for making candle wicks. 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. For example, the illustrated embodiments refer to specific materials such as cotton threads, and various core materials. It will be appreciated that other suitable candle materials can be used within the scope of the invention. Although four different types of candle wick have been illustrated, it will be understood that the invention can be applied to virtually any type of candle wick. Moreover, while a specific number of colored identification filaments has been disclosed as well as specific colors, it will be understood that the color and number of filaments will be chosen to effect the identification function of the invention. It will also be appreciated that multicolored filaments could also be used, e.g., a blue filament with a yellow stripe or a green filament with a red stripe. In addition, the placement of the one or more colored filaments can be varied, as desired, for a particular application, the only requirement being that the colored filament(s) not be generally visible along the outer surface or length of the wick, i.e., only the ends of the colored filament(s) being viewable at the tip of the wick, (e.g., see FIG. 1 ) or when viewed in a cross-sectional cut of the wick, (e.g., see FIGS. 2 and 3 ). 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. | The methods according to the invention include placing a colored yarn or thread into a candle wick during manufacture. The colored portion of the wick is preferably placed in such a way that the color is not visible on the surface of the wick and can only be seen in a cross section of the wick. According to a presently preferred embodiment, multiple color combinations are used to identify a broad range of different types of wicks. According to an optional method, the color coding of the wick also identifies the manufacturer as well as the wick characteristics. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit U.S. Provisional Application No. 61/103,854, filed Oct. 8, 2008, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Most skin lesions are caused by viral infections such as an infection by herpes viruses. There are two types of herpes simplex virus: herpes simplex virus 1 (HSV-1) and herpes simplex virus 2 (HSV-2). Cold sores or fever blisters are often caused by simplex virus 1. Genital herpes are often caused by simplex virus 2.
[0003] Cold sores or fever blisters are characterized by a blister or groups of blisters containing a clear fluid formed on the skin or mucous membranes such as the lips or mouth. In addition, cold sores or fever blisters may be accompanied by a cold or fever or both. The blister associated with this disease may cover a large portion of the lip and cause severe itching, stinging, and localized pain. Without medication, it is common for a blister to remain on the skin in excess of one week and to take two weeks to completely heal. In some instances where secondary infections occur, the healing period can be even further prolonged.
[0004] There are several medications available to treat cold sores. Some are used topically and others are taken orally. For example, penciclovir 1% cream (Denavir®) is believed to reduce the time to healing by two days if starting treatment within one hour of an outbreak; frequent application of acyclovir 5% cream (Zovirax®) is believed to reduce the time to healing by about half a day; taking famciclovir (Famvir®) 1500 mg may shorten the herpes infection by two days; and taking valacyclovir (Valtrex®) 2 gm twice a day for one day may shorten a herpes infection by a little over one day.
[0005] Sometimes, local anesthetics are used to mitigate pain associated with such sores, and antibiotics are used to control secondary bacterial infections when they occur. Ointments may also be used to soften crusts. However, use of an antibiotic frequently causes side reactions and tends to sensitize the patient to further effective or safe use of the drug. Hence, it is important to avoid the secondary infection stage. Until the present invention, it is not believed that an effective cure has been available.
[0006] Therefore, there is a need for an effective method of treating skin lesions caused by viral infection, such as fever blisters or cold sores. The present invention seeks to address this need and provide further related advantages.
SUMMARY OF THE INVENTION
[0007] The present invention relates to a novel method for treating skin lesions. For example, provided is a method of treating a skin lesion in a subject in need of treatment, comprising topically administering to said lesion a composition comprising an effective amount of one or more aluminum salts. Also provided is a method of treating a skin lesion in a subject in need of treatment, comprising topically administering to said lesion a composition consisting essentially of an effective amount of one or more aluminum salts. Embodiments also provide a method of treating a skin lesion in a subject in need of treatment, comprising topically administering to said lesion a composition consisting of an effective amount of one or more aluminum salts.
[0008] The aluminum salt may be selected from a group consisting of potassium aluminum sulfate, anhydrous potassium aluminum sulfate, potassium aluminum sulfate dodecahydrate, ammonium aluminum sulfate, anhydrous ammonium aluminum sulfate, and ammonium aluminum sulfate dodecahydrate.
[0009] A composition of the present invention may further comprise an analgesic, such as lidocaine or benzocaine. A composition may further comprise a pharmaceutically acceptable carrier. The composition may be comprised in a gel, cream, lotion, or liquid formulation. A composition of the present invention may be held in a collapsible container, for example.
[0010] A composition may be applied directly to a skin lesion, and the topical application may be repeated on the subject in need of the treatment twice a day for two to five days.
[0011] Also provided is a method comprising the steps of wetting a styptic pencil with water to provide a wetted styptic pencil and applying the wetted styptic pencil directly on a skin lesion. Also provided is a method that consists essentially of the steps of wetting a styptic pencil with water to provide a wetted styptic pencil; and applying the wetted styptic pencil directly on a skin lesion. Further provided is a method that consists of the steps of wetting a styptic pencil with water to provide a wetted styptic pencil; and applying the wetted styptic pencil directly on a skin lesion.
[0012] Also contemplated is a method comprising the steps of wetting styptic powder with water to provide a styptic powder solution; and applying the styptic powder solution directly on a skin lesion. Provided further is a method consisting essentially of the steps of wetting styptic powder with water to provide a styptic powder solution; and applying the styptic powder solution directly on a skin lesion. Also provided is a method consisting of the steps of wetting styptic powder with water to provide a styptic powder solution; and applying the styptic powder solution directly on a skin lesion.
[0013] Another aspect contemplates a method of treating a skin lesion in a subject in need of treatment, comprising spraying a solution comprising an about 50% (w/v) concentration of one or more aluminum salts on the lesion. Also provided is a method of treating a skin lesion in a subject in need of treatment, comprising spraying a solution consisting essentially of an about 50% (w/v) concentration of one or more aluminum salts on the lesion. Also provided is a method of treating a skin lesion in a subject in need of treatment, comprising spraying a solution consisting of an about 50% (w/v) concentration of one or more aluminum salts on the lesion.
[0014] Methods of the present invention are useful in treating skin lesions, including viral-caused skin lesions such as a herpes lesion or a cold sore.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The present invention is related to a novel method for treating skin lesions. In one aspect, the present invention provides a method of treating a skin lesion, such as lesions caused by a herpes virus. Persons of skill in the art are familiar with methods of identifying skin lesions of the type discussed herein.
[0016] A method may comprise the step of topically administering to a skin lesion a pharmacologically effective amount of a composition comprising one or more aluminum salts. A method may comprise treating a skin lesion in a subject in need of treatment, comprising topically administering to said lesion a composition comprising, consisting essentially of, or consisting of an effective amount of one or more aluminum salts.
[0017] A person skilled in the art will recognize that the aluminum salt useful in the present invention may be an aluminum salt in any form including, but not limited to, potassium aluminum sulfate and ammonium aluminum sulfate. Potassium aluminum sulfate may be in either anhydrous form or any hydrate form. The aluminum salt may be potassium aluminum sulfate dodecahydrate, KAI(SO 4 ) 2 .12H 2 O. Similarly, ammonium aluminum sulfate may be in either anhydrous form or any hydrate form. The aluminum salt may be ammonium aluminum sulfate dodecahydrate, NH 4 Al(SO 4 ) 2 .12H 2 O. Aluminum salt suppliers are well-known in the art (e.g., Hospira, Inc., or Abbott Laboratories).
[0018] Compositions of the present invention may comprise an effective amount of one or more aluminum salts and may optionally include additional agents, as discussed below. As used herein, the term “effective” (e.g., “an effective amount”) means adequate to accomplish a desired, expected, or intended result. For example, an effective amount may refer to an amount necessary to reduce the appearance of a skin lesion. As used herein, a “pharmacologically effective amount” refers to that amount of the compound effective to produce the intended pharmacological result, e.g., reduce the appearance of a skin lesion, reduce pain, or reduce stinging. As such, an “effective amount” may be the same as a “pharmacologically effective amount.”
[0019] A composition of the present invention may comprise, consist essentially of, or consist of one or more aluminum salts in an amount of about 5-100% (w/v) or (w/w). In certain embodiments, the amount is about, at most about, or at least about 5, 10, 20, 30, 40, 50, 60, 70, 80, 90, 95, or 100%, or any range derivable therein. In certain embodiments, the amount is about 25-50%. In certain embodiments, the amount is about 40-60%. In particular embodiments, the amount is about 50%. For example, a solution may comprise a 50% (w/v) amount of an aluminum salt, such as ammonium aluminum sulfate dodecahydrate. As another example, a styptic pencil may comprise 100% of a salt described herein.
[0020] A composition may further comprise an analgesic to reduce the pain caused by the skin lesion. Analgesics useful in the present invention may include lidocaine or lidocaine HCl, benzocaine, butamben picrate, dibucaine or dibucaine HCl, dimethisoquin HCl, dyclonine HCl, pramoxine HCl, tetracaine or tetracaine HCl.
[0021] Antibiotic agents may be added to a composition to control a secondary bacterial infection resulting from the skin lesion. A person skilled in the art will recognize that many topical antibiotic agents may be useful in the present invention, including, but not limited to, polymixin B sulfate, gramicidin, bacitracin, and bacitracin zinc.
[0022] Other ingredients may be added to a composition for application ease such as increasing the softness and improving the smell of the formulation. Therefore, the composition may further comprise a pharmaceutically acceptable carrier. The phrases “pharmaceutically or pharmacologically acceptable” refers to molecular entities and compositions that do not produce an adverse, allergic, or other untoward reaction when administered to a subject.
[0023] The carrier component should be physiologically compatible with human skin and membrane tissues. The carrier may be a mixture of components. It is typically non-irritating and may act as a thickening agent for the composition. A number of such agents are well known in the art, for example, the CTFA Cosmetic Ingredient Dictionary. Carrier components may also act as a solvent for other components of the composition. In addition, the carrier may act as a demulcent and may have emollient properties. Some typical carrier components include glycerin and pectin. Glycerin is a viscous hygroscopic liquid that acts as a solvent and demulcent. Glycerin may be present at a concentration of 15-40% v/v, for example, although concentrations of glycerin may be varied over an even broader range to achieve a desired consistency.
[0024] Another optional carrier component may be pectin. Pectin is a negatively charged polysaccharide that adds viscosity to a composition. Typically, pectin is included at a concentration of 0.5%-2% w/v; however, as for glycerin above, the concentration may be considerably varied to achieve a desired consistency. Other typical carrier components include gums, mucilages, dextrins, and hydroxy- and carboxycelluloses. Carrier components may be added that provide (i) an agreeable feeling (such as camphor or phenol), (ii) improved fluidity (such as polyalcohols), or (iii) improved storage stability (such as sodium benzoate). Except insofar as any conventional carrier is incompatible with the active ingredient, its use in the therapeutic or pharmaceutical compositions discussed herein is contemplated.
[0025] A number of preservatives are available for use in the composition described herein, including: benzalkonium chloride, organic mercury compounds, sorbic acid, hexachlorophene, and parabens. One exemplary preservative is sodium benzoate. Sodium benzoate may be used in compositions of the present invention at a concentration of about 0.1-0.50%, such as 0.25% w/v, for example.
[0026] Methods of formulation are well known in the art and are disclosed, for example, in Remington: The Science and Practice of Pharmacy, Mack Publishing Company, Easton, Pa., 19th Edition (1995). Pharmaceutical formulations for topical administration of a composition include ointments, pastes, creams, lotions, gels, powders, solutions, sprays, inhalants, or patches. An active component (e.g., an aluminum salt) is typically admixed under sterile conditions with a pharmaceutically acceptable carrier and any needed preservatives or buffers as may be required. A composition may be administered by rubbing a cream comprising the composition on the lesion, for example, or by spraying an aqueous solution comprising the composition on the lesion. Other administration methods are discussed herein. The ointments, pastes, creams and gels may contain, in addition to an active compound of this invention, excipients such as animal and vegetable fats, oils, waxes, paraffins, starch, tragacanth, cellulose derivatives, polyethylene glycols, silicones, bentonites, silicic acid, talc and zinc oxide, or mixtures thereof.
[0027] A product including the composition of the present invention may be held in a collapsible container as a liquid, cream, lotion, ointment, or gel form. Alternatively, the product may be in a form of stick. The package of the product may bear the warning such as “do not use this product on or around the eye in any form or shape.” A liquid composition may be comprised in a spray bottle, such as a 30 cc spray bottle.
[0028] The product may be applied directly on the cold sore or herpes lesion on the lips or inside the mouth, or on the external or internal vaginal canal, or on the penile shaft, or on any herpes sore on the outside skin. The topical application of the product may be repeated on the subject in need of the treatment, such as for twice a day for two to five days. Administration may take place two times a day for 2, 3, 4, or 5 days, or any range derivable therein, for example. The sore will likely sting at the time of the application, which will typically last for about 1-2 minutes. The sting will typically go away after the second day of application.
[0029] Another aspect of the present invention contemplates a method of treating a skin lesion in a subject in need of treatment, comprising spraying a solution consisting essentially of an about 50% (w/v) concentration of one or more aluminum salts on the lesion.
[0030] Styptic or hemostatic pencils and styptic powder are known to include an aluminum salt. A styptic or hemostatic pencil is a short stick of medication, usually anhydrous aluminum sulfate or titanium dioxide, which is used for staunching blood by causing blood vessels to contract at the site of the wound. Styptic powder is usually used to stop bleeding from nails that are clipped too closely.
[0031] The inventors of the present invention unexpectedly discovered that a styptic pencil or styptic powder is effective in treating skin lesions, such as cold sores. In one embodiment, the present invention therefore provides a method for treating a skin lesion comprising the steps of wetting a styptic pencil with water to provide a wetted styptic pencil and applying the wetted styptic pencil directly on a skin lesion. In another embodiment, the present invention provides a method for treating a skin lesion, including the step of wetting styptic powder with water to provide a styptic powder solution and applying the styptic powder solution directly on a skin lesion. Any pencil or powder discussed herein comprises an effective amount of the salt(s) for the purpose of treating a skin lesion.
[0032] The method of using the styptic pencil is to wet the styptic stick with water and apply it directly on the cold sore or herpes lesion. The application may be used twice a day for 2, 3, 4, or 5 days, or any range derivable therein. Styptic powder may also be applied with this frequency.
[0033] As used herein, the term “patient” or “subject” refers to a living mammalian organism, such as a human.
[0034] “Treatment” and “treating” as used herein refer to administration or application of an active ingredient, such as one or more aluminum salts, to a patient or performance of a procedure or modality on a patient for the purpose of obtaining a therapeutic benefit of a disease or health-related condition. For example, a patient having a skin lesion may be subjected to a treatment comprising administration of a composition comprising one or more aluminum salts in order to reduce the appearance of the skin lesion or to minimize conditions associated with the lesion, such as pain.
[0035] The term “therapeutic benefit” as used throughout this application refers to anything that promotes or enhances the well-being of the patient with respect to the medical treatment of a condition. This includes, but is not limited to, a reduction in the onset, frequency, duration, or severity of the signs or symptoms of a viral-caused skin lesion.
[0036] In any embodiment herein, the term “comprising” may be substituted with “consisting essentially of” or “consisting of.” For example, the present invention contemplates a method of treating a skin lesion in a subject in need of treatment consisting essentially of topically administering to said lesion a composition comprising an effective amount of one or more aluminum salts. As another example, the present invention contemplates a method of treating a skin lesion in a subject in need of treatment consisting essentially of topically administering to said lesion a composition consisting essentially of an effective amount of one or more aluminum salts. The present invention also contemplates a method of treating a skin lesion in a subject in need of treatment consisting of topically administering to said lesion a composition consisting essentially of an effective amount of one or more aluminum salts. The present invention further contemplates a method of treating a skin lesion in a subject in need of treatment consisting of topically administering to said lesion a composition consisting of an effective amount of one or more aluminum salts. Other similar substitutions in any other embodiment discussed herein are also encompassed by the present invention.
[0037] For those embodiments reciting “consisting essentially of,” it is noted that non-limiting examples of materials and steps that do not materially affect the basic and novel aspects of an aluminum salt(s) include those that do not change the chemical structure of the aluminum salt(s) employed, that do not interfere with access of the aluminum salt(s) to the lesion, or those that do not decrease the effective amount of the aluminum salt(s) that is administered. Any further ingredient described herein (e.g., a carrier, a preservative, an antibiotic, an analgesic, an excipient) may be combined in a composition that comprises, consists essentially of, or consists of one or more aluminum salts.
[0038] It is specifically contemplated that any limitation discussed with respect to one embodiment of the invention may apply to any other embodiment of the invention. Furthermore, any composition of the invention may be used in any method of the invention, and any method of the invention may be used to produce or to utilize any composition of the invention.
[0039] The use of the term “or” in the claims is used to mean “and/or” unless explicitly indicated to refer to alternatives only or the alternative are mutually exclusive, although the disclosure supports a definition that refers to only alternatives and “and/or.”
[0040] As used herein, “a” or “an” means one or more, unless clearly indicated otherwise.
[0041] Throughout this application, the term “about” is used to indicate that a value includes the standard deviation of error for the device and/or method being employed to determine the value.
EXAMPLE 1
[0042] An aqueous solution of 50% (w/v) ammonium aluminum sulfate dodecahydrate was applied to a lesion in the mouth of a patient (a cold sore) the day following discovery of the lesion. The solution was applied as a spray twice a day every 12 hours for three days. Upon application, a stinging sensation was experienced by the patient for about one minute. Future applications did not produce a stinging sensation. By the third day, the lesion had regressed and resolved itself. This patient's cold sores normally lasted seven days or more before healing without treatment.
EXAMPLE 2
[0043] An aqueous solution of 50% (w/v) ammonium aluminum sulfate dodecahydrate was applied to a fever blister experienced by a patient. Sores became smaller after the first application (by spraying of the solution) and application of the solution twice a day for two days caused the blister to disappear.
EXAMPLE 3
[0044] An aqueous solution of 50% (w/v) ammonium aluminum sulfate dodecahydrate was applied to a herpes simplex outbreak experienced by a patient. Starting with the first application of the solution by spraying, the outbreak began to dry up. Following twice-a-day applications, the outbreak had disappeared by the fourth day. This patient's outbreak typically takes 1-2 weeks to disappear without treatment.
[0045] While illustrative embodiments are illustrated and described herein, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | The present invention relates to the treatment of skin lesions such as cold sores and other complications resulting from disorders such as herpes and the like. The invention relates to the use of a composition comprising one or more aluminum salts for treatment purposes. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention claims priority from U.S. Patent Application No. 61/702,381 filed Sep. 18, 2012, which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to an exercise device and in particular to a multi-use exercise device for facilitating a wide range of exercises at various degrees of difficulty.
BACKGROUND OF THE INVENTION
Conventional exercise devices, which enable the user to perform elevated push-ups and dips, include a frame with two vertical stanchions interconnected by a horizontal cross brace. Typically, hand grips are mounted on the vertical stanchions to position the user's hands during the exercise.
Since user's come in various shapes and sizes, prior art inventions, such as those disclosed in U.S. Pat. No. 4,900,015 issued Feb. 13, 1990 to Dissenger, and U.S. Pat. No. 7,637,851 issued Dec. 29, 2009 to Lormil, provide for the lateral adjustment of the vertical stanchions relative to each other, and the vertical adjustment of the hand grips by simply providing telescopic extendible frame members.
Unfortunately, prior art devices provide limited adjustments to increase the degree of difficulty of individual exercises or increase the number of different exercises that can be performed. Moreover, the aforementioned prior art devices include large and cumbersome frames, meant to remain stationary on the ground for all exercise.
An object of the present invention is to overcome the shortcomings of the prior art by providing a multi-adjustable exercise device providing various degrees of difficulty for each exercise, and a large increase in the number of exercises performed as both a stationary stand and a dynamic weight bearing structure.
SUMMARY OF THE INVENTION
Accordingly, the present invention relates to an exercise device comprising:
a ground engaging base including first and second elongated legs extending parallel to each other;
a shaft extending between the first and second legs spaced from the ground by the ground engaging base;
first and second spaced apart arms, each having a longitudinal axis extending perpendicular to the shaft, each of the first and second arms is rotatable relative to the shaft, and lockable into several angular positions relative to the shaft and independent of each other;
first and second handles mounted on the ends of the first and second arms, respectively, each of the first and second handles rotatable relative to the longitudinal axis of the first and second arms, respectively, lockable at a plurality of angular positions; and
first and second weight supporting bars extending outwardly from opposite ends of the shaft, respectively, for supporting additional weights.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in greater detail with reference to the accompanying drawings which represent preferred embodiments thereof, wherein:
FIG. 1 is an isometric view of a first embodiment of the exercise device of the present invention;
FIG. 2 is a top view of the exercise device of FIG. 1 ;
FIG. 3 is a front view of the exercise device of FIGS. 1 and 2 ;
FIG. 4 is a side view of the exercise device of FIGS. 1 to 3 ;
FIG. 5 a is a front view of an extendable arm of the exercise device of FIGS. 1 to 4 ;
FIGS. 5 b and 5 c are side views of the extendable arm of FIG. 5 a in the fully retracted and fully extended positions, respectively;
FIG. 6 is an isometric view of a second embodiment of the exercise device of the present invention;
FIG. 7 is an exploded isometric view of the exercise device of FIG. 6 ;
FIG. 8 is a side view of the exercise device of FIGS. 6 and 7 .
DETAILED DESCRIPTION
With reference to FIGS. 1 to 4 , the exercise device 1 of the present invention includes a ground-engaging base comprising first and second elongated legs 2 a and 2 b extending parallel to each other. The first and second legs 2 a and 2 b provide a wide base, e.g. 16 to 24 inches wide, to support a person's body during exercise without flipping. The first and second legs 2 a and 2 b can be any suitable shape, e.g. V-shaped, C-shaped or rectangular shaped, and are made of a material, e.g. aluminum, strong enough to support a person's weight while exercising. In the illustrated embodiments, each of the first and second legs 2 a and 2 b are V-shaped with a mounting collar 3 at the apex, and rounded, ground-engaging feet at the outer free ends thereof.
A shaft 4 extends between the first and second legs 2 a and 2 b , generally perpendicular thereto. The shaft 4 extends through the mounting collars 3 , which are secured together with a suitable fastener, e.g. a threaded fastener 5 , extending through the collars 3 into contact with the shaft 4 . The legs 2 a and 2 b provide separation between the shaft 4 and the ground, e.g. by approximately 4 to 6 inches, for reasons explained hereinafter. Typically the shaft 4 is cylindrical and made of a strong material, e.g. steel.
First and second arms 6 a and 6 b extend perpendicularly from the shaft 4 and are mounted on the shaft 4 so that the first and second arms 6 a and 6 b can rotate about the longitudinal axis of the shaft 4 and can be locked in several different angular positions relative to the base or floor. In the illustrated embodiment, first and second sleeves 7 a and 7 b , respectively, forming the base of the first and second arms 6 a and 6 b , respectively, surround the shaft 4 , and are therefore rotatable relative to the shaft 4 . Spring loaded pull-pins 8 a and 8 b are used to lock the first and second sleeves 7 a and 7 b , respectively, and therefore the arms 6 a and 6 b , in one of several different angular positions defined by a series of radially extending holes 9 a and 9 b spaced in a line around the circumference of the shaft 4 (see FIGS. 2 and 3 ). The first and second arms 6 a and 6 b can also be moved laterally, i.e. along the longitudinal axis, on the shaft 4 by sliding the sleeves 7 a and 7 b longitudinally towards or away from the first leg 2 a . Additional sets of radially extending holes 10 a and 10 b , 11 a and 11 b ( FIGS. 2 and 3 ) are provided to enable the first and second arms 6 a and 6 b to rotate relative to the shaft 4 at the various lateral positions, which enable the position of the arms 6 a and 6 b to be adjusted depending on the exercise, the user's size and arm separation. Typically, each set of holes 9 a , 10 a and 11 a are separated by approximately 2 to 8 cm (1 to 3 inches) providing a total separation between arms 6 a and 6 b of about 40 cm to 55 cm, e.g. 41 cm, 46 cm and 51 cm. Moreover, for one set of exercises, e.g. pushups, the arms 6 a and 6 b are typically should width apart, while of another set of exercises, e.g. squats with the shaft 4 supported on the user's shoulders, the arms 6 a and 6 b should be slightly wider than the user's shoulders.
Each hole in each set of holes 9 a , 10 a and 11 a are angular spaced apart around the circumference of the shaft 4 by approximately 20° to 40°. Accordingly, the angular position of the first and second arms 6 a and 6 b can be adjusted to provide a position that is generally perpendicular to a person's body during a push up, e.g. 0° to 15° from vertical or 75° to 90° from horizontal ground. Alternate positions provide a more difficult push up exercise, e.g. 30° to 50° from vertical, and rotating the first and second arms to a substantially horizontal position, e.g. 70° to 85° from vertical, provides an easier carry and storage arrangement, as well as a more convenient lifting position.
Alternative mechanical structures are possible to enable the first and second arms 6 a and 6 b to rotate about the shaft 4 , and for locking the first and second arms 6 a and 6 b into position at the various angular positions.
The length of each of the first and second arms 6 a and 6 b is also adjustable, by providing a telescopic structure, including an inner tube 13 a , 13 b and an outer tube 14 a , 14 b . The relative positions of the inner and outer tubes can be unlocked and locked in various ways, including a lever actuated expanding friction sleeve 15 a and 15 b extending through a hole in the outer tube 13 a / 13 b to the inner tube 14 a / 14 b . Rotation of the levers 15 a and 15 b causes the expanding friction sleeve to shrink enabling the outer tubes 14 a and 14 b to be slid relative to the outer tubes 13 a and 13 b , respectively, from a retracted position to any number of extended positions. Rotating the levers 15 a and 15 b back to the locked position expands the friction sleeve locking the outer tubes 14 a and 14 b relative to the inner tubes 13 a and 13 b , respectively.
Extending perpendicularly from the outer free ends of the first and second arms 6 a and 6 b are first and second handles 17 a and 17 b , which are rotatable relative to the longitudinal axis of the first and second arms 6 a and 6 b , respectively, about a 360° angle providing various hand positions for exercises, such as pushups (handles 17 a and 17 b fixed, pointed inwardly at each other), curls (handles 17 a and 17 b fixed, pointed outwardly in opposite directions), and squats (fixed, parallel to each other, pointing towards user). In this embodiment, the angular position of the handles 17 a and 17 b is adjusted in the same manner as the length, i.e. releasing the levers 15 a and 15 b , which enables the outer tubes 14 a and 14 b to be rotated about the longitudinal axis of the inner tubes 13 a and 13 b , respectively, thereby rotating the handles 17 a and 17 b about the longitudinal axis of the inner tubes 13 a and 13 b.
To provide additional exercises, extension bars 21 a and 21 b are provided, extending outwardly from the ends of the shaft 4 , separate from the arms 6 a and 6 b , for supporting conventional weight plates. The extension bars 21 a and 21 b can be permanently fixed to the opposite ends of the shaft 4 or they can be removable and conveniently locked into position, when desired. If the first and second arms 6 a and 6 b are rotated to the closed or storage position, proximate the first and second legs 2 a and 2 b , the shaft 4 can be grasped by one or both hands, and the device 1 can be lifted like a dumbbell. Clips (not shown) can be provided for securing the weights on the bars 21 a and 21 b.
Handles 22 , extending perpendicular to the shaft 4 , can be provided on the first and second legs 2 a and 2 b , respectively, to facilitate lifting of the entire device 1 with the extra weight plates on the bars 21 a and 21 b , in an alternative weight lifting exercise. A tray 24 , extending between the first and second legs 2 a and 2 b for contacting the ground, provides a foot rest to stabilize the device during some exercises or during adjustment of the various elements.
With reference to FIGS. 5 a to 5 c , in an alternate embodiment of the present invention is provided for adjusting the length of the arms 6 a and 6 b , and the rotational position of the handles 17 a and 17 b . The inner tubes 13 a and 13 b are provided with a series of spaced apart and aligned holes 31 , while the outer tubes 14 a and 14 b are provided with a spring loaded pin 32 , which extends through the outer tubes 14 a and 14 b into engagement with one of the holes 31 for locking the outer tubes 14 a and 14 b relative to the inner tubes 13 a and 13 b , respectively. A set screw 33 , with a lever or knob 34 on the end to facilitate rotation, is provided for loosening and tightening the handles 17 a and 17 b in any angular position desired perpendicular to the arms 6 a and 6 b , respectively.
With reference to FIGS. 6 to 8 , an alternative mechanical structures can be provided for locking the inner and outer tubes in position, such as a compression friction clamp 40 , positioned at the top of the outer tubes 14 a and 14 b for locking both the position of the inner tubes 13 a and 13 b , i.e. the length of the arms 6 a and 6 b , as well as the angular position of the handles 17 a and 17 b.
In the embodiment illustrated in FIGS. 6 to 8 , the handles 22 and the tray 24 are omitted to simplify the design. Furthermore, each outer tube 14 a and 14 b includes a strengthening brace 42 extending from approximately the midpoint of the outer tube 14 a and 14 b to the base of the outer tube 14 a and 14 b , i.e. the collar 7 a and 7 b , respectively. The braces 42 provide reinforcement for the first and second arms 6 a and 6 b , while the first and second arm 6 a and 6 b are in an upright position ( FIG. 6 ), and provide handles for lifting the device, while the first and second arms 6 a and 6 b are in a closed position ( FIG. 8 ). All the other elements are substantially the same as the previous embodiment.
The structure and adjustability of the present invention enables the user to perform dozens of different exercises, including several with the device stationary on the ground, several with the device being lifted off of the ground, several with the device lifted from one raised position to another, and several with the device supported on the user's body.
The first set of exercises in which the legs 2 a and 2 b are stationary on the ground and the arms 6 a and 6 are extended upwardly in the upright position include pushups, high planks and side planks all with various arm angles and handle angles.
The second set of exercises in which the device is lifted off the ground with the arms 6 a and 6 b extended upwardly include, chest presses and curls. The handles 17 a and 17 b can be rotated to extend towards each other or away from each other. The bars 21 a and 21 b enable additional weight to the added for a more strenuous workout. When the arms 6 a and 6 b are rotated substantially parallel with the ground in the closed position, the device can also be used for deadlifts, arm raises, pull overs, and leg raises. With the arms 6 a and 6 b rotated downwardly, the shaft 4 or the braces 42 provide hand grips, and the bars 21 a and 21 b enable additional weight to be added. With the arms 6 a and 6 b in the closed position, the device becomes much less awkward to lift, eliminating the moment caused by the arms 6 a and 6 b extending in a direction perpendicular to the legs 2 a and 2 b.
The third set of exercises are performed with the arms 6 a and 6 b rotated down adjacent the legs 2 a and 2 b , respectively in the closed position. They include single arm curls, double arm curls, shoulder presses, triceps curls. Again, additional weight can be added onto the bars 21 a and 21 b , and the arms 6 a and 6 b and the legs 2 a and 2 b extend in the same general direction providing a much less awkward device during lifting.
The fourth set of exercise are performed with the shaft 4 supported on the user's shoulders, and with the arms 6 a and 6 b rotated down parallel to the legs 2 a and 2 b , respectively, in the closed position extending outwardly from each side of the user's head, wherein the handles 17 a and 17 b , rotated to extend in opposite directions, provide convenient hand grips for balancing and supporting the device in place. Providing the handles 17 a and 17 b in front of the user and below shoulder height instead of behind the user and above should height greatly enhances the ease at which the device can be balanced on the user's shoulders throughout the range of exercises and movements. These exercises include a wide variety of squats and lunges. | A multi-use exercise device includes a shaft extending between ground-engaging support structures with a pair of arms rotatable around the shaft into a plurality of various angular positions relative to the ground providing a plurality of different exercises with a plurality of different levels of difficulty. The exercise device can be used as a support structure for pushup and planking exercises, as well as shoulder mounted weight support for squats and lunges. | 0 |
This application is the U.S. National Phase of, and Applicants claim priority from, International Application Number PCT/CU2007/000010 filed 28 Feb. 2007 and Cuban Application bearing Serial No. CU 2006-0049 filed 28 Feb. 2006, which are incorporated herein by reference.
TECHNICAL FIELD
The present invention is related to the field of molecular and experimental oncology, in particular to the description of a pharmaceutical combination directed to the treatment and/or chemosensibilization of refractory tumors to conventional cytostatics.
PRIOR ART
In the last three decades, the use of chemical drugs as cytostatics for cancer therapy constitutes one of the choices as first-line treatment for some solid and hematopoietic tumors. The most commonly used chemical drugs for cancer therapy are: cisplatin, taxols, alcaloids from Vinca, doxorubicin, 5-fluorouracil, cyclophosphamide among others (Jackman A. L., Kaye S., Workman P. (2004) The combination of cytotoxic and molecularly targeted therapies-can it be done? Drug Discovery Today 1:445-454). However, results from clinical trials exhibit a low therapeutic index for this kind of drug in cancer therapy as evidenced by the marginal therapeutic benefit along with the high toxicity profile observed in the patients (Schrader C., et al. M. (2005) Symptoms and signs of an acute myocardial ischemia caused by chemotherapy with paclitaxel (taxol) in a patient with metastatic ovarian carcinoma. Eur J Med Res 10:498-501). For example, many authors agree that cisplatin constitutes the first-line treatment for lung cancer, however a modest efficacy is commonly observed with little improvement on the clinical symptoms and 6-weeks increase of survival (Grillo R., Oxman A., Julian J. (1993) Chemotherapy for advanced non-small cell lung cancer. J Clin Oncol 11:1866-1871; Bouquet P. J., Chauvin F., et al (1993) Polychemotherapy in advanced non-small cell lung cancer: a meta-analysis. Lancet 342:19-21). Therefore, the current strategies to achieve an optimal therapeutic benefit are focused to pharmaceutical combinations based on conventional cytostatic drugs along with molecular targeted therapies. Some of the current anticancer drugs are classified as cancer targeted therapy, for instance, Gleevec (Imatinib) which targets the Abl kinase that in turns play an essential role on the development of Chronic Myeloid Leukemia (Giles J. F., Cortes J. E., Kantarjian H. M. (2005) Targeting the Kinase Activity of the BCR-ABL Fusion Protein in Patients with Chronic Myeloid Leukemia. Current Mol Med 5:615-623), also Iressa that targets tyrosine kinase associated to the Epidermal Growth Factor (EGF) receptor (Onn A., Herbst R. S. (2005) Molecular targeted therapy for lung cancer. Lancet 366:1507-1508) and Velcade (Bortezomib) which blocks the protein degradation by targeting the proteasome machinery (Spano J. P., et al. (2005) Proteasome inhibition: a new approach for the treatment of malignancies. Bull Cancer 92:E61-66), among others. Considering that the non-specific mechanisms of the conventional chemotherapeutics converge on the abrogation of cellular mitosis, the use of the new cancer targeted therapeutics provides great perspectives to achieve pharmaceutical combinations which produce synergism of the antitumor effect.
On the other hand, drug resistance phenomenon is recognized as the primary cause of the failure on cancer therapy when chemotherapeutic agents are employed. In spite of that sub-optimal drug concentration on the tumor milieu could influence the drug resistance, other factors like cellular origin plays an essential role on the chemo resistance for many tumors. Drug resistance is a multifactorial phenomenon depending on multiple independent mechanisms which involve intracellular detoxification, changes on the cellular response, tolerance to stress and defects on the apoptosis signaling pathways (Luqmani A. (2005) Mechanisms of drug resistance in cancer chemotherapy. Med Princ. Pract 14:35-48). The Glycoprotein-P and the Gluthathion S-transferase are the major proteins that mediate the intracellular detoxification process linked to the drug resistance phenomenon in cancer (Saeki T., Tsuruo T., Sato W., Nishikawsa K. (2005) Drug resistance in chemotherapy for breast cancer. Cancer Chemother Pharmacol 56:84-89) (Hara T., et al. (2004) Gluthathione S-transferase P1 has protective effects on cell viability against camptothecin. Cancer Letters 203:199-207). Other proteins like beta-tubulins have been reported to be involved on the drug resistance phenomenon and whose levels directly correlate with the tumor resistance to Paclitaxel (Orr G. A., et al. (2003) Mechanisms of Taxol resistance related to microtubules. Oncogene 22:7280-7295). Otherwise, the cisplatin resistance has been reported to be influenced by the over expression of different proteins like T-plastin (Hisano T., et al. (1996) Increased expression of T-plastin gene in cisplatin-resistant human cancer cells: identification by mRNA differential display. FEBS Letters 397:101-107), the Heat Shock Protein (HSP70) and (HSP90) (Jaattela M. (1999) Escaping cell death: survival proteins in cancer. Exp Cell Res 248:30-43) and the transcription factor YB1 (Fujita T., et al. (2005) Increased nuclear localization of transcription factor Y-box binding protein accompanied by up-regulation of P-glycoprotein in breast cancer pretreated with paclitaxel. Clin Cancer Res 11:8837-8844). Additionally, exacerbation of Glycolisis and Piruvate pathways has been reported to play an essential role on the chemo resistance phenomenon observed in tumor cells (Boros L. G., et al. (2004) Use of metabolic pathway flux information in targeted cancer drug design. Drug Disc. Today 1:435-443).
Reports from different groups have indicated the existence of a set of proteins which either inhibit apoptosis or increase cell survival on tumor cells thus contributing to the chemoresistance phenomenon of tumors. One of the examples is the Nucleophosmin protein which plays a central role on cell cycle promoting, inhibition of apoptosis and it has been regarded as a poor prognosis marker in cancer (Ye K. (2005) Nucleophosmin/B23, a multifunctional protein that can regulate apoptosis. Cancer Biol Ther 4:918-923). Likewise, the CK2 enzyme plays an important role on cell survival and in the resistance of tumor cells toward apoptosis (Tawfic S., Yu S., Wang H., Faust R., Davis A., Ahmed K. (2001) Protein kinase CK2 signal in neoplasia. Histol. Histopathol. 16:573-582). Previous findings have revealed the elevation of CK2 activity from 3- to 7-fold in epithelial solid tumors respect to the normal tissues (Tawfic S., Yu S., et al. (2001) Protein kinase CK2 signal in neoplasia. Histol Histopatol. 16:573-582; Faust R. A., Gapany M., et al (1996) Elevated protein kinase CK2 activity in chromatin of head and neck tumors: association with malignant transformation. Cancer Letters 101:31-35). Furthermore, the CK2 activity is an important cellular event for the malignant transformation and it constitutes a tumor progression marker (Seldin D. C., Leder P. (1995) Casein Kinase IIα transgene-induced murine lymphoma: relation to theileroiosis in cattle. Science 267:894-897). The fact that the CK2 phosphorylation represents a strong signal to protect tumor cells from apoptosis, it leads to the consideration of this enzyme as an antiapoptotic mediator on cellular physiology (Ahmed K., Gerber D. A., Cochet C. (2002) Joining the cell survival squad: an emerging role for protein kinase CK2 . Trends Cell Biol, 12:226-229; Torres J., Rodríguez J., et al (2003) Phosphorylation-regulated cleavage of the tumor suppressor PTEN by caspase-3: implications for the control of protein stability and PTEN-protein interactions. J Biol Chem, 278:30652-60).
Altogether, the CK2 phosphorylation is a biochemical event that represents a potential target for cancer therapy and specific inhibitors of this event could lead to drug candidates with perspectives cancer management.
Different groups have developed different strategies to inhibit the CK2 phosphorylation using two independent approaches. a) Direct inhibition of the CK2 alpha catalytic subunit, b) Direct targeting of the acidic domain on the CK2 substrates (patent WO 03/054002 and Perea S. E., et al. (2004) Antitumor effect of a novel proapoptotic peptide impairing the phosphorylation by the protein kinase CK2 . Cancer Res. 64:7127-7129). Using both approaches, authors have demonstrated the proof-of-principle that the CK2 inhibition lead to apoptosis on tumor cells. These findings reinforce the experimental validation of CK2 as a suitable target to develop anticancer drugs.
The comparative proteomic studies along with the development of molecular biology have permit in part, the understanding of the molecular mechanisms involved both in cell malignant transformation and tumor chemoresistance. Therefore, cancer therapy regimens should focus their attention in achieving effective drug combinations which greatly reduce toxicity and also reduce the possibility of chemoresistance arising. Thus, one of the major goals today in cancer therapy is to increase the therapeutic index of the current cytostatic drugs by reducing the effective dose and the intrinsic toxicity displayed by this kind of medicines. Other current strategy is to bypass the tumor chemoresistance toward the conventional cytostatic drugs.
DETAILED DESCRIPTION OF THE INVENTION
This invention solves the problem above mentioned as it provides a pharmaceutical combination that contains two ingredients: a CK2 phosphorylation inhibitor (P15 peptide) and a cytostatic drug pharmaceutically acceptable.
In this invention, “cytostatic drug pharmaceutically acceptable” referrers to all the cytostatic chemical compounds used for cancer chemotherapy both for solid tumors and those from hematopoietic origin. The preferred cytostatics are cisplatin and carboplatin, paclitaxel and docetaxel, vincristine and vinblastine, 5-fluouracil, doxorubicin, cyclophosphamide, etoposide, mytomicin C, imatinib, iressa, and velcade (bortezomib) mixed with appropriated vehicles.
In this invention, the concept of “inhibition of CK2 phosphorylation” also includes any chemical or peptidic compound that blocks either the substrate or the enzyme itself. Depending on the situation, the active ingredients of this pharmaceutical combination can be administered simultaneously, separated o sequentially. The administration of this pharmaceutical combination can be performed by systemic, topic or oral routes. This invention also referrers to the treatment and/or the bypassing of the chemoresistance in refractory tumors occurring in human beings using the pharmaceutical combination mentioned above.
Likewise, this invention referrers to the use of the ingredients of this pharmaceutical combination to prepare a medicine to treat chemorefractory tumors and to increase the antitumor effect of the cytostatic drugs cited in this invention.
The example 1 (Table 1) shows that the pharmaceutical combinations described in this invention produce a synergistic antineoplastic effect in vitro. Thus, the simultaneous combination of sub-optimal doses from the P15 peptide along with cisplatin, paclitaxel, doxorubicin, vincristin, etoposide, mitomicin C, 5-fluouracil, imatinib, or iressa, achieves a 10- or 100-fold reduction of the effective dose for each cytostatic drug mentioned in this invention. Effective dose is that achieves a 50% of the antineoplastic effect which is also termed Inhibitory Concentration 50% (IC50) in proliferation assays in vitro. In this invention, “sub-optimal doses” referrers to those lower than the IC50.
The example 2 illustrates the potentiation of the antitumor effect in vivo by using this pharmaceutical combination containing the P15 peptide along with cisplatin ( FIG. 1A ), cyclophosphamide ( FIG. 1B ) and mytomicin C ( FIG. 1C ). The pharmaceutical combination leads to the complete tumor regression in a relevant animal model like that consisting in a human tumor xenografted in nude mice. However, the use of the ingredients of this pharmaceutical combination like monotherapy did produce only a marginal delay on tumor growth compared to the effect observed in placebo group.
The sequential administration of the ingredients from this pharmaceutical combination demonstrates that P15 treatment bypasses the tumor chemoresistance both in vitro and in vivo. In this invention, it is understood that “bypassing of tumor chemoresistance or chemosensibilization” referrers to the event of reducing the drug dose needed to produce the 50% of the antitumor effect after pretreatment with the P15 peptide. The example 3 illustrates the effect of P15 peptide pretreatment in the chemosensibilization of tumor cells and it produces from 10- to 100-fold reduction of the effective drug dose. Similarly, data showed in table 3 represent that sequential administration of the pharmaceutical combination bypasses the intrinsic chemoresistance of tumors cells in vitro. In this invention, the in vitro chemoresistance is considered when the IC50 value reaches values upper than 1000 μM of concentration.
Similar to the in Vitro results, pretreatment with P15 peptide in vivo bypasses the tumor intrinsic chemoresistance (example 4) ( FIG. 2A , 2 B, 2 C).
The P15 peptide ingredient (amino acid sequence: CWMSPRHLGTC SEQ ID NO: 1) has been previously reported as a CK2 inhibitor (Perea S. E., et al. (2004) Antitumor effect of a novel proapoptotic peptide impairing the phosphorylation by the protein kinase CK2. Cancer Res. 64:7127-7129). However, this peptide unexpectedly did regulate a group of proteins on tumor cells (Table 4) which reinforce and explain the synergistic antitumor effect of the ingredients among the pharmaceutical combination as well as the chemosensibilization produced by the pretreatment with the P15 peptide. For instance, the P15-regulated proteins play an essential role on the control of tumor cell proliferation and apoptosis and these mechanisms are not the same induced by the rest of the ingredients from this pharmaceutical combination, specifically the cytostatic preferred in this invention.
Likewise, other proteins that are regulated by the ingredient P15 are those involved in the molecular mechanisms of the tumor chemoresistance to the cytostatic preferred in this invention. These unexpected results constitute the molecular basis of the tumor's chemosensibilization produced by this pharmaceutical combination when the ingredients are sequentially administered.
A hallmark in this invention is the fact that effective concentrations of the cytostatic drugs in the pharmaceutical combination are 10- to 100-fold reduced compared to the effective dose when the cytostatic drugs are used alone. It means that a synergistic interaction occurs between the CK2 inhibitor and cytostatic drugs preferred in this invention. Since the practical point of view, this synergistic interaction means that the toxicity of the medicine based on this pharmaceutical combination is much lower than that observed for single cytostatic drugs.
Similarly, the tumor's chemosensibilization elicited after sequential administration of the ingredients from this pharmaceutical combination represents a great advantage as it permits to treat the chemoresistance which is frequently observed in solid tumors and in those ones from hematopoietic origin.
DESCRIPTION OF FIGURES
FIG. 1 : Potentiation of the antitumor effect by the pharmaceutical combination in a cancer animal model: (A) represents the synergism between cisplatin+P15, (B) represents the synergism between cyclophosphamide+P15, (C) represents the synergism in vivo of mytomicin C+P15.
FIG. 2 : Effect of tumor's chemosensibilization by the P15 peptide in vivo: (A) represents the bypassing of chemoresistance toward cisplatin, (B) represents the bypassing of chemoresistance toward paclitaxel and (C) represents the bypassing of chemoresistance toward doxorubicin.
DETAILED EXPOSITION OF THE EXAMPLES
General Procedures
Cell cultures: The H-125 cell line was arisen from a human Non-Small Cell Lung Carcinoma (NSCLC) and the SW948 cell line was arisen from a human colon carcinoma. Both cell lines were maintained in RPMI 1640 (Gibco) culture medium supplemented with 10% Fetal Calf Serum and y gentamicin (50 μg/ml). Incubation of cell cultures was performed at 37° C. in 5% CO 2 .
Cell viability assay: For this purpose, 20 μl of Tetrazolium (MTS) (Promega) were added to the cells on each plate. After 2 hours at 37° C., the absorbance at 492 nm was taken. Finally, the IC50 values were estimated from the respective dose-response curves using the “CurveExpert” software.
Cancer animal model: The animal model used in this invention was based on the implantation of human tumors in nude mice (Nu/Nu, BaIBC). Briefly, 5×10 6 H-125 cells were suspended in Phosphate Buffer Solution (PBS) and inoculated subcutaneously. After tumor debut (approx. 30 mm 3 ), treatment was started using the pharmaceutical combination described in this invention. To evaluate the antitumor effect of the pharmaceutical combination, the tumor mass volume was measured and the respective volume was calculated using the formula: V=widght 2 ×length/2.
Analysis of the protein profile on the cell extracts: H-125 cells were treated or not with the P15 peptide ingredient of the pharmaceutical combination described in this invention during 40 minutes. Subsequently, cell monolayers were washed with PBS and cells were scrapped from the surface. After two further washes with cold PBS, cellular pellets were resuspended in 10 mM tris-HCl pH 7.5, 0.25M sucrose, 1 mM EGTA+protease inhibitor cocktail and nuclear protein fraction was obtained as previously described (González L. J., et al (2003) Identification of nuclear proteins of small cell lung cancer cell line H82: An improved protocol for the analysis of silver stained proteins. Electrophoresis 24:237-252). To analyze the P15-regulated proteins, the respective nuclear protein extracts were alternatively solved by 2D bidimensional gels (pH 4-7) and/or Liquid chromatography (nano HPLC) coupled to Mass spectrometer.
This invention is explained by the following examples:
Example 1
Synergistic Effect of the Combination of P15 Peptide+Conventional Cytostatic Drugs
It was evaluated the antineoplastic synergistic effect between the P15 peptide ingredient combined with different cytostatic drugs in the following experimental conditions: H-125 cells were seeded in 96-well plates and P15 peptide was added at 10 and 50 μM to each plate. Simultaneously, each of the cytostatic drugs preferred in this invention was added at doses ranging from 1 to 2000 nM and the incubation was prolonged during 72 hours in the same conditions. Finally, the cell viability and the IC50 values were determined as above described in this invention. Results showed in Table 1 demonstrate that the IC50 values for each cytostatic drug is 10- to 100-fold reduced when simultaneously combined with the ingredient P15 either at 10 or 50 μM. These results clearly demonstrate the potentiation of the antitumor effect of the pharmaceutical combination containing the P15 peptide and the cytostatic drugs preferred in this invention as ingredients.
TABLE 1
Antineoplastic synergistic interaction by the simultaneous administration
of the ingredients in this pharmaceutical combination.
Cytostatic
Cytostatic drug +
Cytostatic drug +
Variant
drug alone
P15 (10 μM)
P15 (50 μM)
Cisplatin
720
nM
530
nM
40
nM
Paclitaxel
17
nM
8
nM
3
nM
5-Fluouracil
1200
nM
420
nM
60
nM
Vincristin
856
nM
100
nM
8
nM
Doxorubicin
423
nM
200
nM
76
nM
Cyclophosphamide
2400
nM
1004
nM
85
nM
Mitomicin C
994
nM
93
nM
9
nM
Imatinib
600
nM
200
nM
58
nM
Velcade
2000
nM
1200
nM
700
nM
Iressa
689
nM
174
nM
47
nM
Example 2
Potentiation of the Antitumor Effect by the Pharmaceutical Combination in a Cancer Animal Model
For this purpose, 5×10 6 H-125 tumor cells were implanted as above mentioned in this invention in 6-8 week-old BalBc nude mice. After tumor debut, the ingredients of the pharmaceutical combination were administered as follow: The P15 peptide in saline solution was administered intraperitoneal at 0.5 mg/kg/day during 5 days. Concomitantly, intraperitoneal injection of cisplatin ( FIG. 1A ), or cyclophosphamide ( FIG. 1B ) or Mytomicin ( FIG. 1C ) were performed at 1 mg/kg/day in the same frequency. The cytostatic drugs are also solved in saline solution. Tumor volume was registered as described above in this invention. The results showed in FIGS. 1A , 1 B and 1 C indicate that the pharmaceutical combination potentiate the antitumor effect when ingredients are simultaneously administered and as it was observed by the complete tumor regression. Otherwise, when ingredients are administered as monotherapy only a marginal antitumor effect was observed respect to the Placebo group. Thus, we further demonstrate the synergistic interaction between the ingredients among this pharmaceutical combination in an outstanding preclinical cancer model.
Example 3
Effect of P15 Peptide in Bypassing the In Vitro Chemoresistance
In this assay we evaluated the effect of the pharmaceutical combination in bypassing the chemoresistance phenomenon when ingredients are sequentially administered. For this purpose, H-125 cells were seeded at 2000 cells/well in 96-well plates and after 24 hours 20 μM of the P15 peptide was added. After 16 hours of incubation with the P15 peptide ingredient, cell monolayers were washed twice with saline solution. Finally, the cytostatic drugs preferred in this invention were added at concentration ranging from 1 to 2000 nM and the incubation was prolonged during 72 hours. At the end, cell viability and the IC50 values for each cytostatic drug were determined as previously described in this invention. Results displayed in Table 2 demonstrate that pre-treatment of tumor cells with the P15 peptide ingredient increases the sensitivity of these cells to each of the cytostatic drugs preferred in this invention. Furthermore, we evaluated the effect of P15 pre-treatment on SW948 cells which are intrinsically resistant to the effect of the cytostatic drugs. Results demonstrated that the P15 peptide ingredient also converts to the intrinsic drug-refractory tumor cells into sensitive cells to the cytostatic drugs preferred in this invention. (Table 3).
Our data demonstrate that the sequential administration of the P15 peptide ingredient respect to the cytostatic drugs preferred in this invention leads to the sensibilization of tumor cells to the antineoplastic effect of such drugs.
TABLE 2
In vitro chemosensibilization of the pharmaceutical combination
by sequential administration of the ingredients
Cytostatic drug
Cytostatic drug +
Variants
alone
P15 pre-treatment
Cisplatin
720
nM
20
nM
Paclitaxel
17
nM
0.9
nM
5-Fluouracil
1200
nM
105
nM
Vincristin
856
nM
83
nM
Doxorubicin
423
nM
72
nM
Cyclophosphamide
2400
nM
100
nM
Mitomicin C
994
nM
20
nM
Imatinib
600
nM
10
nM
Velcade
2000
nM
370
nM
Iressa
689
nM
63
nM
TABLE 3
In vitro chemosensibilization of the pharmaceutical
combination by sequential administration of the ingredients
on intrinsic drug-refractory tumor cells
Cytostatic drug +
Variants
Cytostatic drug alone
P15 pre-treatment
Cisplatin
≧1000 μM
120
μM
Paclitaxel
≧1000 μM
97
μM
Doxorubicin
≧1000 μM
320
μM
The effect of the P15 peptide ingredient on the chemosensibilization is further verified by the drug-regulated protein profile observed on the tumor cells used in this invention. For this purpose, nuclear protein extracts coming from H-125 cells treated or not with the P15 peptide ingredient were analyzed as previously described in this invention. Table 4 displays a group of proteins which are regulated by the P15 peptide ingredient and because of their known function; it reinforces the molecular basis for the tumor's chemosensibilization produced by this peptide in the pharmaceutical combination in this invention.
TABLE 4
P15-regulated protein profile
Down-regulated proteins by the P15 peptide ingredient
Inhibition rate
Nucleofosmin
48
T-Plastin
3.34
Heat Shock Proteins (HSP-27, -70 y -90)
2.5
Y-box1 transcription factor
3.33
Eritropoietin precursor
120
S-gluthathione transferase
4.87
Proteasome activator complex
3.35
Ubiquitin activated E1 enzyme
2.49
Glucose-6-phosphate isomerase
8.53
Gliceraldehyde 6-phosphate deshydrogenase
6.62
Piruvate kinase
8.34
Translational controled tumor protein
4.32
Up-regulated proteins by the P15 peptide ingredient
Activation rate
Prohibitin
2.28
Tubulin alpha-1
3.23
Tubulin beta-2
2.56
Tubulin beta-3
3.15
Example 4
In Vivo Chemosensibilization Produced by the P15 Peptide Ingredient
For this purpose, 5×10 6 SW948 cells were implanted in nude mice as previously described in this invention. After tumor debut the pharmaceutical combination was sequentially administered as follow: First, the P15 peptide ingredient was administered intraperitoneal at 0.5 mg/kg/day during 5 days. Subsequently, cisplatin ( FIG. 2A ), Paclitaxel ( FIG. 2B ) and doxorubicin ( FIG. 2C ) were administered at 5 mg/kg/day during further 5 days. The results here demonstrate that the in vivo P15 pre-treatment is able to revert the chemorefractory phenotype of the tumors which become responsible to the cytostatic drugs preferred in this invention. These findings also provide the evidences that the pharmaceutical combination in this invention is able to bypass the commonly observed intrinsic tumor resistance when the ingredients are sequentially administered.
INCORPORATION OF SEQUENCE LISTING
Incorporated herein by reference in its entirety is the Sequence Listing for the application. The Sequence Listing is disclosed on a computer-readable ASCII text file titled, “sequence_listing.txt”, created on Apr. 10, 2014. The sequence_listing.txt file is 1 kb in size. | This invention is related to a pharmaceutical combination that contains a Casein kinase 2 (CK2) peptide inhibitor (termed P15) along with the standard chemotherapeutic drugs used in cancer treatment and which are administered together, separated or sequentially. The chemotherapeutic drugs include cisplatin, taxol, alkaloids from Vinca, 5-fluorouracil, doxorubicin, cyclophosphamide, etoposide, mitomicin C, imatinib, iressa and velcade (vortezomib). The synergism between the P15 peptide and the anticancer drugs achieves an efficient concentration of each cytostatic drug in the combination which is from 10- to 100-fold lower than that for each cytostatic drug alone. The pharmaceutical combination described in this invention exhibits lower toxicity compared to that reported by the anticancer therapeutics and therefore, it represents a crucial advantage for its use in cancer therapy. Furthermore, the sequential administration of this pharmaceutical combination through the pretreatment with the P15 peptide leads to the chemo sensibilization of refractory tumors to the anticancer therapeutics. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention:
This invention relates to a pin-tucking device for folding a fabric in a pleated-like pattern at desired intervals in transverse relation to the direction of advance of the fabric at a stage prior to sewing by a sewing machine for sewing pin tucks.
2. Prior Art:
Generally, pin-tucking devices of this kind are so designed that a fabric is passed through a gap defined between a pair of guide plates, being thereby squeezed to have pleat-like folds formed thereon. If pleat-like folds are to be formed in a specified number and at given intervals, such device has a plurality of pairs of guide plates arranged in position.
One known type of such pin-tucking device has pairs of guide plates fixed integrally to upper and lower base plates by welding or otherwise. Another known type has such guide plates removably held in engagement with engagement grooves formed in upper and lower base plates.
The pin-tucking device of the former type has a difficulty that since it forms pleat-like folds on the fabric at uniform intervals, the guide plates have to be replaced together with the base plates if it is desired to change the intervals, and therefore that base plates having various different dimensions have to be prepared so as to meet needs for such change in intervals. As such, this known type is not economical. Furthermore, the fact that the guide plates are integral with the base plates requires that, if said intervals are to be changed without the base plates being replaced, sewing needles must be disposed correspondingly to the desired intervals of folds, instead of the intervals of folds formed by the pin-tucking device being changed, so that when tucks are actually formed on the fabric by sewing, some of the folds remain unstitched, it being thus necessary to carry out a post-stitching operation for removing such unstitched folds, in which respect the known type is far from being said to be of practical use.
The known pin-tucking device of the latter type, which has guide plates held in engagement with the engagement grooves in the base plates, has on one hand an advantage that the intervals of the pleat-like folds may be changed by suitably removing one of any particular pair of guide plates, but on the other hand it has a drawback that a multiplicity of engagement grooves of a particular configuration corresponding to that of guide plates must be formed in both of the base plates which are metal or synthetic resin made, which fact requires special machine tools and elaborate machining, thus involving high cost.
In aforesaid conventional devices, the upper base plate is made of transparent resin so as to facilitate early visual detection of any possible fabric lodging in the gap between a pair of guide plates while the fabric being passed through the gap, as well as of any irregularity present in the fabric, but the trouble is that such fabric lodging or fabric irregularity, if detected, cannot be removed unless the upper- and lower-base plate assembly is disassembled.
SUMMARY OF THE INVENTION
This invention, made in view of the above difficulties with the prior art, has as its object the provision of a pin-tucking device which permits easy changing of the intervals of the pleat-like folds formed on a fabric, and yet can eliminate any possible fabric jamming on lodging or fabric irregularity without the necessity of disassembling the base plate assembly, and which is inexpensive to construct with less machining work involved.
The aforesaid object is accomplished by the arrangement in accordance with the invention, which comprises a frame-shaped base plate, guide-plate mounting plates mounted individually to front and rear of the base plate, fixing plate connected to respective one sides of the guide-plate mounting plates in surface contact relation, and a required number of guide plates mounted over a space between the guide-plate mounting plates, said guide-plate mounting plates each having a required number of comb tooth-shaped kerfs spaced from one another in transverse relation to the direction of movement of the fabric to be sewn, said guide plates including parallel plate portions each having a first hook portion which is fitted in one of the kerfs of the front guide plate mounting plates and thereby locked in position and which is fixed to said guide plate mounting plate by being pressed thereagainst by said fixing plate, and radial plate portions individually extending at specified angles from said parallel plate portions to said rear guide plate mounting plate, said radial plate portions each having a second hook portion which is fitted in one of the kerfs of the rear guide plate mounting plates and thereby locked in position and which is fixed to said guide plate mounting plate by being pressed thereagainst by said fixing plate.
According to the pin-tucking device constructed as above, the first hook portion of each guide plate is fitted in one of the kerfs of the front guide plate mounting plates and thereby locked in position and the second hook portion of each guide plate is fitted in one of the base end-side guide plate mounting plates and thereby locked in position, whereby the individual guide plates are arranged in position on the base plate. Therefore, individual guide plates may be dismounted by removing the fixing plate and guide plate mounting plates. As such, the pin-tucking device according to the invention permits easy removal and mounting of any of the guide plates and easy variation of intervals of pleats-like folds on the fabric to be sewn in various different ways. The construction of the base plate requires less machining work and the kerfs in the guide plate mounting plates are of a simple comb-tooth type; therefore, the device of the invention is easier and less expensive to manufacture than conventional types of pin-tucking devices in which base plates having engagement grooves or guide plates fixed by welding to base plates are employed, and provides a definite economical advantage.
Furthermore, the fact that the base plate is of a frame shape permits easy visual detection of fabric jamming or fabric irregularity through the base plate and correction of such troubles by hand or with the air of a bar or the like, thus saving any trouble or time loss which may be otherwise involved in eliminating fabric jamming or fabric irregularity by disassembling the base plate assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 7, inclusive, illustrate one embodiment of the invention;
FIG. 1 is an exploded view in perspective of a lower base plate-side assembly;
FIG. 2 is a plan view thereof;
FIG. 3 is an exploded view in perspective of an upper base plate-side assembly;
FIG. 4 is a plan view thereof;
FIG. 5 is a sectional view in side elevation of the lower base plate-side assembly;
FIG. 6 is a sectional view in side elevation of the upper base plate-side assembly;
FIG. 7 is a sectional side view showing the upper and lower base plates in assembled condition; and
FIGS. 8 and 9 are schematic front views taken on line Z--Z' in the FIG. 7, showing guide plates of the invention arranged in place by way of example.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
One embodiment of the invention will now be described with reference to the accompanying drawings.
The embodiment represents a pin-tucking device for forming folds A' on a fabric A to be sewn up by a sewing machine for sewing pin tucks (not shown) to which the invention is applied.
Referring to FIGS. 1, 2, and 5, numeral 1 designates a lower base plate comprised of a metal member which is generally rectangular in its planar configuration, with stepped portions 3, 4 informed respectively in its top surface and in its front, at both sides, and in its Top and in its rear portion. On the stepped portion 3 there is mounted a front edge guide plate mounting plate 5 in flush relation with the Top surface of lower base plate 1 through screws 6, 6. The screws 6, 6 are in thread engagement with threaded holes 3a, 3a in the stepped portion 3 through elongate holes 5a, 5a in the front edge guide plate mounting plate 5 at both sides thereof. At the rear portion of the front edge guide plate mounting plate 5 there are formed a suitable numbers of kerfs 7 and comb teeth 8 in transversely spaced apart relation to the direction of fabric movement X. The intervals of the comb teeth 8 correspond to the intervals of sewing needles (not shown).
At the stepped portion 4 there is mounted a rear edge guide plate mounting plate 9 through screws 10, 10 in flush relation with the top surface. The screws 10, 10 are in thread engagement with threaded holes 4a, 4a in the stepped portion 4 through elongate holes 9a, 9a in the guide plate mounting plate 9 at both sides thereof. At the front portion of the guide plate mounting plate 9, that is, at the opposite side of the front edge guide plate mounting plate 5 there are formed suitable numbers of kerfs 11 and comb teeth 12 in transverse relation to the direction of fabric movement X and at wider intervals than those of the kerfs 7 in the guide plate mounting plate 5. A recessed portion 40 is formed in the bottom surface rear edge guide plate mounting plate 9 so that the comb toothed portion 12 is thinner than the other portion of the plate 9.
A required number of first guide plate 13 extending between the two guide plate mounting plates 5 and 9 are mounted in a raised condition on the lower base plate 1. The first guide plates 13, being metal plates having a specified thickness, comprise parallel plate portions 14 arranged in spaced apart parallel relation at the front edge 1a of the lower base plate 1, and the radial plate portions 15 continued from the parallel plate portions 14 and extend toward the rear edge 1b of the lower base plate 1 at specified angles, first fabric fold guide edges 16 being formed by continued upper edges of the parallel plate portions 14 and radial plate portions 15. The parallel plate portion 14 of each guide plate 13 has a first hook portion 17 of L-shape integrally formed thereon and which is fitted in one of the kerfs 7 in the front edge guide plate mounting plate 5 and locked in position by comb teeth 8. The radial plate portion 15 of each guide plate 13 has a second hook portion of L-shape which is fitted into one of the kerfs 11 of in the rear edge guide plate mounting plate 9, and locked in position by comb teeth 12, said second hook portion being pressed in position between the stepped portion 4 and the recess 40.
The kerfs 7, 11 in the guide plate mounting plates 5, 9 are slightly larger in width than the thickness of the guide plates 13.
Referring to FIGS. 3, 4, and 6, numeral 20 designates an upper base plate, which is a thick metal-made member having a frame contour of a trapezoidal like configuration, for example. On the front portion 21 of the upper base plate 20 there are placed a guide plate mounting plate 22 and a fixing plate 35 in that order, the both plates being mounted in position through screws 41, 41. The screws 41, 41 are in thread engagement with threaded holes 21a, 21a in the front portion 21 through elongate holes 22a, 22a, 35a, 35a at both sides of the guide mounting plate 22 and fixing plate 35. At the rear portion of the guide plate mounting plate 22, a suitable numbers of kerfs 23 and comb teeth 24 are arranged in transversely spaced apart relation to the direction of fabric movement X. It is noted in this connection that the kerfs 23 and comb teeth 24 are positioned within the frame. On the rear portion 25 of the upper base plate 20 there are placed a rear guide plate mounting plate 26 and a fixing plate 36 in that order, the both plates being mounted in position through screws 42, 42. The screws 42, 42 are in thread engagement with threaded holes 25a, 25a in the rear portion 25 through elongate holes 26a, 26a, 36a, 36a at both sides of the guide plate mounting plate 26 and fixing plate 36. At the front portion of the rear guide plate mounting plate 26, kerfs 27 and comb teeth 28 are arranged in transverse relation to the direction of fabric movement X and at greater intervals than those of the kerfs 23 in the front portion guide plate mounting plate 22. It is noted in this connection that the kerfs 27 and comb teeth 28 are position within the frame of the upper base plate 20.
The kerfs 23, 28 in the guide plate mounting plates 22, 26 are slightly larger in width than the thickness of second guide plates 29 which are to be described hereinafter. Second guide plate 29 extending between the front and rear guide plate mounting plates 22, 26 are arranged in a raised but downwardly slanted position on the upper base plate 20.
The guide plates 29, being metal plates having a specified thickness, comprise parallel plate portions 30 positioned in spaced parallel relation at the front edge 20a of the upper base plate 20, and radial plate portions 31 continued from the parallel plate portions 30 and extending toward the rear edge 20b of the upper base plate 20 of a specified angle, the continual lower edges of the parallel and radial plate portions 30 and 31 defining fold guide edges 32 for the fabric. Each of the parallel plate portions 30 of the guide plates 29 has a first hook portion 33 of L-shape integrally formed therewith which is fitted in one of the kerfs 23 of the front guide plate mounting plate 22 and engaged by comb teeth 24. The first hook portion 33 is pressed in position between the front guide plate mounting plate 22 and the fixing plate 35. Each of the radial plate portions 31 of the guide plates 29 has a second hook portion 34 of L-shape integrally formed therewith which is fitted in one of the kerfs 27 of the guide plate mounting plate 26 and engaged by comb teeth 28. The second hook portion 34 is pressed in position between the guide plate mounting plate 26 and the fixing plate 36.
Through such arrangement, as FIG. 7 shows, the second guide plates 29 of the upper base plate 20 are assembled into unity with the first guide plates 13 of the lower base plate 1 in mating relation and then fabric A is passed through gaps defined by the first and second guide plates 13, 29 in the direction of movement X of the fabric A, that is, toward the sewing machine for sewing pin tucks (not shown); and as continuous folds are formed by the first and second fabric folding guide edges 16, 32 of the first and second guide plates 13 . . . , 29 . . . , folds A' folded in pleated-like pattern are formed.
If it is desired to change the intervals of pleat-like folds A', some of the second guide plates 29 . . . of the upper base plate 20 should be removed from the front and rear guide plate mounting plates 22, 26 in such a manner that, as FIG. 8 illustrates, second guide plates are thinned out in alternate order. If it is desired to change the needle intervals in the sewing machine for sewing pin tucks it is only necessary to change the front guide plate mounting plates 5, 22 of the lower and upper base plates 1, 20 correspondingly to the change in needle intervals. This is intended to utilize the deformation of first and second guide plate 13, 29 according to the change. Thus, the trouble of parts replacement can be saved considerably.
Also, it is possible to freely change the direction of folding a A' as FIG. 9 illustrates by way of example. | In a pin-tucking device for forming a plurality of pleats-like folds on a fabric, guide-plate mounting plates have comb-like kerfs for engaging and disengaging hook portions of guide plates so that guide plates may be varied in number to change the intervals of the pleats-like folds in various different ways. Frame shaped based plates permit easy removal of fabric jamming or the like trouble without the necessity of the base plates being put out of assembly. The guide-plate mounting plates are mounted to the base plates by fixing plates. The device is easy to manufacture and economical. | 3 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel injection pump for an internal combustion engine which may be, but is not limited to, the distribution type.
Fuel injection systems are popular in the field of internal combustion engines due to their many advantages, especially where adapted to combustion ignition or Diesel engines. Typical of such systems is the distribution system in which a plunger is simultaneously rotated and reciprocated to pump fuel to injection nozzles of a number of engine cylinders.
In a known distribution type fuel injection pump, a fuel control sleeve is positioned by flyweights to control the amount of fuel injection in accordance with engine speed. The flyweights urge a governor rod toward a tension lever as the engine speed increases.
A problem has existed in this type of pump in that a stroke of the governor rod available with the flyweights is limited due to the inherent arrangement and, thus, zero fuel injection is unachievable at the no-load maximum engine speed condition should a substantial stroke of the governor rod be employed for increasing the amount of fuel injection for a start of engine operation.
Meanwhile, a fuel injection advance angle control member of the pump is generally designed to move to increase a fuel injection advance angle as the engine speed increases. This gives rise to another problem that the angle cannot be increased for a start of engine operation.
SUMMARY OF THE INVENTION
A fuel injection pump embodying the present invention includes a fuel injection advance angle control member which is controlled to increase the angle as an engine speed is increased, a fuel control member which is controlled to decrease the amount of fuel injection as an engine speed is increased, a knob located in a position accessible for manipulation, and an operative connection between the knob and at least the fuel injection advance angle control member for permitting said member to be manually controlled through the knob to increase the angle before the engine is started.
In accordance with the present invention, a fuel injection advance angle control member and a fuel control member are manually and simultaneously controllable to increase the fuel injection angle and the volume of fuel injection, before an engine is started. A knob is located in a position accessible for manipulation. A wire connects the knob to cams which are associated with the fuel injection advance angle control member and the fuel control member, respectively. The connection between the knob and the cam associated with the advance angle control member includes a spring which is yieldable when the knob is pulled, so that a reaction force counteracting the pulling effort is reduced to promote manipulation with a minimum of effort. Upon an engine start, the resilient force accumulated in the spring is released to move the member to a desired advanced angle position through the cam.
It is an object of the present invention to provide a fuel injection pump which permits the fuel injection timing to be advanced and the amount of fuel injection to be increased manually at the same time for a start of an engine.
It is another object of the present invention to provide a unique operative connection for the manual control which minimizes an effort necessary for the manipulation.
It is another object of the present invention to provide a generally improved fuel injection pump.
Other objects, together with the foregoing, are attained in the embodiments described in the following description and illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal section of a fuel injection pump embodying the present invention;
FIG. 2 is a section as seen in a direction indicated by an arrow II--II in FIG. 1;
FIG. 3 is a section as seen in a direction indicated by an arrow III--III in FIG. 2;
FIG. 4 is a graph showing a variation in a reaction force which acts on a manually operated knob;
FIG. 5 is a fragmentary section of a second embodiment of the present invention;
FIG. 6 is a plan view of the arrangement shown in FIG. 5; and
FIG. 7 is a schematic diagram representing a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the fuel injection pump of the present invention is susceptible of numerous physical embodiments, depending upon the environment and requirements of use, substantial numbers of the herein shown and described embodiments have been made, tested and used, and all have performed in an eminently satisfactory manner.
Referring now to FIGS. 1-3 of the drawing, a fuel injection pump embodying the present invention includes a housing 10 which has a chamber 12 defined therein. A vane pump 14 is disposed inside the housing 10 and mounted on an input shaft 16 which is driven from an engine (now shown). The vane pump 14 sucks and compresses fuel from a tank or reservoir 18 to feed it into the chamber 12 of the housing 10. A pressure control valve 20 is mounted in the housing 10 in order to control the fluid pressure in the chamber 12 in accordance with engine speed in a well known manner. The pressure in the chamber 12 therefore is increased as the engine speed increases.
A piston or plunger 22 is rotatably disposed in a bore 23 of a barrel 24 which is mounted in the housing 10. A cam disc 26 is fixed to the lower end of the piston 22 and urged by a spring (not shown) into engagement with a roller carrier 28. The carrier 28 is in the form of a disc and carries balls or rollers 30 in recesses (not designated) in its upper surface which rollingly engage with the cam 26. The lower surface of the cam 26 is formed with projections (not designated) in a number equal to the number of cylinders of the engine. The cam 26 is in driven connection with the input shaft 16 through a drive disc (not shown). Rotation of the piston 22 causes the cam 26 to ride up and down on the rollers 30 and thereby causes the piston 22 to reciprocate inside the barrel 24.
During a downward (as viewed in FIG. 1) or return stroke of the piston 22, fuel from the chamber 12 flows into the upper closed end of the bore 23 through a passageway 32 formed through the housing 10, a passageway 34 formed through the barrel 24 and one of a plurality of axially extending peripheral grooves 36 formed on the piston 22.
As the piston 22 moves upward during a fuel injection stroke, the lower end of the groove 36 moves above the opening of the passageway 34 so that the passageway 34 no longer communicates with the upper portion of the bore 23. This causes fuel to be compressed and displaced through an axial passageway 38 in the piston 22 and a distribution groove 40 which communicates with the passageway 38 into an outlet passageway 42 formed through the housing 10 via a passageway 44 in the barrel 24. When the pressure in the passageway 42 reaches a sufficiently high value, the fuel is fed through a delivery valve 46 to a fuel injection nozzle 48 and thereby into the engine cylinder.
The piston 22 is further formed with a radial passageway 50 which leads from the axial passageway 38. A sleeve 52 is slidably disposed around the piston 22. The sleeve 52 is positioned so as to cover the passageway 50 and allow the piston 22 to compress fuel in the bore 23 and displace the same through the passageway 42 for fuel injection. However, after the piston 22 has moved upwardly to a certain extent, the opening of the passageway 50 moves above the upper end of the sleeve 52 and thereby communicates the upper portion of the bore 23 with the chamber 12 via the passageways 38 and 50. At this point, the pressure in the bore 23 drops almost instantaneously to the level of the pressure in the chamber 12 and the delivery valve 46 closes. This terminates fuel injection. Thus, it will be seen that the point of fuel injection termination and, therefore, an amount of fuel injection can be controlled by varying the position of the sleeve 52 relative to the piston 22 by a mechanism which will be described hereinafter.
A drive gear 54 is mounted on the input shaft 16 and in driving mesh with a gear 56 which is rotatably mounted on a shaft 58. Flyweights 60 are received in a pocket member which is fixedly carried on the gear 56. Rotation of the input shaft 16 is thus imparted to the flyweights 60 via the gears 54, 56 and pocket member 62. The flyweights 60 in rotation cause a governor sleeve 64 to be moved upwardly around the shaft 58 to an extent which depends on the engine speed.
A lever 66 is rotatably mounted on a pin 68 and opposed by the top of the governor sleeve 64 from below. One end of the lever 66 carries a ball 70 which fits in a socket 72 formed in the control sleeve 52. The lever 66 at the other end is resiliently engaged by a tension lever 74 which is in turn urged by a governor spring 76.
As the flyweights 60 are moved radially outwardly away from each other by the pocket member 62 in accordance with increasing engine speed, they lift the governor sleeve 64 to transmit a centrifugal force related with the engine speed to the lever 66. This moves the lever 66 clockwise about the pin 68 as viewed in FIG. 1 and thereby lower the sleeve 52 relative to the piston 22 to reduce the amount of fuel injection.
A corrector lever 78 is rotatably supported by a pin 80 which is in turn fixed to the housing 10. The corrector lever 78 carries at one end the pin 68 around which the lever 66 is rotatable and, at the other end, it is engaged by an eccentric cam 82. A spring 84 is positioned between the housing 10 and one end of the corrector lever 78 to urge the latter downwardly. A shaft 86 extends axially from the cam 82 to project outwardly from the housing 10. Outside the housing 10, the shaft 86 carries an arm 88 which is movable to vary the position of the corrector lever 78 through the cam 82 on the shaft 86.
An arm 90 extends radially outwardly from the roller carrier 28 which is rotatably positioned in the housing 10 in concentric relation with the input shaft 16. The free end of the arm 90 is engaged with a cylindrical member 92 which is rotatably received in a piston 94. The piston 94 is slidably within a bore formed in a member (not designated) integral with the housing 10. The piston 94 defines a spring chamber 96 and a fluid chamber 98 at its opposite ends in cooperation with the adjacent end walls of the bore, respectively. The spring chamber 96 accommodates a spring 100 therein while the fluid chamber 98 is held in communication with the chamber 12 of the housing 10.
A relation between the force of the spring 100 and the fluid pressure communicated from the chamber 12 to the chamber 98 determines an axial position of the piston 94 which in turn determines an angular position of the roller carrier 28 through the arm 90. A change in the angular position of the roller carrier 28 causes a change in the angular position at which the cam disc 26 engages with the rollers 30 and, eventually, a relative change in the relationship between the angular phase of the input shaft 16 and the above-mentioned angular position of the cam disc 26 engaging with the rollers 30, i.e. operating position of the piston 22. As a result, the fuel injection timing is varied relative to the rotation of the input shaft 16. In the illustrated embodiment, when the piston 94 is moved upwardly in FIG. 2 by a fluid pressure against the action of the spring 100, the roller carrier 28 will be rotated clockwise through the arm 90 to advance the injection timing.
An eccentric cam 102 is also engaged with the roller carrier 28. A shaft 104 extends axially from the cam 102 to project outwardly from the housing 10. Outside the housing 10, the shaft 104 carries an arm 108 which is movable to vary the angular position of the roller carrier 28 through the cam 102.
The arm 88 associated with the cam 82 and the arm 108 associated with the cam 102 are commonly connected with a wire 110. The wire 110 extends from the fuel injection pump as far as a knob 112 which is accessible for manipulation.
Before a start of engine operation, when the operator pulls the knob 112 and thereby the wire 110 connected therewith, the arm 88 is rotated clockwise as viewed in FIG. 1 while the arm 108 is rotated counterclockwise at the same time. Then, the cam 82 connected with the arm 88 drives the corrector lever 78 counterclockwise about the pin 80 against the spring 36. This shifts the pin 68 on the corrector lever 78 so that the sleeve 52 is raised relative to the piston 22 through the lever 66, resulting in an increase in the amount of fuel injection from the fuel injector 48.
The counterclockwise rotation of the arm 108 brings the cam 102 into contact with the roller carrier 28 to move it clockwise as viewed in FIG. 2 against the bias of the spring 100 and thereby advance the injection timing.
In this manner, an increased amount of fuel injection and an advanced injection timing can be provided simultaneously at a start of engine operation with the pump held inoperative, merely by manipulating the knob 112 which connects to the arms 88 and 108 via the wire 110.
When the knob 112 is returned to its inoperative or depressed position, the pump will be operated in a usual mode. Under this condition, the roller carrier 28 is allowed to be moved without any interference by the piston 94 since a play is defined in a notch 28a of the roller carrier 28 at one side of the cam 46.
Now, when the knob 112 is pulled manually to rotate the arm 108 counterclockwise in FIG. 2, a reaction force acts on the knob 112. FIG. 4 is a graph showing a variation of the reaction force before and after the fuel injection pump is started to operate the engine. After a start of pumping operation, the reaction force remains relatively small as indicated by a line a in FIG. 4, partly because the frictional resistance in the engaging portions of the roller carrier 28 grows less and partly because a force in the injection timing advancing direction acts on the roller carrier 28 due to the action of the piston 94. However, while the pumping operation is stopped, the resistance to the movement of the roller carrier 28 in the advancing direction is substantial and reflected by a substantial reaction force as indicated by a line b in FIG. 4. Such a large reaction force cannot be overcome unless the operator exerts a sufficient and disproportionate pulling force on the knob 112. Additionally, at the time when the pulling force exceeds the reaction force, the rod 112 is moved all of a sudden from its standstill, imparting a shock to the operator's hand.
A second embodiment of the present invention which is improved to preclude the above drawback will be described with reference to FIGS. 5 and 6.
In FIGS. 5 and 6, the shaft 104 having the cam 102 therewith is journalled to the housing 10 by a bearing 200. A lever 202 is secured to that portion of the shaft 104 projecting outwardly from the housing 10 and is formed at the other end with a flat stop 204 which extends in parallel with the shaft 104. A tubular member 206 is rotatably mounted on a reduced diameter section of the shaft 104. Secured to the tube 206 is an arm 208 which functions in the same way as the lever 108 of the first embodiment. The wire 110 is connected with the other end of the arm 208. By a stop (not shown), the clockwise movement of the arm 208 as viewed in FIG. 6 is limited to the illustrated position.
A characteristic feature of the embodiment shown in FIGS. 5 and 6 consists in winding a spring 210 around the tube 206. The spring 210 is retained at one end by the arm 208 and at the other end by the lever 202, constantly urging the arm 208 into contact with the stop 204.
With this arrangement, when the operator pulls the knob 112 and so the wire 110, a rotating force is imparted to the lever 202 via the compression spring 210 so that the shaft 104 is rotated to in turn rotate the roller carrier 28 in the advancing direction. In detail, before the engine is started, the knob 112 is pulled by a force which should only be large enough to flex the spring 210 and move the knob 112 and corresponds to a reaction force c in FIG. 4. As the engine is started, the reaction force diminishes to the level a of FIG. 4 as previously discussed so that the lever 202 is rotated by the force stored in the spring 210. This allows the roller carrier 28 to be rotated in the advancing direction.
If desired, a spring 300 may be employed to form a part of the length of the wire 110 as illustrated in FIG. 7. A pull of the knob 112 will cause the spring 300 to function in the same way as the spring 210 in moving the roller carrier 28 subsequently with a force stored therein.
In summary, it will be seen that the present invention provides a new and improved fuel injection pump which overcomes the drawbacks inherent in the prior art previously described and promotes the ease of manipulation for a start of engine operation as in choking ordinary gasoline powered engines.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof. | A fuel injection advance angle control member (28) and a fuel control member (52) are manually and simultaneously controllable to increase the fuel injection angle and the volume of fuel injection, before an engine is started. A knob (112) is located in a position accessible for manipulation. A wire (110) connects the knob (112) to cams (102, 82) which are associated with the fuel injection advance angle control member (28) and the fuel control member (52), respectively. The connection between the knob (112) and the cam (102) includes a spring (210, 300) which is yieldable when the knob (112) is pulled, so that a reaction force counteracting the pulling effort is reduced to promote manipulation with a minimum of effort. Upon an engine start, the resilient force accumulated in the spring (210, 300) is released to move the member (28) to a desired advanced angle position through the cam (102). | 5 |
RELATED APPLICATIONS
The present invention was first described in a notarized Official Record of Invention on Sep. 26, 2008, that is on file at the offices of Montgomery Patent and Design, LLC, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a tree stand for use while hunting, and in particular, to a collapsible, impermanent tree stand with an integral dolly for transporting the tree stand easily.
BACKGROUND OF THE INVENTION
Hunting is an increasingly popular and technological endeavor. Much of the success and enjoyment of hunting comes from the ability to approach hunting from a variety of different angles and different challenges. In particular tree stands are a popular way to approach various hunting situations, allowing a user the ability to spot game from an elevated and hidden position.
While tree stands provide added safety to a hunter in an elevated perch, they have many difficulties. The ease of access and installation is one such consideration. Stability is another concern. While some simple, permanent type tree stands are relatively simple to install and stable as well, transporting and uninstalling them is very difficult. In many areas, tree stands are not allowed to be left in place, and the user has great difficulty managing the removal and transport of the stand after use.
Various attempts have been made to provide a tree stand. Examples of these attempts can be seen by reference to several U.S. patents. U.S. Pat. No. 4,582,165, issued in the name of Latini, describes a portable tree stand. The Latini stand has backpack type straps for the transportation of the apparatus.
U.S. Pat. No. 7,306,074, issued in the name of Voorhies, describes a climbing tree stand. The Voorhies apparatus helps a user to scale a tree as well as providing a perch.
While these devices fulfill their respective, particular objectives, each of these references suffer from one or more of the aforementioned disadvantages. Many such apparatuses are cumbersome or uncomfortable to transport. Also, many such apparatuses do not provide the user with easy access to the upper reaches of a tree. Also, many such apparatuses do not provide easily installable, secure perches to the user. Furthermore, many such apparatuses do not provide any additional storage or transportation capabilities to assist the hunter in the storage and placement of other hunting accessories in addition to the tree stand. Accordingly, there exists a need for a transportable tree stand without the disadvantages as described above. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for a means to provide a transportable tree stand which allows a single user to easily transport the device while also providing secure installation, easy perch access, item storage, and quick and simple single-person breakdown capabilities. Thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.
To achieve the above objectives, it is an object of the present invention to combine a portable laddered tree stand with a combined wheeled platform. The apparatus comprises a ladder portion, a bottom portion able to be transported and anchored, a top portion comprising a seat assembly, and an intermediate portion comprising an adjustable tree brace.
Another object of the present invention is to comprise the ladder portion of a plurality of rungs, a pair of upper side rails, and a pair of lower side rails in the form of a tubular inclined rigid ladder. Ratcheting tie-downs are preferably utilized to securely position the apparatus to a tree.
Yet still another object of the present invention is to comprise the bottom portion of a pair of first wheels and a ground anchor. The ground anchor comprises a pair of parallel metal rods with pointed ends which easily puncture a ground surface.
Yet still another object of the present invention is to comprise an intermediate portion of the apparatus of an adjustable tree brace to stabilize the apparatus on a tree. The brace comprises a plurality of adjustment indentations and an extension rod with an adjustment fastener. The brace mates with the extension rod in a slidably engaging manner and is secured via the adjustment fastener.
Yet still another object of the present invention is to comprise the adjustment fastener of a bolt which is screwed into a desired depressed portion of the tree brace by means of a washer which is welded to the extension rod. The extension rod is permanently attached to an intermediate rung of the ladder portion.
Yet still another object of the present invention is to comprise the top portion of the apparatus of a seat frame, a back portion, a seat portion, a hanger, and a foot portion. This provides a user with a sitting position and a hanging storage for equipment such as a coat, gun, bag, or the like. The seat frame is integrated into a horizontal top portion of the apparatus.
Yet still another object of the present invention is for the first wheels to provide movement while in the collapsed position in conjunction with the tree brace. A perpendicular contoured extrusion of the brace allows the user to grip and pull the brace like a handle and easily transport the apparatus due to the first wheels. The wheels are mounted to a lower side rail via a wheel bracket, and they use a conventional axle system.
Yet still another object of the present invention is to comprise a pair of second wheels located behind the seat frame to guide the invention while it is being placed against a tree. The wheel assembly also includes a pair of tree anchors. The tree anchors comprise a means of stabilizing the apparatus against a tree in the deployed position. A pair of compression springs allows the wheels to be depressed toward the seat portion, thereby extracting the tree anchors and allowing them secure to a tree.
Yet still another object of the present invention is to provide a pair of hinges at a pivot joint located between the upper and lower side rail portions. The hinge provides a conversion means allowing the apparatus to fold into the collapsed, movable state. The hinge further comprises a sliding bracket and a fastener to allow a user to adjust the length of the hinge as well as locking the hinge in place when used in the straight, deployed position.
Yet still another object of the present invention is to provide a method of utilizing the device that provides a unique means of allowing a user to utilize an impermanent tree stand in a manner which is quick, efficient, and physically tenable for a single user.
Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is a perspective view of a collapsible tree stand with dolly 10 depicting an erected state and a cross-section view of an adjustable brace 60 , according to a preferred embodiment of the present invention;
FIG. 2 is a perspective view of the collapsible tree stand with dolly 10 depicting a collapsed position, according to a preferred embodiment of the present invention;
FIG. 3 is a close-up view the collapsible tree stand with dolly 10 depicting a pair of tree anchors 82 and associated components, according to a preferred embodiment of the present invention;
FIG. 4 a is a close-up view of a hinge 92 depicting a collapsed state, according to a preferred embodiment of the present invention; and,
FIG. 4 b is the close-up view of the hinge 92 depicting an erected state, according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 collapsible tree stand with dolly
20 seat frame
25 back portion
27 seat portion
30 hanger
40 foot portion
42 first bracket
44 second bracket
50 rung
55 upper side rail
56 lower side rail
59 ground anchor
60 tree brace
62 adjustment indentation
64 adjustment fastener
66 extension rod
68 washer
70 first wheel
72 wheel bracket
75 second wheel
80 compression spring
82 tree anchor
84 plate
85 plate fastener
86 second wheel fastening means
88 fork
90 hinge brace
92 hinge
94 bracket fastening means
96 sliding bracket
100 ratcheting tie-down
110 weld
120 tree
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 4 b . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes a device and method for a collapsible tree stand with dolly (herein described as the “apparatus”) 10 , which provides a means for a portable laddered tree stand therewith a combined wheeled platform. The apparatus 10 comprises a seat frame 20 , a hanger 30 , a foot portion 40 , a plurality of rungs 50 , a pair of upper side rails 55 , a pair of lower side rails 56 , a ground anchor 59 , a tree brace 60 , a pair of first wheels 70 , a pair of second wheels 75 , and a tree anchor 82 . The apparatus 10 is ideal for a hunter whom hunts in areas which prohibit the use of permanently erected tree stands. Said apparatus 10 also allows for the removal and transportation of game animals therewith the wheeled platform.
Referring now to FIG. 1 , a perspective view of the apparatus 10 depicting an erected state and a cross-section view of an adjustable brace 60 , according to the preferred embodiment of the present invention, is disclosed. The apparatus 10 takes the form of a tubular inclined rigid ladder, thereby enabling a user to climb therein and situate them in an elevated position. The ladder portion is similar to conventional ladders and/or ladder tree stands and comprises a plurality of rungs 50 , a pair of upper side rails 55 , and a pair of lower side rails 56 . The apparatus 10 is envisioned to be fabricated from a metal such as, but not limited to: steel, aluminum, or the like. Ratcheting tie-downs are also preferably utilized thereto securely position said apparatus 10 to a tree 120 .
A bottom portion of the apparatus 10 comprises a pair of first wheels 70 and a ground anchor 59 (see FIG. 2 ). An intermediate portion comprises an adjustable tree brace 60 , thereby stabilizing the apparatus 10 thereon a tree 120 or other vertical surface. The tree brace 60 comprises a plurality of equidistantly-spaced adjustment indentations 62 and works in conjunction with an extension rod 66 which comprises an adjustment fastener 64 . The tree brace 60 mates with the extension rod 66 by a slidably engaging technique and is secured to a desired length with the adjustment fastener 64 mating with a desired adjustment indentation 62 . An aperture (not shown) is located on an end portion of the extension rod 66 , thereby permitting an insertion of the adjustment fastener 64 . Said adjustment fastener 64 is a bolt that which is inserted and screwed onto the desired depressed portions of the tree brace 60 by means of an attached washer 68 . Said washer 68 is attached to the extension rod 66 with welding 110 techniques parallel to the aperture. The extension rod 66 is attached to an intermediately located rung 50 with common fastening means such as, but not limited to: welding 110 , hinges, or the like. The adjustment indentations 62 are located on an end portion of the tree brace 60 and comprise a slight depression to mate to the corresponding adjustment fastener 64 . The tree brace 60 comprises a perpendicular extrusion at one (1) end, thereby enabling resting against the tree 120 for support. The tree brace 60 also provides a handle to enable the user to pull the apparatus 10 when in a collapsed position (see FIG. 2 ). The tree brace 60 and extension rod 66 are fabricated from similar materials to the ladder portion aforementioned. The intermediate portion also comprises a hinge 92 , thereby allowing the apparatus 10 to fold and collapse for transporting (see FIGS. 4 a and 4 b ).
A top portion of the apparatus 10 comprises a seat frame 20 , a back portion 25 , a seat portion 27 , a hanger 30 , and a foot portion 40 , thereby providing the user with a sitting position and hanging storage for associated equipment while in use. The seat frame 20 enables the user to sit therein, which is integrated into a horizontal top portion of the apparatus 10 . The seat frame 20 comprises a back portion 25 and a seat portion 27 comprising interweaved fabric, thereby creating a backing platform and sitting platform for the user. The seat frame 20 is supported via a pair of downwardly angled second brackets 44 each attached to a lower section of the seat portion 27 and to the upper side rails 55 . The second bracket is fabricated from a metal material such as, but not limited to: steel, aluminum, or the like.
The top portion of the apparatus 10 also comprises a foot portion further comprising a grated platform located below the seat portion 27 . A rear section of said foot portion 40 is attached to a downwardly positioned “U”-shaped first bracket 42 which is attached to a lower portion of the seat frame 20 . A front section of said foot portion 40 is attached to the upper side rails 55 . Said attachments are created with conventional fastening techniques such as, but not limited to: welding 110 , hinges, or the like. The foot portion 40 and first bracket 42 , are also fabricated from a metal material such as, but not limited to: steel, aluminum, or the like.
The top portion of the apparatus 10 further comprises a triangular hanger 30 , thereby providing a hanging storage for the user to associated equipment such as, but not limited to: a coat, a gun, an equipment bag, or the like. The hanger 30 is attached to the upper side rail 55 with fastening means such as, but not limited to: clamps, welding 110 , or the like. Said hanger 30 is also fabricated from similar metal materials as above-mentioned.
Referring now to FIG. 2 , a perspective view of the apparatus 10 depicting a collapsed position, according to the preferred embodiment of the present invention, is disclosed. Shown collapsed position enables the user to transport hunted animals or other equipment, thereby placing the animal and/or equipment above the upper side rails 55 and carting the apparatus 10 with a pair of first wheels 70 and tree brace 60 .
The apparatus 10 also comprises a pair of first wheels 70 , thereby providing movement to said apparatus 10 while in the collapsed position. The first wheels 70 work in conjunction with the tree brace 60 , thereby allowing the user to grip and pull the perpendicular contoured extrusion thereon the tree brace 60 , as like a handle, with ease due to the first wheels 70 . Said first wheels 70 are mounted to each lower side rail 56 and utilize a conventional axle system. Each first wheel 70 is supported therewith a “U”-shaped wheel bracket 72 which is further welded 110 thereto a respective lower side rail portion 56 . Said first wheels 70 are preferably fabricated with a plastic rim and solid rubber tire, thereby enabling a user to transport the apparatus 10 in a variety of terrain. Said first wheels 70 are also preferably sixteen (16) inches in diameter, yet other sized wheels may be utilized without limiting the function of the apparatus 10 .
The apparatus 10 comprises a pair of parallel ground anchors 59 , thereby providing stabilizing support while said apparatus 10 is in use. The ground anchors 59 are comprised of metal rods pointed ends to easily puncture a ground surface. Said ground anchors 59 extend from each lower side rail 56 and are fabricated from similar aforementioned materials.
The apparatus 10 further comprises a pair of second wheels 75 , thereby a guiding the apparatus 10 while positioned against a tree 120 in the erected position. Said second wheels 75 are located at a rear portion of the seat frame 20 and are an appropriately spaced distance to engage the tree 120 , thereby allowing for a stabilized vertical upward motion to said tree 120 . Said second wheels 75 work in conjunction with a pair of compression springs 80 and a pair of tree anchors 82 (see FIG. 3 ).
Referring now to FIG. 3 , a close-up view the apparatus 10 depicting a pair of tree anchors 82 and associated components, according to the preferred embodiment of the present invention, is disclosed. The apparatus 10 comprises a pair of second wheels 75 , a pair of compression springs 80 , and a pair of tree anchors 82 , thereby providing a stabilizing aspect while in the deployed position. These components allow the apparatus 10 to glide upward against the tree 120 and secure into said tree 120 . The second pair of wheels 75 is similar to common caster wheels which each are fastened to a fork 88 by means of a second wheel fastening means 86 . Each fork 88 is attach to a flat plate 84 and each second wheel fastening means 86 is preferably a bolt and nut combination, yet other fastening means may be incorporated without limiting the function of the apparatus 10 . The plate 84 is fastened to the seat frame 20 by means of a plate fastener 85 which comprises a bolt and nut inserted through and fastened to the plate 84 and seat frame 20 .
The plate 88 is attached to the pair of compression springs 80 and the pair of tree anchors 82 . Said compression springs 80 allow the plate 88 to be depressed toward the seat portion 27 , thereby allowing the tree anchors 82 to extract and secure to the tree 120 . Each of said tree anchors 82 are affixed to the seat frame 20 and routed through the plate 84 and each of the pair of compression springs 80 encompass the span of each tree anchor 82 between the seat frame 20 and plate 84 .
Referring now to FIG. 4 a , a close-up view of the hinge 92 depicting a collapsed state and FIG. 4 b , a close-up view of a hinge 92 depicting an erected state, according to the preferred embodiment of the present invention, are disclosed. The intermediate portions of the apparatus 10 comprise a pair of hinges 92 , thereby providing a joint to pivot said apparatus 10 to a collapsed state or erected state. The hinge 92 is welded 110 onto the lower portion of the upper side rails 55 and an upper portion of the lower side rails 56 although other fastening techniques may be incorporated without limiting the functions of the apparatus 10 . The length of the hinge 92 may be adjusted by means of a sliding bracket 96 and locked into position by means of a bracket fastening means 94 .
The apparatus 10 also comprises a hinge brace 90 , thereby limiting the rotation of the hinge 92 and supporting said hinge 92 while in the erected position. The hinge brace 90 is a tubular metal section welded 110 onto a rear portion of the lower side rail 56 . As the hinge 92 is rotated to erect the apparatus 10 the upper side rail 55 engages the lower side rail 56 to form one (1) rigid member, thereby allowing the hinge brace 90 to align parallel to each side rails 55 , 56 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the apparatus 10 , it would be installed as indicated in FIGS. 1 through 4B .
The method of installing and utilizing the apparatus 10 may be achieved by performing the following steps: acquiring said apparatus 10 ; collapsing said apparatus 10 by means of the hinge 92 ; utilizing the tree brace 60 and first wheels 70 in order to transport said apparatus 10 to a desired location; erecting said apparatus 10 by engaging the upper rails 55 with the lower rails 56 ; locking the hinge 92 with the bracket fastening means 94 ; utilizing the second pair of wheels 75 to guide the apparatus 10 upward against the tree 120 ; engaging the ground with the ground anchors 59 ; adjusting the tree brace 60 and extension rod 66 with the adjustment fastener 64 and adjustment indentations 62 to a desired position to engage the tree 120 ; encompassing the tree 120 with a ratcheting tie-down 100 and attaching to an intermediate position on the apparatus 10 ; utilizing the rungs 50 , upper side rails 55 , and lower side rails 56 to climb the apparatus 10 to the elevated position; gripping the plate 84 , compressing the compression springs 80 , and puncturing the tree 120 with the tree anchors 82 ; encompassing the tree 120 therewith a ratcheting tie-down 100 and attaching to an upper position on the apparatus 10 ; sitting on the seat portion 27 and resting against the back portion 25 ; positioning the user's feet on the foot portion 40 ; hanging equipment on the hanger 30 ; partaking in a normal hunting activity for a desired period of time; depressing the plate 84 to retract the tree anchors 82 ; removing ratcheting tie-down 100 from the upper portion of the apparatus 10 and tree 120 ; descending from the apparatus 10 ; removing ratcheting tie-downs 100 from the intermediate portion of the apparatus 10 and tree 120 ; collapsing said apparatus 10 by pivoting the hinge 92 ; utilizing the tree brace 60 to transport said apparatus 10 to a desired location; utilizing the apparatus 10 when necessary; and, enjoying the features and benefits of the portable tree stand.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. | A combination tree stand and hand truck are herein disclosed, comprising a seat mounted on the bottom of a conventional wheeled hand truck. The rear of the hand truck comprises a plurality of cross members and is attached via a pair of hinges to an additional section of a ladder like structure that is capable of being foldable extended to form a ladder. In use, the wheeled hand truck may be used to transport items to and from a hunting location. Once at a hunting location, the hand truck may be converted into a tree stand by deploying the folding ladder section and placing the deployed stand upside down against a tree or other structure therewith a securing means. The apparatus is particularly useful in game lands and other restricted hunting areas where an all-terrain vehicle or other motorized vehicle is not permitted. | 4 |
RELATED APPLICATIONS
[0001] This is a continuation-in-part of U.S. patent application Ser. No. 09/643,085 entitled “MANIPULATABLE DELIVERY CATHETER FOR OCCLUSIVE DEVICES” filed Aug. 21, 2000, now pending and incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention is in the general field of surgical instruments and is specifically a catheter having a flexible, proximally-manipulated hinge region. The inventive catheter may include a balloon. The catheter may have a shaft of varying flexibility which contains several lumen. The inner, or delivery, lumen generally may be used with a guide wire to access target sites within the body through the flexible, small diameter vessels of the body. The delivery lumen may be also used for placement of occlusive materials, e.g., in an aneurysm. Inflation of the optional micro-balloon, located near the distal tip of the catheter, is effected using the inflation lumen. The push/pull wire tubing contains a wire, which when manipulated, flexes the catheter's distal tip.
BACKGROUND OF THE INVENTION
[0003] Endovascular therapy has been used to treat different conditions, such treatments including control of internal bleeding, occlusion of blood supply to tumors, and occlusion of aneurysm. Often the target site of the malady is difficult to reach. Because of their ability to access remote regions of the human body and deliver diagnostic or therapeutic agents, catheters are increasingly becoming components of endovascular therapies. Vascular catheters may be introduced into large arteries, such as those in the groin or in the neck, and then pass through narrowing regions of the arterial system until the catheter's distal tip reaches the selected delivery site. To be properly utilized, catheters are often stiffer at their proximal end to allow the pushing and manipulation of the catheter as it progresses through the body but sufficiently flexible at the distal end to allow passage of the catheter tip through the body's blood vessels without causing significant trauma to the vessel or surrounding tissue.
[0004] Microcatheters, such as those shown in U.S. Pat. Nos. 4,884,579 and 4,739,768, each to Engleson, allow navigation through the body's tortuous vasculature to access such remote sites as the liver and the arteries of the brain. Although other methods of causing a catheter to proceed through the human vasculature exist (e.g., flow directed catheters), a guidewire-aided catheter is considered to be both quicker and more accurate than other procedures. Catheters with deflectable or variable stiffness distal ends (which increase the flexibility of the catheter's distal end) have been disclosed in U.S. Pat. No. 6,083,222, to Klein et al; U.S. Pat. No. 4,983,169, to Furukawa; U.S. Pat. No. 5,499,973, Saab; and U.S. Pat. No. 5,911,715, to Berg et al.
[0005] The addition of a fluid-expandable balloon on the distal end of the catheter and a coupler-on the proximal end allows various percutaneous medical treatments such as pressure monitoring, cardiac output and flow monitoring, angioplasty, artificial vaso-occlusion, and cardiac support. Balloon catheters generally include a lumen that extends from the proximal end and provides fluid to the balloon for inflation. Examples of balloon catheters are disclosed in U.S. Pat. No. 4,813,934 to Engleson et al and U.S. Pat. No. 5,437,632 to Engelson et al. A balloon catheter with an adjustable shaft is shown in U.S. Pat. No. 5,968,012, to Ren et al.
[0006] For certain vascular malformations and aneurysms, it may be desirable to create an endovascular occlusion at the treatment site. A catheter is typically used to place a vaso-occlusive device or agent within the vasculature of the body either to block the flow of blood through a vessel by forming an embolus or to form such an embolus within an aneurysm stemming from the vessel. Formation of an embolus may also involve the injection of a fluid embolic agent such as microfibrillar collagen, Silastic beads, or polymeric resins such as cyanoacrylate. Ideally, the embolizing agent adapts itself to the irregular shape of the internal walls of the malformation or aneurysm. Inadvertent embolism due to an inability to contain the fluid agent within the aneurysm is one risk which may occur when using fluid embolic agents.
[0007] Mechanical vaso-occlusive devices may also be used for embolus formation. A commonly used vaso-occlusive device is a wire coil or braid which may be introduced through a delivery catheter in a stretched linear form and which assumes an irregular shape upon discharge of the device from the end of the catheter to fill an open space such as an aneurysm. U.S. Pat. No. 4,994,069, to Ritchart et al, discloses a flexible, preferably coiled, wire for use in a small vessel vaso-occlusion.
[0008] Some embolic coils are subject to the same placement risks as that of fluid embolic agents in that it is difficult to contain the occlusive coil within the open space of the aneurysm. A need exists for a delivery system which accurately places the occluding coil or fluid and ensures that the occluding coil or fluid does not migrate from the open space within the aneurysm. The delivery catheter must have a small diameter, have a highly flexible construction which permits movement along a small-diameter, tortuous vessel path, have a flexible method of placement to ensure accuracy, and must have a method to prevent coil or embolizing agent leakage.
SUMMARY OF THE INVENTION
[0009] This invention is a catheter or catheter section. Although it desirably has a balloon region located from distal of an inflatable member to proximal of that inflatable member, where the inflatable member is within the balloon region, it need not have a balloon region or an inflatable member. The inventive catheter has a flexible joint region located generally in the distal area of the catheter, often within that balloon region. The catheter includes a wire configured to flex the flexible joint region. Where the catheter includes an inflatable member, the flexible joint may variously be distal of the inflatable member, within the inflatable member, or proximal of the inflatable member. The flexible joint region preferably has a flexibility of up to about 90°. The flexible joint region, because the catheter wire may be too rigid, may also be manipulatable in a circular direction relative to the axis of the catheter.
[0010] The wire may be slidingly held, e.g., within a separate tubing. This tubing may potentially be used to aid in adjusting the flexibility of the joint region. This may be accomplished by several different variations. One variation utilizes a wire tubing having collinear consecutive sections of decreasing wall thickness. Alternatively, the wire tubing may be tapered according to the desired degree of joint flexibility. The tubing itself may be a braided tubing which may be of varying flexibility.
[0011] The flexible joint itself may be, for instance, a coil member, perhaps having a section with a pitch which is larger than adjacent coil pitches. The flexible joint may instead be a braid, perhaps with a section with a pic which is larger than the pic of one or more adjacent sections. The flexible joint may also be made up of a polymer tubing with a section which is softer than adjacent tubing polymers or a region having a wall thickness that is thinner than adjacent wall thickness.
[0012] In taking advantage of the flexibility and capabilities of the present invention, a variation capable of twisting in a helical or corkscrew-like manner may be accomplished with or without an inflatable member or balloon region. This variation is particularly useful in traversing tortuous vasculature and in making difficult approaches to aneurysms. This alternative varation utilizes a wire which may be wound about the guidewire or inner tubing and fixedly attached. It is thus possible to wind the wire any number of times or just a few degrees off the wire axis depending upon the vasculature being traversed and the degree of flexibility or twisting desired. Moreover, different variations may be developed capable of twisting in a left or right handed orientation.
[0013] The present invention may also incorporate various rapid exchange variations.
[0014] The inflatable member or balloon may be of a material selected from the group consisting of elastomers such as silicone rubber, latex rubber, natural rubber, butadiene-based co-polymer, EPDM, and polyvinyl chloride or thermoplastic polymers such as polyethylene, polypropylene, and nylon.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIGS. 1A, 1B , and 1 C are external views of several variations of the inventive catheter device.
[0016] FIG. 2A depicts a cross sectional view of a proximally placed hinge region in a variation of the distal region of the inventive catheter.
[0017] FIG. 2B depicts a cross sectional view of a mid-balloon hinge region placement for a variation of the distal region of the inventive catheter.
[0018] FIG. 2C depicts a cross sectional view of a distally placed hinge region in a variation of the distal region of the inventive catheter.
[0019] FIG. 2D depicts a cross sectional view of an additional mid-balloon hinge region placement for one variation of the distal region of the inventive catheter.
[0020] FIG. 3A depicts a cross-sectional view of an alternate hinge region construction for the distal region of the inventive catheter. The hinge region of FIG. 3A is composed of a section of material which is surrounded by regions of greater stiffness.
[0021] FIG. 3B depicts a cross-sectional view of an alternate hinge region construction for the distal region of the inventive catheter. The hinge region of FIG. 3B is composed of a coil of varying pitch.
[0022] FIG. 3C depicts a cross-sectional view of an alternate hinge construction for the distal region of the inventive catheter. The hinge of FIG. 3C is composed of a region of thinned tubing wall surrounded by regions of thickened tubing wall.
[0023] FIG. 3D depicts a cross-sectional view of an alternate hinge region construction for the distal region of the inventive catheter. The hinge region of FIG. 3B is composed of a braided region which is flanked by regions of higher braid density.
[0024] FIGS. 4A-4H are cross-sectional views of catheter shafts displaying the various relative positions of the push/pull wire lumen, inflation lumen, and delivery lumen.
[0025] FIG. 5 depicts the positions of the radio-opaque markers positioned within the distal end of the catheter tip.
[0026] FIG. 6A depicts the relative position of the distal end of the catheter tip when not flexed.
[0027] FIG. 6B depicts the relative position of the distal end of the catheter when flexed by pulling the push/pull motion wire.
[0028] FIG. 6C depicts the relative position of the distal end of the catheter when flexed by pushing the push/pull motion wire.
[0029] FIG. 7A depicts a variation having a push/pull wire tubing with consecutively smaller cross-sections.
[0030] FIG. 7B depicts an alternative variation having a tapering push/pull wire tubing.
[0031] FIG. 7C depicts a cross-sectional view of the sectioned push/pull wire tubing from FIG. 7A .
[0032] FIG. 7D depicts a cross-sectional view of the tapered push/pull wire tubing from FIG. 7B .
[0033] FIG. 8A depicts a variation where the push/pull wire may be partially wound about the guidewire tubing.
[0034] FIG. 8B depicts a cross-section of FIG. 8A where the push/pull wire is wound in a right-handed orientation.
[0035] FIG. 8C depicts a cross-section of FIG. 8A with an alternative variation where the push/pull wire is wound in a left-handed orientation.
[0036] FIG. 9 depicts a variation having a catheter tip which may be rotated by a twisting push/pull wire.
[0037] FIGS. 10A, 103B , and 10 C are external views of several variations of the inventive catheter device incorporating a rapid exchange variation.
[0038] FIGS. 11A, 11B , 11 C, and 11 D depict the steps of using the inventive catheter by respectively inserting the distal end of the inventive catheter into a blood vessel, placing a vaso-occlusive device within an aneurysm, and removing of the catheter.
DETAILED DESCRIPTION OF THE INVENTION
[0039] This invention involves a multi-lumen, catheter having a manipulatable distal tip and is for the delivery of vaso-occlusive materials or implants. The inventive catheter may include one or more distally placed balloon members. The device is shown in detail in the Figures wherein like numerals indicate like elements. The catheter preferably includes a shapeable, flexible distal section. The flexible section, or “hinge region”, preferably is manipulated from outside the body during the process of delivering the verso-occlusive device or material. The terms “hinge region”, “hinge”, or “flexible joint” may be used interchangeably for our applications.
[0040] FIG. 1A shows a catheter assembly 23 made according to one variation of the invention. This variation of the catheter assembly 23 includes a catheter shaft 25 comprised of a flexible, thin walled body or tube 26 having an inner lumen which extends between proximal and distal catheter ends 24 , 37 , respectively. The tube 26 is preferably a generally nondistensible polymer having the appropriate mechanical properties for this application, and preferably polyethylene (e.g., HDPE, LDPE, LLDPE, MDPE, etc.), polyesters (such as Nylon), polypropylene, polyimide, polyvinyl chloride, ethylvinylacetate, polyethylene terephthalate, polyurethane (e.g. Texin such as that made by Bayer Corporation), PEBAX, fluoropolymers, mixtures of the aforementioned polymers, and their block or random co-polymers.
[0041] This variation of the inventive catheter assembly generally has several overall functions: a.) access through the vasculature to the brain (or other vascular site) often, but not necessarily, using a guide wire; b.) inflation of the inflatable member or balloon to close or to restrict an artery or the mouth of an aneurysm prior to or during placement of a vaso-occlusive device, thereby requiring a fluid pathway for inflation of the inflatable member; c.) flexion of a “hinge region” in the neighborhood of the distal end of the catheter by a wire extending proximally through the catheter; and d.) introduction of a vaso-occlusive device or material for eventual placement in the vasculature, thereby requiring a pathway or storage region for the vaso-occlusive device. These functions may be achieved by features found at the proximal and distal regions of the catheter.
[0042] The proximal catheter end 24 may be provided with a fitting 18 (e.g., a “LuerLok”) through which fluid may be supplied to the catheter's inflation lumen through a side port 16 . The proximal end of the catheter is provided with a second port 20 and a fitting 22 through which a push/pull wire may be used to manipulate the hinge region 32 in the distal catheter tip. The proximal end fitting 18 includes an axially extending port 14 which communicates with the catheter's delivery/guide wire lumen. The optional guide wire 12 may have any suitable construction for guiding the flexible catheter to its intended site within the body. The proximal end of the guide-wire 12 may be equipped with a handle 10 for applying torque to the guide wire 12 during catheter operation. The guide-wire may have a variable stiffness or stepped diameter along its length which typically, e.g., a larger-diameter, stiffer proximal region and one or more smaller-diameter, more flexible distal regions.
[0043] The distal portion 35 of the catheter is made of an inflatable member 30 , typically a balloon, a hinge region 32 , and an opening or aperture 36 for delivery of the vaso-occlusive device or material. This opening 36 may also be used for delivery of drugs and the vaso-occlusive device to the selected vascular site. The distal end region 35 of the catheter 25 is provided with an inflatable balloon 30 which, when inflated, aids in the placement of vaso-occlusive materials or devices by blocking the entrance to the aneurysm or the artery adjacent to the aneurysm.
[0044] The balloon wall section (discussed in greater detail below) is preferably formed from a thin sleeve of polymeric material and attached at its opposite sleeve ends to a relatively more rigid tube section. FIGS. 1A, 1B , and 1 C display various configurations of the distal catheter tip 35 positioning based on the placement of the flexible hinge region. FIGS. 1A, 1B , and 1 C respectively show variations of the inventive catheter 23 in which the hinge region 32 is placed proximal to ( FIG. 1A ), within ( FIG. 1B ), and distal to ( FIG. 1C ) the inflatable member region 30 . Flexion of the hinge region is achieved through remote manipulation of the push/pull wire 21 .
[0045] FIGS. 2A through 2D illustrate variations of the distal end region 35 and hinge region 32 of the catheter illustrated in FIG. 1A, 1B , and 1 C.
[0046] The catheter tube 40 of FIG. 2A has an inflatable member 44 , preferably a balloon, which is formed by an inflatable sleeve secured at its ends 41 , 43 to the catheter tube wall 40 . The inflatable member or balloon 44 may be of a shape, thickness, and material as is typical of balloons used in neurovascular balloon catheters. Preferably, though, the inflatable member or balloon 44 is formed of a thin polymeric material, and preferably an elastomeric, stretchable material such as silicone rubber, latex rubber, polyvinyl chloride, complex co-polymers such as styrene-ethylene butylene-styrene copolymers such as C-FLEX, or alternatively, a non-stretchable film material such as polyethylene, polypropylene, or polyamides such as Nylon. Attachment of the sleeve ends to the catheter tube may be by gluing, heat shrinkage, mechanical fastener, or other suitable method. The inflation lumen 42 allows communication between the inflation fluid source and the balloon 44 through at least one opening 50 formed in the catheter tube 40 . Inflation and deflation of the balloon are effected by the passage of radio-opaque fluid, saline, or other fluid. The push/pull wire tubing 60 extends throughout the catheter tube 40 and protects the passage of the push/pull wire 62 which is connected to the inner wall of the catheter tube 40 . To assist in preventing collapse of the tube 60 enclosing the push/pull wire 62 and to prevent kinking or bulging during actuation, the push/pull wire tubing 60 may have additional structure preferably provided by a layer of higher stiffness polymer (e.g., a polyimide), a support coil, or a support braid.
[0047] Axial manipulation of the push/pull wire 62 via the proximal wire port ( 20 in FIG. 1A ) allows flexion of the distal end 35 of the catheter ( 25 in FIG. 1A ). The guide wire 57 extends through the delivery lumen 55 which lies interior to the catheter tube 40 . The push/pull wire 62 extends through the push/pull wire tubing 60 and may be bonded to the radio-opaque band 67 which surrounds the catheter's distal end 65 . Radio-opaque bands may be made of any number of conventional radio-opaque materials, e.g., platinum. The hinge region 58 at which the distal catheter tip 65 flexes due to proximal manipulation of the push/pull wire 62 may be located proximal to, within, or distal to the balloon, as displayed respectively in FIGS. 2A, 2B , and 2 C.
[0048] As shown in FIG. 2A , when the hinge region 58 is placed proximally of the balloon 44 , the push pull wire tubing 60 extends to a region which is proximal of the distal end of the balloon 44 to allow flexion of the region of the catheter's distal end 65 which includes the entire balloon 44 . If the hinge region 58 is placed interior to the balloon, as in FIG. 2B , flexion of the catheter's distal end 65 occurs such that the point of flexion is within the balloon (also displayed in FIG. 1 B ). FIG. 2C shows the placement of hinge 58 distal to the balloon; flexion during distal-hinge placement occurs such that the manipulatable region of the catheter's distal end 65 does not include any portion of the balloon 44 .
[0049] FIG. 2D shows placement of the hinge region 58 interior to the balloon 44 . The balloon 44 extends between the guidewire/delivery tube 56 and the outer catheter tube 40 enclosing the annular inflation lumen 42 . The push/pull wire 62 is attached to the distal end 65 of the guidewire/delivery tube 56 .
[0050] In each of the variations shown in FIGS. 2A, 2B , 2 C, and 2 D, the push/pull wire 62 is distally attached to a radio-opaque band 67 . Although this is a preferred variation, other attachment sites for attachment of the push/pull wire 62 distal to the hinge region 58 will be apparent.
[0051] The hinge region may be made up of any material or structural configuration which allows flexion based on remote manipulation by movement of the push/pull wire 62 . Several variations of preferred configuration are shown in FIGS. 2D, 3A , 3 B, and 3 C.
[0052] In FIG. 2D , extension of the delivery tube 56 beyond the end of the inflation lumen 42 allows remote manipulation of the catheter's distal end 65 if the push/pull wire 62 is attached to a marker or platinum band 67 which is located distal to the end of the inflation lumen. In this configuration, remote manipulation of the push/pull wire allows flexion to occur between the end of the inflation lumen 42 and the marker 67 to which the push/pull wire 62 is attached. The delivery tube 56 may be made of any of the materials listed above with respect to tube 26 in FIG. 1 .
[0053] FIG. 3A displays a cross section of the catheter 70 wall. The hinge section of FIG. 3A is made from contiguous regions of tubing where one section of the catheter wall 77 is made from a material with a stiffness which is less than the stiffness of the material of the flanking sections of catheter wall 75 , 79 . These regions of tubing are preferably made through extrusion, by doping, or heat treating a region of the tubing.
[0054] FIG. 3B displays a hinge region 88 which utilizes a coil 90 of varying pitch imbedded in the catheter wall. Because the variation in pitch of the coil 90 produces regions of varying flexibility, the lower pitch region 88 is more flexible than the region of higher pitch 89 . The higher pitch region 89 is stiffer during manipulation of the push/pull wire 86 .
[0055] As shown in FIG. 3C , if a thinned region of catheter wall 105 is flanked by regions of greater wall cross-sectional area 100 , 108 , the section 108 of the catheter wall which is distal to the thinned section 105 will act as a hinge when the distal end of the catheter is manipulated using the push/pull wire 96 . The variations in wall cross sectional area may preferably be created during an extrusion process.
[0056] FIG. 3D displays a hinge which utilizes a braided ribbon 94 with varying braid pitch, that is embedded between outer 101 and inner 103 layers of the catheter wall. The variation in pitch of the braided ribbon 105 produces regions of varying flexibility. If a region of lower braid pitch 92 is flanked by regions of higher braid pitch 90 , the region of greater pitch 89 is stiffer during manipulation of the distal catheter tip. The braid 94 is preferably made from a number of metallic ribbons or wires which are members of a class of alloys known as super-elastic alloys, but may also be made from other appropriate materials such as stainless steel or polymers such as liquid crystal polymers (LCP's). Preferred super-elastic alloys include the class of titanium/nickel materials known as nitinol. Additional treatment to the braid prior to assembly, such as heat-treatment, may be required or desired to prevent braid unraveling, changes in diameter, or spacing during handling. The braids which may be utilized in this invention are preferably made using commercially available tubular braiders. The term “braid” is meant to include tubular constructions in which the ribbons making up the construction are woven radially in and in-and-out fashion as they cross to form a tubular member defining a single lumen. The braid is preferably made from a suitable number of ribbons or wires.
[0057] Some of the various configurations of the catheter's lumina (inflation, push/pull, and delivery) are displayed in FIGS. 4A through 4H . In FIG. 4A , the inflation lumen 122 and push/pull wire lumen 124 are formed interior to the catheter wall 120 , while the interior catheter wall forms the guide wire lumen 128 . In FIG. 4B , the catheter wall 120 forms the guide wire lumen 128 which contains the inflation lumen 122 and push/pull wire lumen 124 . The inflation lumen 122 is formed interior to the catheter wall 120 of FIG. 4C , while the push/pull wire lumen 124 lies within the larger coil lumen 128 (which is formed by the catheter wall 120 ). FIG. 4D is a variation of FIG. 4C in which the push/pull wire lumen 124 lies interior to the catheter wall 128 while the inflation lumen 122 lies within the larger coil lumen 128 . In FIG. 4E , the interior catheter wall 120 forms the inflation lumen 122 , and the push/pull wire lumen 124 and the guide wire lumen 128 are found within the inflation lumen 122 . The inflation lumen 122 surrounds the guide wire lumen 128 and lies within the region formed interior catheter wall 120 in FIG. 4F , while the push/pull wire lumen 124 lies within the catheter wall 120 . In FIG. 4G , one shared lumen 123 serves as the push/pull and inflation lumen; the shared push/pull and inflation lumen 123 along with the guide wire lumen 128 lie within the catheter wall 120 . Another alternate variation of the lumina positioning, shown in FIG. 4H , has the push/pull wire lumen 124 lying interior to the inflation lumen 122 which is contained within the catheter wall 120 , while a separate lumina for the guide wire 128 also is contained within the catheter wall.
[0058] The tube constructions, hinge region construction, and other tubing forming the various lumina discussed herein may be created through extrusion, sequential production (in which the parts are manufactured separately and later assembled together), or some other method.
[0059] As displayed in FIG. 5 , another variation of the present invention may involve the addition of radio-opaque markers 190 . The lengthened distal section 200 may be provided with a number of spaced radio-opaque markers 190 , 191 , 192 , and 193 . Balloon markers 195 , 196 may be provided to indicate the position of the balloon during the vascular procedure. The markers may be spaced, for instance, such that the inter-marker distance corresponds to the length of the coil to be delivered. Markers 195 , 196 may be spaced apart by a known or predetermined distance, e.g., 3 cm, both proximally and distally of the balloon member. Also, the various markers, particularly those located adjacent the balloon member, may be disposed outside the balloon member, as depicted, or optionally inside.
[0060] FIGS. 6A, 6B , and 6 C show the operation of the inventive flexible distal catheter tip.
[0061] In FIG. 6A , the remotely-manipulatable distal end 136 extends beyond the hinge 135 and allows greater access to the delivery site of the vaso-occlusive member 137 during surgical procedures. Manipulation of the push/pull wire 143 allows flexion of the catheter distal tip 136 .
[0062] If the push/pull wire 143 is pushed or axially manipuliated, as shown in FIG. 6B , the distal tip 145 is flexed upward through an angle determined by the pressure applied to the push/pull wire. Generally, the deflection angle of the catheter 140 as the push/pull wire 143 is pushed may approach up to about 90° in one direction.
[0063] If the push/pull wire 143 is pulled as in FIG. 6C , rotation from the un-manipulated position through an angle up to about 90° opposite the direction shown in FIG. 6B is initiated; again, this angle is in a direction which is opposite to that of the pull-manipulation but generally in the same plane. The push/pull wire 143 extends through out the push/pull wire lumen 141 and may be bonded to the radio-opaque band 142 found at the distal end 145 of the catheter 140 tip.
[0064] FIG. 7A depicts an alternative variation 210 which is similar to that shown in FIG. 2D . The tubing 56 itself may be a braided tubing which may be of varying flexibility. However, variation 210 depicts a push/pull wire tubing 212 having a stepped distal end 213 . Stepped push/pull wire tubing 212 may be comprised of similar materials and structures as push/pull wire tubing 60 but having a series of successively decreasing cross-sectional areas on stepped distal end 213 . The number of successively decreasing cross-sections and the associated lengths of each decreased section may vary depending upon the degree of flexibility necessary or desired within catheter distal end 65 . Moreover, variation 210 depicts stepped distal end 213 extending into inflatable member 44 ; however, the relative positioning of stepped push/pull wire tubing 212 to inflatable member 44 may be altered again depending on the desired flexibility of catheter 40 . Push/pull tubing 212 may itself be a braided tubing which may be of varying flexibility. Also, the figure depicts push/pull wire tubing 212 as a separate tube, but it may also be in any of the variational cross-sections discussed herein having the push/pull wire tubing 212 disposed, e.g., within the tubing and any braiding or coils, or disposed exteriorly of any braiding or coils.
[0065] FIG. 7C depicts the cross-sectional view of the stepped push/pull wire tubing 212 from FIG. 7A . Tubing 212 may be attached or held to tubing 56 by any of the various methods discussed herein, e.g., shrink-wrap. The figure depicts tubing 212 with three sections for illustrative purposes and tubing 212 may comprise any number of sections with variable thickness depending upon the degree of flexibility necessary or desired.
[0066] FIG. 7B depicts an additional alternative variation 214 which is similar to variation 210 . However, variation 214 depicts push/pull wire tubing 216 having a tapering distal end 217 . Here, the degree of tapering may be varied depending upon the degree of flexibility necessary or desired, as above.
[0067] FIG. 7D depicts the cross-sectional view of the tapered push/pull tubing 216 from FIG. 7B . Tubing 216 may also be attached or held to tubing 56 by any of the various methods discussed herein, e.g., shrink-wrap. Tubing 216 may be made to have any degree of tapering again depending upon the degree of flexibility necessary or desired.
[0068] FIG. 8A depicts another variation 218 which enables a user to not only manipulate catheter distal end 65 within generally one plane, but also to manipulate or to twist catheter distal end 65 , e.g., in a helical or corkscrew-like manner. As illustrated, push/pull wire 62 emerges from push/pull wire tubing 60 and may be rotated about guidewire/delivery tube 56 for attachment to an attachment point, e.g., radio-opaque band 67 as shown, at some point not on the axis with the tubing 60 . Instead it may be attached preferably on an opposite side from where push/pull wire 62 emerges. The attachment point is preferably located distally from push/pull wire tubing 60 , but may vary depending upon the degree of torque desired. Also, attachment of push/pull wire 62 along radio-opaque band 67 may also vary depending upon the desired range of torquing or twisting of catheter distal end 65 . For example, push/pull wire 62 may be placed along, e.g., radio-opaque band 67 , in any location ranging from about 0° where little or no twisting occurs and up to about 180° where full rotation of catheter distal end 65 occurs about a longitudinal axis defined by catheter tube 40 and guidewire/delivery tube 56 . At about 0°, push/pull wire 62 is attached to radio-opaque band 67 at a point in aposition to where wire 62 emerges from tubing 60 . At about 180°, as depicted in FIG. 8A , push/pull wire 62 is attached to radio-opaque band 67 at a point on an opposite side of guidewire/delivery tube 56 from where wire 62 emerges.
[0069] In variation 218 , push/pull wire tubing 60 may be held relative to guidewire/delivery tube 56 by any conventional shrink-wrap material 220 or by any number of fastening methods discussed herein. Moreover, any number of cross-sectional arrangements described herein for guidewire/delivery tube 56 and push/pull wire tubing 60 may be utilized as well. Also, the arrangement of variation 218 for wire 62 may be utilized with or without inflatable balloon member 44 and is shown in FIG. 9 without balloon member 44 .
[0070] Although FIG. 8A depicts push/pull wire 62 wrapped half-way around guidewire/delivery tube 56 , push/pull wire 62 may be wrapped any number of times around tube 56 before being attached at a desired location on radio-opaque band 67 .
[0071] FIG. 8B shows section A-A from FIG. 8A depicting push/pull wire 62 wrapped in a right-handed orientation about guidewire/delivery tube 56 . Wire 62 may alternatively be wrapped in a left-handed orientation about guidewire/delivery tube 56 , as shown in FIG. 8C , which depicts the same cross-section of FIG. 8B .
[0072] In wrapping push/pull wire 62 about tube 56 , manipulation of catheter distal end 65 forces wire 62 to not only undergo tensile and compressive forces along its longitudinal axis, but also torquing forces about its axis. FIG. 9 depicts variation 221 without a balloon member. Alternatively, the inventive catheter design also allows twisting of the catheter tip without having to attach push/pull wire 62 along band 67 at variable positions. This may be accomplished by utilizing open area 222 , the area without push/pull wire tubing 60 , and the stiffness of wire 62 . Wire 62 may be torqued or twisted about its own axis at its proximal end by a user to bring about a rotation of the distal end of wire 62 and, in turn, catheter distal end 65 . The degree of torquing or twisting of catheter distal end 65 may be controlled not only by the choice of catheter tubing materials, as discussed herein, but also by the length of open area 222 as well as by the choice of material and desired stiffness of wire 62 . This variation may allow a catheter having a combined ability to not only be pushed and pulled in a single plane, but to also be twisted in a helical or corkscrew-like manner, if desired. Although FIG. 9 depicts this variation without a balloon member, it may be used with one as described in the other variations herein. Any number of materials having sufficient strength and elasticity may be used for wire 62 . Some materials which may be used include stainless steels, titanium, superelastic alloys (e.g., nitinol), or any of their combinations and alloys.
[0073] As depicted in the Figures, particularly FIGS. 7A-7B and 8 A- 8 C, radio-opaque bands 67 may optionally be used in conjunction with the different variations as marking known or predetermined distances between the bands 67 , as discussed above.
[0074] FIG. 10A depicts variation 230 of the present invention which may incorporate rapid exchange catheter apparatus and methods. A typical rapid exchange catheter is described in detail in U.S. Pat. No. 4,748,982 entitled “Reinforced Balloon Dilatation Catheter with Slitted Exchange Sleeve and Method” by Horzewski et al., which is herein incorporated by reference in its entirety. In this variation 230 , the apparatus and methods of the present invention, as described herein, may be used with guidewire 12 . Rather than having guidewire 12 inserted from the proximal end of the catheter, guidewire 12 may instead be inserted through entry 232 , which may be located along catheter 25 at a predetermined location proximal of distal end 35 . This variation 230 may facilitate rapid exchanges of the inventive catheter assembly from a body lumen with other catheters, as desired by the operator.
[0075] FIGS. 10B and 10C depict entry 232 and insertable guidewire 12 used in conjunction with the manipulatable balloon catheter.
[0076] A remotely flexible distal tip is particularly useful when treating an aneurysm by placement of a vaso-occlusive device or material in the aneurysm. FIGS. 11A-11D depict such a placement.
[0077] FIG. 11A displays an inventive catheter 156 that has its distal end positioned outside the mouth of an aneurysm 149 to deliver a vaso-occlusive coil. The device is positioned using a guidewire 159 .
[0078] Introduction of the catheter's distal end 165 into the aneurysm neck 147 , shown in FIG. 11B , displays the advantages of the inventive remotely manipulatable catheter. Flexion of the catheter's distal tip using the push/pull wire allows for greater maneuverability when accessing the aneurysm neck and aneurysm sac. The push/pull wire system allows the distal end to be positioned as desired during the procedure, instead of before the procedure begins. Once the distal tip 165 has been properly positioned in the aneurysm neck 147 , inflation of the balloon 157 is then commenced to occlude the aneurysm neck 147 , as shown in FIG. 11C . Full occlusion of the aneurysm neck is desirable to ensure that the coils 175 do not escape into the vessel when the coils are discharged into the aneurysm sac 149 . Once the coil or coils 175 have been completely discharged 180 into the aneurysm sac 149 , deflation of the balloon 157 allows retraction of the catheter's distal end 165 from the aneurysm (shown in FIG. 11D ).
[0079] The applications of the inventive catheter discussed above are not limited to the treatment of aneurysms, but may include any number of vascular maladies. Modification of the above-described methods for carrying out the invention, and variations of the mechanical aspects of the invention that are obvious to those of skill in the mechanical and guide wire and/or catheter arts are intended to be within the scope of the claims. | This is in the general field of surgical instruments and is specifically a delivery catheter with a flexible, proximally-manipulated hinge or joint region. The inventive catheter may have a balloon region. The catheter may have a shaft of varying flexibility which contains several lumen. The inner, or delivery, lumen generally may be used with a guidewire to access target sites within the body via the flexible, small diameter vessels of the body. The delivery lumen may be also used for placement of occlusive materials, e.g., in an aneurysm. Inflation of the micro-balloon, located near the distal tip of the catheter, is effected using the inflation lumen. The push/pull wire lumen contains a wire, which when manipulated, flexes the catheter's distal tip. The push/pull wire tubing may have a variable thickness to aid in adjusting the degree of flexibility. Moreover, the delivery catheter may be capable of twisting in a helical or corkscrew-like manner for traversing certain vasculature. This may be accomplished by winding the push/pull wire within the catheter and fixedly attaching it. The catheter may further include an entry in the catheter wall to allow for the insertion of a guidewire; this may facilitate the rapid exchange of catheter devices as desired by the user. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a non-provisional application based upon U.S. provisional patent application Ser. No. 60/752,069, entitled “IMPROVED SCRIM FOR SEAMS AND JOINS”, filed Dec. 20, 2005.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a scrim, and, more particularly, to a scrim used to cover a join or seam of a papermaking fabric.
[0004] 2. Description of the Related Art
[0005] Scrims are known to reinforce joins and seams in press fabric applications. Scrims provide, for example, fiber bonding adhesion, extra strength, and extra wear resistance. U.S. Pat. No. 6,712,100 describes the use of a scrim referred to as a strip of flow resistant material that is disposed over a seam regions, straddling it by an amount in the range from 0.5 to 2.0 inches and is attached thereto by sewing or by an adhesive.
[0006] A fibrous web is formed upon a papermaking forming fabric by the deposition of a fibrous slurry, which includes an aqueous dispersion of cellulose fibers on the forming fabric. A significant amount of water is removed from the aqueous fiber web by the drainage from the slurry through the forming fabric, leaving the fibrous web on the surface of the forming fabric. The web is directed through press sections, which may include press nips and shoe presses often between two press fabrics. The web then proceeds to a dryer section, where the web is directed in a circuitous path around a series of drums that provide heat to the forming web for the removal of water therefrom.
[0007] The fabrics utilized in the papermaking include forming fabrics, press fabrics and dryer fabrics, all of which are in the form of endless loops in the papermaking machine, and they function as a conveyor of the web.
[0008] A seam or join, which is used to close the ends of a fabric into an endless construct during installation on the papermaking machine, represents a discontinuity in an otherwise uniform construct of the press fabric. The presence of the seam substantially increases the marking that occur on the forming paper sheet, particularly as it is conveyed through a press nip.
[0009] A disadvantage of scrims include that there is locally added mass and caliper to the seam area of the fabric. This results in different performance of the fabric proximate to the scrim, for example, sheet marking, bounce in the press nip.
[0010] What is needed in the art is a scrim that reduces or eliminates sheet marking and/or press nip bounce.
SUMMARY OF THE INVENTION
[0011] The present invention provides a scrim for covering a join or seam in a papermaking fabric.
[0012] The invention in one form is directed to a paper machine fabric, including a base fabric having a join or a seam, and a strip of material covering the join or seam. The strip of material has an edge with a plurality of crenulations.
[0013] An advantage of the present invention is that the scrim is less likely to cause performance issues with the papermaking fabric.
[0014] Another advantage of the present invention is that even if a relatively wide scrim material is used there are minimal performance issues associated therewith.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0016] FIG. 1 is a perspective partially sectioned view of a papermaking fabric using an embodiment of the scrim of the present invention;
[0017] FIG. 2 is an illustration of another embodiment of a scrim of the present invention;
[0018] FIG. 3 is an illustration of yet another embodiment of a scrim of the present invention;
[0019] FIG. 4 is an illustration of yet another embodiment of a scrim of the present invention;
[0020] FIG. 5 is an illustration of yet another embodiment of a scrim of the present invention;
[0021] FIG. 6 illustrates still yet another embodiment of a scrim of the present invention;
[0022] FIG. 7 is an illustration of a further embodiment of a scrim of the present invention; and
[0023] FIG. 8 is an illustration of still yet another embodiment of a scrim of the present invention.
[0024] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate embodiments of the invention and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to the drawings, and more particularly to FIG. 1 , there is shown a fabric assembly 10 including a base fabric 12 and a strip of material 14 also known as a scrim 14 . For ease of illustration, layers of fabric assembly 10 that may be added to that which has been illustrated have not been shown and could include woven and non-woven fabrics and fibers that are attached to base fabric 12 and/or scrim 14 . An end 16 of base fabric 12 and an end 18 are joined together at 20 to form join 20 or seam 20 . Seam 20 is formed by any manner known in the joining of end 16 and end 18 of fabric 12 . Scrim 14 is connected to base fabric 12 mechanically by needling, sewing, adhesives and/or a melting operation.
[0026] Scrim 14 has edges that are not straight, narrow, rectangular strips as those used in the prior art. A relatively wide scrim is used and the sides are crenulated, for example crenulations 22 and 24 . The crenulations may be circular, semi-circular, sinusoidal, square, triangular, trapezoidal and/or angular in shape. The crenulations occur in a repeating or in a random/irregular fashion. Scrim 14 should be more than approximately 1 inch wide, but less than approximately 24 inches wide. Preferably, scrim 14 should be approximately 2 inches wide to 16 inches wide. The indentions of the crenulations are approximately 5% to 30% in depth as compared to the total width of scrim 14 or at least a minimum of 0.10 inch. An advantage of these indentations is that it minimizes the caliper/mass transition as the scrim passes through the nip resulting in a more uniform performance of the joined fabric. The crenulations also break up the border of the scrim so there is less chance that the eye can detect its presence in the resulting web. This is ultimately reflected in the formed paper web resulting in less visible marking.
[0027] Now, additionally referring to FIGS. 2-8 there are illustrated some of the numerous crenulation possibilities. For example, in FIG. 2 there is depicted a scrim 14 having a crenluation 26 and a straight side 28 . Crenulations 26 are regularly spaced between end A and end B. Side 28 , defined as an edge CD is not crenulated. An imaginary line connecting AB is generally parallel to CD. Lines AD and BC may or may not be parallel. The result is a shape ABCD that is a polygon, which can be substantially rectangular, substantially trapezoidal, and if AD is sufficiently narrow substantially triangular.
[0028] FIG. 3 depicts a portion of a scrim where both side edges are crenulated as shown as crenulation 30 and crenulation 32 . Both crenulation 30 and 32 are regularly spaced and may be substantially a mirror image of each other.
[0029] FIG. 4 depicts a scrim 14 where crenulations 34 and 36 are curved crenulations. Crenulations 34 and 36 are illustrated as being in phase with each other contrary to those illustrated in FIG. 3 . FIGS. 3 and 4 each illustrate crenulations that are a pattern having regular spacing of the repeated pattern.
[0030] FIG. 5 depicts a scrim 14 having crenulations 38 and 40 that are irregular in spacing as well as irregular in shape. There is no symmetry between crenulation 38 and 40 and seemingly no pattern of repetition.
[0031] FIG. 6 depicts a scrim 14 having crenulations 42 and 44 , similar to FIG. 3 . However, the crenulations of FIG. 6 extend in both directions relative to imaginary lines AB and DC. In a similar fashion crenulations 46 and 48 of FIG. 7 illustrate a repeating shape of irregular spacing of crenulations entirely on one side of imaginary line AB and extending outside of imaginary line AB, while crenulations 48 extend in both directions of an imaginary line CD.
[0032] In FIG. 8 a scrim 14 is illustrated as being used over a pin-seam 20 or other type of join that has approximately a 15% to 45% open area, and may be approximately 4 inches wide having a thickness of between 0.003 inches to 0.010 inches thick. The scrim is made of a high strength and wear resistant material, such as a high-density polyethylene, polyester or polyurethane. A low melt adhesive layer, like Ethylene Vinyl Acetate (EVA), may be coated on the scrim to improve fiber bonding of scrim 14 to fabric 12 . Crenulations 50 and 52 are a repeated pattern of semi-circular shape approximately 0.5 inches deep and spaced approximately 1 inch apart. The permeability of the finished fabric assembly 10 in the area of scrim 12 will typically be somewhat lower than base fabric 12 apart from scrim 14 by 3% to 15%.
[0033] Advantageously the use of scrim 14 prevents the cross-directional bar that is seen on fabrics with prior art scrims. The prior art scrims have caused problems like press bounce, faster rate of filling and sheet marking due to the added scrim material and also because of the abrupt transition caused by the shape of the scrim. The purpose of the indentions, which are shown as circular type shapes in FIG. 8 , which are advantageous because of the circular shapes, is that they distribute the compressive load more uniformly and are as such less prone to cause a visible mark. The circular shapes provide a better pressure uniformity and mass/caliper/permeability transition from the body of base fabric 12 to scrim 14 versus the prior art, straight, sudden boundary edge. This significantly reduces the risk of the above-noted problems.
[0034] Crenulations 22 , 24 , 26 , 30 , 32 , 34 , 36 , 38 , 40 , 42 , 44 , 46 , 48 , 50 and 52 each have a peak and a valley associated therewith. The difference between the peak and the valley is a distance that is from 5% to 30% of the total width of scrim 14 . The width of scrim 14 can be thought of as the length from A to D or from B to C.
[0035] While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A papermachine fabric includes a base fabric and a strip of material covering a join or seam of the base fabric. The strip of material has an edge with a plurality of crenulations therein. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to a flexible control system and in particular, to an automatic working system including a plurality of machine units each implementing an individual role. For example, machine units include a welding robot and at least one positioner. The positioner serves to orientate a workpiece for the convenience of welding by the welding robot.
In a conventional automatic working system, the welding robot and positioners are controlled by a single controller, as disclosed in U.S. Pat. No. 4,042,161, and its control scheme is to operate a plurality of machine units simultaneously or one at a time in turn.
The above-mentioned prior art does not intend to control separately machine units which constitute an automatic working system, and cannot direct machine units to operate individually.
SUMMARY OF THE INVENTION
An object of this invention is to provide an efficient automatic working system capable of operating a plurality of machine units to work in concert or to work independently or individually.
The above objective is achieved by the automatic working system including a plurality of machine units each implementing a specific role of a working plan, the system comprising individual operation control units each of which directs a machine unit to perform an individual operation, at least one concerted operation control unit which directs a plurality of machine units to perform a concerted operation, and an operation program interpretation unit which interprets an operation program and supplies the individual operation control units and the concerted operation control unit with individual operation instructions and a concerted operation instruction, and control means which controls machine units instructed to carry out the concerted operation to work under the concerted operation control unit and controls machine units left aside from the concerted operation to operate under the individual operation control units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1, 2 and 3 are block diagrams of the robot control system embodying the present invention;
FIG. 4 is a timing chart showing the execution of robot working according to an embodiment of the invention;
FIG. 5 is a timing chart showing the execution of the same robot working as of FIG. 4 implemented by the conventional system;
FIG. 6 is a diagram showing an example of operation program according to this invention;
FIGS. 7, 8, 11, 13 and 14 are flowcharts used to explain the operation of the inventive system;
FIGS. 9, 10 and 12 are diagrams showing the structure of the operation program; and
FIG. 15 is a diagram showing an example of the hardware structure according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before entering into the description of the embodiment, the invention will be stated in general terms for better understanding.
As mentioned previously, the inventive automatic working system includes a plurality of machine units each implementing an, individual role in a working plan. The system is characterized by individual operation control units each of which directs a machine unit to perform an individual operation, at least one concerted operation control unit which directs a plurality of machine units to perform a concerted operation and an operation program interpretation unit which interprets an operation program and supplies the individual operation control unit and the concerted operation control unit with individual operation instructions and a concerted operation instruction. Control means are provided to control machine units designated for a concerted operation that work under the concerted operation control unit an to control machine units left aside or released from the concerted operation that operate under the individual operation control units.
The machine units include, for example, a main working unit and auxiliary units of n in number assisting the main working unit. The operation program includes operational commands for the main working unit, operational commands for the auxiliary units that operate in concert with the main working unit, and operational commands for the auxiliary units that operate individually. The main working unit is, for example, an industrial robot and the auxiliary units are positioners which hold workpieces at appropriate positions for treatment by the robot.
More specifically, the control means is arranged to include the following sections.
(1) Operation program interpreting means which generates operational commands for: an independent operation of the main working unit, a concerted operation with auxiliary units, and individual operational commands of auxiliary units by interpreting the operation program. The commands are issued to the respective operation control units.
(2) Robot-arm/concerted-operation control means which receives main working unit operational commands from the operation program interpreting means and prepares and issues positioning servo commands for control axes of the main working unit so that the main working unit moves to the target position along the specified route and, in the case of a concerted operation with auxiliary working units, prepares and issues axis positioning servo commands so that these axes have a concerted operation with the main working unit.
(3) Additional axis individual operation control means which receives operational commands for an auxiliary unit operating independently or individually of the main working unit, and prepares and issues positioning servo commands so that the control axes of the auxiliary unit operate at specified speeds.
(4) Positioning servo control means which produces servo commands from the positioning servo commands and current position feedback values for all control axes of the main working unit and auxiliary units.
(5) Positioning supervisory means which supervises the positioning of the control axes of the main working unit and auxiliary units.
In the automatic operation by an operation program, the operation program interpretation unit interprets the prepared operation program to produce operational commands for the main working unit, i.e., commands for the robot-arm independent operation or concerted operation with auxiliary units, and delivers the commands to the robot-arm operation controller. Unless the wait for the end of robot arm operation is specified, the operation program interpretation unit proceeds to interpreting the successive operation program and produces individual operation commands for another auxiliary unit, for example, and delivers the commands to the additional axis individual operation controller.
The arm operation controller produces positioning servo commands of control axes in accordance with the received arm operation command so that the robot arm and a specified group of additional axes operate in concert, delivers the commands to the respective positioning servo controllers, initiates the positioning supervisory units for the main unit arm and auxiliary units at the issuance of target position servo commands, and upon completion of both operations indicates the end of operation to the operation program interpretation unit. Similarly, the additional-axis operation controllers produce positioning servo commands for the controlled axis group in accordance with the received auxiliary unit operation command, delivers the commands to the positioning servo controllers, initiates the positioning supervisory units associated with the auxiliary units at the issuance of target position servo commands, and upon completion of operation indicates the end of operation to the operation program interpretation unit.
The operation program interpretation unit waits for the end of each operation when the wait for the end of preceding operation is needed or when it is specified in the operation program, so as to carry out the operations of the main working unit and auxiliary units in concert with the execution of the operation program.
The foregoing control means and control scheme enables remaining auxiliary units to implement a post process for the previous working or a preprocess for the next working during a concerted operation of the main working unit and auxiliary units.
Next, an embodiment of this invention will be described with reference to the drawings. FIGS. 1, 2 and 3 are block diagrams each showing the arrangement of the robot control system and information exchanged among functional blocks in the system according to an embodiment of this invention. The control object in this embodiment is a 6-axis multi-joint robot 1 as main working unit and two peripheral units (auxiliary units) 2g and 2h each having two control axes as the additional axes.
The robot control system consists of an additional-axis group information setting unit 4 which sets additional-axis group information 3 used for the additional axes, an operation program instruction or teaching unit 5 which produces an operation program 6 from the operational sequence and positional data of the robot 1 and peripheral units 2g-2h by being manipulated by the operator, an operation program interpretation unit 7 which interprets the operation program 6 to produce and issue a robot-arm-operation/concerted-operation command 12 and specified additional-axis group operation command 13 to the respective operation control units, and receive respective operation end signals 16a and 16b, a robot-arm-operation/concerted-operation controller (concerted operation control unit) 8 which receives a robot-arm-operation/concerted-operation command 12 to issue positioning servo commands 14a for the robot axes so that the robot arm moves to the target position along the specified path and, in the case where a simultaneous or concerted operation of an additional-axis group is specified, produces and issues positioning servo commands 14b for the additional axes so that they operate in concert or simultaneously with the robot arm, a group of additional-axis operation controllers (individual operation control unit) 9 which receive the specified additional-axis group operation commands 13 to issue positioning servo commands 14c for the axes of specified axis group so that they operate at specified speeds, a group of positioning servo controllers 10a-10c which produce servo commands 17a-17c for the robot arm and additional axes from the positioning servo commands 14a-14c and current position feedback values 18a-18c, and positioning supervisory units lla-llc which supervise the positioning of the robot arm axes and all axes of the axis group prescribed by the additional-axis group information 3, and issue positioning end signals 15a-15c to the positioning servo command sources. Instead of being provided separately, the robot-arm-operation/concerted-operation controller 8 and the additional-axis operation controllers 9 may be formed in one controller as shown in FIG. 15 to be described later.
Next, the operation of this embodiment will be explained using the drawings. As mentioned previously, the automatic operation by the operation program 6 takes place in such a way that the operation program interpretation unit 7 interprets and executes the operation program 6 sequentially or in the specified order. FIGS. 1 and 2 show the flow of information and signals when a simultaneous operation of the robot and a peripheral unit having one additional-axis group is specified in the operation program. FIG. 1 is the case of a concerted or simultaneous operation of the robot 1 and auxiliary unit 2g, and FIG. 2 is the case of a concerted or simultaneous operation of the robot 1 and auxiliary unit 2h.
The operation program interpretation unit 7 produces a concerted operation command 12 for the robot arm and an additional axis group of a specified auxiliary unit, and sends the command to the robot-arm-operation/concerted-operation controller 8. The robot-arm-operation/concerted-operation controller 8 responds to the command, produces positioning servo commands 14a and 14b (or 14c) for the robot arm and the specified additional axis group at a constant time interval so that the robot arm moves at the specified speed along the specified path and the axes of specified additional-axis group operate in concert or simultaneously with the robot arm, and sends the commands to the positioning servo controllers 10a and 10b (or 10c) of each axis.
After these positioning servo commands for the respective target positions have been issued, the positioning supervisory units lla and llb (or llc) of the robot and specified additional axis group are activated, and upon arrival of the positioning end signals 15a and 15b (15c), the operation end signals 16a and 16b (16c) are indicated to the operation program interpretation unit 7. If the wait for the end of operations of the robot and additional axis group is specified at the issuance of the above operational command 12, the operation program interpretation unit 7 waits for the entry of the operation end signals 16a and 16b (or 16c). If, on the other hand, the wait is not specified, the operation program interpretation unit 7 continues to interpret the operation program and, upon detection of an independent or individual operation of an additional-axis group of an inactive peripheral unit for example, produces an individual operation command 13 for the additional axis group and sends the command to the additional-axis operation controller 9. Also in this case, if the wait for operation end is not specified, the unit 7 proceeds to the interpretation and execution of the operation program.
The additional axis operation controller 9 produces the positioning servo command 14b and/or 14c for each axis at a constant interval so that the axes of specified additional axis group operate at specified speeds, sends the command to the positioning servo controller 10b and/or 10c for the corresponding axis, and, after issuance of the target positioning servo command, activates the positioning supervisory unit llb and/or llc of the relevant additional axis group and, upon arrival of the positioning end signal 15b and/or 15c, indicates the operation end signal 16b and/or 16c to the operation program interpretation unit 7. The operation program interpretation unit 7 waits for the end of operation for the issued operation command when waiting for the operation end is specified in the operation program or when waiting for the operation end has become necessary due to the process, continuation, thereby synchronizing the operation of the controlled object with the execution of the operation program. The simultaneous operation or independent operation of the robot arm and additional axis groups is specified by the operation program, and the flow of information is switched in accordance with the specification. FIG. 1 shows the information flow of the case where the robot and a peripheral unit 2g located on its left side operate in concert or simultaneously and a peripheral unit 2h on the right side operates independently. FIG. 2 shows another case where the robot and the peripheral unit 2h operate in concert or simultaneously, and the peripheral unit 2g operates independently. It is not always necessary for any additional-axis group to operate in concert or simultaneously with the robot, but there are cases where the robot and additional-axis groups operate all independently, as shown in FIG. 3.
This embodiment enables an operation pattern as shown by the timing chart of FIG. 4, in which the robot and one peripheral unit operate in unison for arc welding, for example, while another peripheral unit operates independently for a post treatment for the previous working operation or a pre-treatment for the next working operation, whereby the working time can be reduced as compared with the conventional system shown in FIG. 5. In the conventional system, positional data for the robot and all additional axes at each operating position shown in FIG. 5 are held integrally, whereas in this embodiment positional data of each operating position are held for the robot and each additional axis group and an operation is instructed by combining these data at the simultaneous or concerted operation, whereby the same operation program can be produced with less amount of position instruction data as compared with the conventional system. In FIGS. 4 and 5, the solid line of the graph indicates that the main working unit 1 or an auxiliary unit is moving, and the dashed line indicates that the units are stationary.
FIG. 6 shows the structure of an operation program based on this embodiment. The operation program 6 consists of a program code section 20 which indicates the working procedure in a string of virtual robot control commands, a robot position data section 21 which is a string of robot arm attitude data, additional axis group position data sections 22-23 which are strings of position data for the additional axis groups, and a management data section 19 which stores the size of these data sections and other various management information. The above-mentioned virtual robot control instruction consists of an OP code which represents the type of instruction, and a group of information (operands) necessary for the execution of that instruction, and instructions include robot independent operation instructions, additional-axis independent operation instructions, robot and additional axis simultaneous operation instructions, etc.
An operation program is entered, e.g., in the case of program code, using a user-familiar robot language through the console of robot control system, and after it is converted into the above-mentioned control commands it is stored. The console is a part of the operation program instruction or teaching unit 5. Position data for the robot and additional axis groups are produced through the teaching operation in which the operator moves the axes manually, by utilizing a teaching box, to the intended positions so that the current positional data of the axes are stored in the position data areas specified in the operation program. The teaching box is a part of the operation program instruction or teaching unit 5.
FIG. 7 is a flowchart showing the main process implemented by the operation program interpretation unit.
FIG. 8 is a flowchart showing the execution of a robot independent or individual operation command and robot and additional axis simultaneous or concerted operation command by the operation program interpretation unit. In the case of a robot independent or individual operation command, the robot independent or individual operation instruction (corresponding to the robot-arm-operation/concerted-operation command 12 in FIG. 3) shown in FIG. 9 is issued, and in the case of a robot and additional axis simultaneous or concerted operation command, the robot and additional axis concerted operation instruction (corresponding to the robot-arm-operation/concerted-operation command 12 shown in FIGS. 1 and 2) shown in FIG. 10 is issued to the robot-arm-operation/concerted-operation controller.
FIG. 11 is a flowchart showing the execution of an additional axis independent operation command by the operation program interpretation unit, and in this case the additional-axis independent operation instruction 13 shown in FIG. 12 is issued to the additional axis operation controller.
FIG. 13 is a flowchart showing in brief the operation of the robot arm operation controller.
FIG. 14 is a flowchart showing in brief the operation of the additional axis operation controller.
FIG. 15 shows an example of the hardware arrangement based on another emboidment. In this embodiment, the robot control system consists of a main controller MCP 27 which implements the major control for the system, an input/output controller IOP 28 which implements various input and output controls, a servo controller SVP 29 which implements the positioning servo processes for the robot arm axes, servo controllers SVP 29' for the additional axis groups, a system bus 30 which connects the input/output controller 28 and various input/output devices to the main controller 27 and a common RAM 32 which stores data shared among these components, a system bus 31 which connects the servo controllers 29 to the main controller 27 and a common RAM 33 which stores data shared by these components, and servo amplifiers 35 for the respective axes. The servo amplifiers 35 are connected with servo motors M 36 and pulse encoders PE 37 located on the part of the robot main body and peripheral units. Each controller consists of a microprocessor MPU, a ROM/RAM module for storing the control program and data, a bus interface BIF for interfacing with the system bus, and a servo interface SVIF for interfacing with the servo circuit. (The SVIF is necessary only for the servo controllers).
Among the functional blocks shown in FIG. 1, the additional-axis group information setting unit 4, operation program instruction or teaching unit 5, operation program interpretation unit 7, robot-arm-operation/concerted-operation controller 8 and all additional-axis operation controllers 9 are located in the main controller 27, while the positioning servo controllers 10 and positioning supervisory unit 11 for the robot arm axes are located in the servo controller SVP 29 for robot axes and the positioning servo controllers 10 and positioning supervisory units 11 for all additional-axis groups are located in the servo controllers SVP 29' for additional axes. The additional axis group information in FIG. 1 which has been set is stored in an auxiliary memory 34, and it is loaded into the common RAMs 32 and 33 by the main controller at successive power-on events. The operation program 6, after it has been produced, is stored in the auxiliary memory 34, and it is loaded into the common RAM 32 and executed through interpretation when the automatic operation is initiated.
According to this invention, additional axes are grouped in accordance with controlled peripheral units, and concerted or simultaneous operations with the robot or independent operations can be specified for each additional axis group, whereby one peripheral unit is operated in concert or simultaneously with the robot for working and the remaining peripheral units are operated independently to perform other work concurrently, thereby reducing the working time. In addition, position instruction data can be controlled for each axis group, which prevents the system from holding position data for axes unrelated to the working, and the quantity of position instruction data can be reduced. | A control system including a plurality of machine units each implementing a role for a specific working, the system comprising independent operation control units which direct the machine units to perform independent operations, at least one concerted operation control unit which directs machine units to perform concerted-operations and control means which operates on machine units designated to perform a concerted operation to work under control of the concerted operation control unit and operates on said machine unit left aside from the concerted operation to work under control of the independent operation control units. The arrangement enables a plurality of machine units to have a concerted operation or quit a concerted operation, allowing a machine unit which is put aside from said concerted operation to implement independent operation, whereby a high-efficiency control system is realized. | 6 |
BACKGROUND OF THE INVENTION
In one aspect, the invention relates to the processing of a hydrogen sulfide stream to facilitate its disposal. In another aspect the invention relates to controlling sulfur emissions from a synthetic fuels plant.
The liberation of hydrocarbon values from many sources also produces undesired gaseous sulfur compounds. Hydrogen sulfide, sulfur dioxide, and volatile sulfates are obnoxious materials and environmentally damaging. The environmentally acceptable disposal of sulfur-containing compounds is facilitated where they are in solid form. Thus, it is in many instances advantageous to convert gaseous sulfur compounds to solid ones where their disposal is desired. New techniques for accomplishing conversion of gaseous sulfur compounds would clearly be very desirable.
OBJECTS OF THE INVENTION
It is an object of this invention to convert hydrogen sulfide to a solid substance via a simple, two-step process.
It is another object of this invention to provide a mineral upgrading process in which gaseous sulfur emissions are controlled.
It is a further object of this invention to provide a solid mineral upgrading process for producing fuel values in gaseous and liquid form and sulfur byproduct in solid form.
STATEMENT OF THE INVENTION
In one aspect of the invention a normally solid mineral material is pyrolyzed to produce gaseous and/or liquid fuel values. Hydrogen sulfide byproduct is produced along with the fuel values. A solid, spent mineral product is also produced which is reactable with gaseous oxides of sulfur to form sulfur-containing solids. In accordance with the invention, the hydrogen sulfide is separated from the liquid and/or gaseous fuel values and combusted with an oxygen-containing gas to form gaseous oxides of sulfur. The thus produced gaseous oxides of sulfur are then reacted with the solid, spent mineral product to form sulfur-containing solids which are relatively easy to dispose of in an environmentally sound manner.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE illustrates schematically certain features of one embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the one embodiment of the invention, an apparatus comprises a means 2 for providing liquid and/or gaseous fuel values from a normally solid mineral such as lignite, coal or oil shale. For lignite gasification, the fuel value stream is predominantly CO and H 2 . For other pyrolysis processes, the fuel values may be predominantly hydrocarbon, depending on the process. A separation zone 4 is provided for separating an undesired hydrogen sulfide stream from the fuel value stream. A zone 6 is provided for combusting the hydrogen sulfide stream with an oxygen-containing gas.
A conduit means 10 connects the pyrolysis means 2 with the separation zone 4. A conduit means 12 connects the separation zone 4 with the combustion zone 6. A line 14 carrying an oxygen-containing gas empties into zone 6. An optional steam line 16 is shown to empty into zone 6 in the illustrated embodiment. It should be appreciated that the combustor 6 could be positioned in the pyrolyzer 2 if desired, such as below a grate 11 in a lower portion thereof.
The means 2 will usually be determined by a vessel 8 which preferably contains a moving bed of the solid mineral particles. Preferably, the unit is of the vertical downflow type and uses countercurrent upward flow of gas, although the invention could be applied to a bed traveling on a circular grate through the treating zones as well, or to batch operations in which a plurality of vessels are operated under sequenced processing with cross-flow of gases between the vessels. For lignite liquefaction or gasification, the unit 8 can suitably be of the Lurgi type. For oil shale liquefaction or gasification, the unit 8 can be of the Hytort or Paraho type. Preferably, the particulate moves first through a preheat/pyrolysis zone 18 in which it is heated to a pyrolysis temperature in the range of from about 800° to about 1200° F.; then into a combustion zone 20, where combustion of residual carbonaceous material with oxygen containing gas occurs and then into a cooling zone 22 where the particulate is cooled by flow of relatively cool gas. The combustion zone 20 may achieve a temperature of up to 2000° F. The particulate in the cooling zone 22 is preferably cooled to a temperature of between 100° and 300° F. prior to discharge.
The stream 13 containing the gaseous oxides of sulfur formed in the combustor 6 is perferably diluted with sufficient oxygen-containing gas so as to be at a temperature of only in the range of from about 100° to about 300° F. to adequately cool the particulate to be discharged. As these gases flow upwardly in the illustrated embodiment through the cooling section 22 they encounter increasingly hot descending particulate from the combustion zone 20 until a capture of the sulfur oxide species by alkaline or alkaline earth ash components from the zone 20 occurs.
The vessel 8 preferably has an inlet 24 adjacent to its upper end for introducing the normally solid mineral to be pyrolyzed and an outlet 26 ajacent to its lower end for withdrawing spent mineral product and sulfur-containing solid. An outlet 28 near the upper end of the vessel 8 provides for the withdrawal of the liquid and/or gaseous fuel values containing hydrogen sulfide byproduct. At least one inlet 30 near the lower end of the vessel 8 provides for the introduction of the gaseous oxides of sulfur from the combustor 6 as well as the oxygen containing gas supply for the zone 20.
The separation zone 4 will normally contain one or more fractionators, with a normally gaseous fractionator product containing acid gases being passed to an acid gas treater such as an alkanolamine absorber. The stream 12 will usually be withdrawn from the acid gas stripper following the amine absorber. The stream 12 thus may also contain substantial quantities of CO 2 and H 2 O as well as H 2 S. The product stream containing the desirable fuel values in gaseous and/or liquid form may be withdrawn from the zone 4 via the line 32.
The combustion process occurring in the zone 6 will be facilitated where the combustion of the hydrogen sulfide occurs under near stoichiometric conditions. The additional oxygen requirements for the combustion zone 20 can be metered in downstream of the H 2 S combustion so that a high enough temperature can be maintained to support the combustion process occurring in the zone 6. If desired, oxygen-containing gas can be introduced into the vessel 8 separately from the line 13.
The sulfur oxides produced in the zone 6 are reactive with oxides of alkaline and/or alkaline earth metals. Because the reaction product between sulfur oxides and oxides of alkaline earth metals are highly insoluble it is preferred that alkaline earth metal oxides be present in the cooling zone 22. Good results are expected where in the range of from about 0.5 up to about 5 percent by weight of alkaline earth metal oxides, calculated as the metal, are present in zone 22, preferably in a finely dispersed form. Where alkaline earth metal oxides, or precursors of alkaline earth metal oxides, such as dolomite, limestone, calcium hydride, etc., which are convertible to alkaline earth metal oxides in the combustion zone 20 are present in the feed to the pyrolyzer 2, the sulfur oxides from the combustor 6 will react in the pyrolyzer 8 in a satisfactory manner. Where alkaline earth metal oxides or their precursors are not a natural component of the solid mineral to be pyrolyzed, or are not present in sufficient amounts, as may be the case with low-ash coals, they can be incorporated into the mineral feed as an additive to promote reaction between solid spent mineral product and the gaseous oxides of sulfur. For example, lime (CaO) or limestone can be added to the feed to the pyrolyzer 2 to promote the formation of sulfur-containing solids in the cooling zone 22 with spent residual from lignite pyrolysis.
Any gaseous oxides of sulfur which may be emitted from the pyrolyzer 2 can of course also be recycled to near the particulate discharge end of the pyrolyzer after having first been separated from the fuel values. Preferably, the recycled SO x emissions from the unit are cooled to within the range of 100°-300° F. such as by dilution with cool oxygen-containing gas prior to introduction into the cooling zone 22. | Hydrogen sulfide recovered from pyrolysis zone effluent is separated and burned to produce sulfur oxides which are reacted with solid spent mineral byproduct. | 2 |
[0001] The present invention relates to a medical dispenser which may be able to determine when a user gains access to medical doses held thereby and which may be able to inform the user of when to take one or more medical doses or how the user conforms to a medication schedule. In addition, the invention relates to a blister card for use in the dispenser, the blister card providing a novel feature in that it may inform the dispenser of certain functionalities and situations, and the user may inform the dispenser of certain selections via the blister card.
[0002] Intelligent dispensers are heavily researched these days in that they may unload the public service functions (doctors, hospitals, other caretakers) as well as prevent or reduce wrongful medication.
[0003] Such dispensers may be seen in WO00/25720, FR2 787 317, WO98/42591, U.S. Pat. No. 4,660,991, and WO02/24141.
[0004] Most of these intelligent dispensers aim to overtake the full responsibility for the providing of the medication and are aimed at weak patients that tend to forget their medication or take wrong doses at the wrong times.
[0005] The present invention aims at stronger patients that only need to be reminded to take the medication or who need to be reminded of how closely they follow a given medication schedule.
[0006] In a first aspect, the invention relates to a medical dispenser being adapted to hold a number of medical doses and being adapted to determine when a user or patient gains access to one or more of the medical doses, the dispenser comprising:
means for determining each of a first plurality of points in time or time intervals at which the user or patient should take a medical dose, means for detecting each of a second plurality of points in time where the user or patient gained access to the medical doses, and means for providing to the user or patient information relating to a relation between the first and second pluralities.
[0010] In the present context, the dispenser holds the medical doses but does not necessarily dispense only a single dose to the user or patient. The access of the user may be to all doses in the dispenser, whereby the user will then dispense the dose(s) required himself.
[0011] In the present context, “gains access to” means that the dispenser is able to determine when the user has the ability to take a dose of medication. This does not necessarily mean that the user actually takes the medication. This rather simple dispenser needs not have means for preventing the user from gaining access to the medication, but it will detect that access.
[0012] Normally, when determining a medication schedule for a user or patient, the medication should preferably be given with fixed time intervals in order to control the concentration of the medicine in the users body. Thus, in order to obtain that, preferred times or time intervals (usually starting at or shortly before the preferred time of intake of the medication) are normally set for the actual medication and the person in question.
[0013] In the present context, the user should preferably (taking into account the optimal function of the medication) take the medicine at the points in time or within the time intervals. However, as is described above, the present dispenser needs not ascertain that the user in fact does take the medication.
[0014] Knowing when the medication should have been taken and when the medication was (presumably) taken, a relation between those periods of time may be made in order to have a measure of how well the user conforms to the medication schedule.
[0015] Preferably, the first and second pluralities are taken within a predetermined period of time or within a predetermined number of accesses to the medication or a predetermined number of times/intervals in the first plurality. The period of time or number of accesses/times/intervals may be varied from user to user and medication to mediation. For some medications, providing a relation over the intake of medication over a month may be desired, whereas a relation extending over only a few days may be suitable for other medications.
[0016] Preferably, the providing means are adapted to provide a relation between pairs of one of the first plurality of points in time or time intervals and one of the second plurality of points in time. A suitable manner of providing the relation is to compare pairs of an optimal time of intake and the actual (presumed) intake. In that situation, the compliance may be determined or quantified simply by the time difference between recommended intake and access to the medication.
[0017] Also, preferably, the providing means are adapted to provide a relation between the pairs of one of the first plurality of points in time or time intervals and a first of the second plurality of points in time occurring after the pertaining point in time of the first plurality or within the pertaining time interval of the first plurality. In this manner, if the user gains access to the medication (such as by accident) multiple times per point in time or time interval, only the first time the user gains access to the medication is used in the relation. Any remaining times of access are discarded. In this aspect, the dispenser may have means for warning the user, if he has already gained access to the medication once during this interval or after the last point in time for recommended intake or the dispenser may inform the user that dose intake is allowed and that the dose access is registered as a dose intake.
[0018] As mentioned, one manner of determining the relation is to have the relation relate to a time difference between the pairs of the point in time or a starting time of the time interval of the first plurality and the point in time of the second interval.
[0019] Another manner of quantifying compliance is one where the providing means are adapted to provide a relation between a number of times wherein a point in time of the second number occurs within a time interval of the first plurality, and a number of times wherein a point in time of the second number does not occur within a time interval of the first plurality. Thus, the number of times where the user actually gains access to the medication when he should are registered together with the number of times where he did not.
[0020] A number of manners exist of informing the user of the compliance. According to a first manner, the providing means are adapted to provide, as the information, one of a plurality of predetermined colours to the user, the colour being determined on the basis of the relation. Suitable colours may be red, yellow and green.
[0021] According to another manner, the providing means are adapted to provide, as the information, one of a plurality of predetermined numbers to the user, the number being determined on the basis of the relation. Suitably, the higher the number the higher the compliance.
[0022] A third manner is one wherein the providing means are adapted to activate, as the information, one or more of a plurality of predetermined areas of a display, such as a LCD display, visible to the user, the area(s) activated being determined on the basis of the relation. Such a display may illustrate a bar or pie diagram.
[0023] A fourth manner is one wherein the providing means are adapted to provide, as the information, one of a plurality of predetermined sound signals to the user, the sound signal being determined on the basis of the relation. This sound may vary from pleasant (high compliance) to unpleasant (low compliance).
[0024] Yet another manner is one wherein the providing means are adapted to provide, as the information, one of a plurality of predetermined graphical images to the user, the image being determined on the basis of the relation. Suitable images may be happy/neutral/sad face or thumb up/down.
[0025] The dispenser preferably further comprises, as described above, means for informing the user, if a point in time of the second plurality occurs outside a time interval of the first plurality in order to e.g. warn the user if he gains access to the medication outside an interval.
[0026] A second aspect of the invention relates to a medical dispenser being adapted to hold a number of medical doses and to inform a user or patient of when to take a dose, the dispenser comprising:
means for informing the user in one of a plurality of different manners, means for determining a compliance of the users taking of medical doses, and means for selecting a manner of informing based on the determined compliance.
[0030] Thus, the dispenser may be able to inform the user differently depending on the users compliance.
[0031] Again, “when” to take a dose would normally be in accordance with a medication schedule determined either for the actual medication or set in the dispenser.
[0032] A number of different manners of informing a user are known. However, the most preferred manners are ones where the informing means are adapted to inform the user using one of sound, visual information, and/or vibration.
[0033] In that situation, the determining means may be adapted to determine a compliance selected between a predetermined number of compliances, and wherein the selecting means are adapted to select visual information based on a first compliance of the predetermined number of compliances, vibration based on a second compliance of the predetermined number of compliances, and sound based on a third compliance of the predetermined number of compliances.
[0034] Normally, especially when in a public place, visual information is the most pleasant and private information, where sound information (especially if loud) is the most unpleasant information. Thus, the dispenser may use this information manner in order to ensure that the user both takes his medication and is informed (such as by the severity of the information manner) of his compliance. This may bring the user to a better compliance in order to avoid that particular manner of informing.
[0035] Preferably, the informing means are adapted to provide the sound, visual information, or vibration with different intensities and/or frequencies.
[0036] In that manner, the determining means are preferably adapted to determine a compliance selected between a predetermined number of compliances, and wherein the selecting means are adapted to select an intensity and/or frequency based on the determined compliance. Again, the lower the compliance, the hither the frequency or intensity may be in order to ensure that the user “gets the message”. The predetermined number of compliances may be the numbers of an interval (e.g. integers in the interval 0-10), a number being selected or calculated relating to the compliance.
[0037] As mentioned above, preferably, the dispenser is adapted to hold a number of medical doses and being adapted to determine when a user or patient gains access to one or more of the medical doses, the dispenser comprising:
first means for determining each of a first plurality of points in time or time intervals at which the user or patient should take a medical dose, and means for detecting each of a second plurality of points in time where the user or patient gained access to the medical doses,
wherein the compliance determining means determine the compliance as a relation between the first and second pluralities.
[0040] As mentioned above:
the compliance determining means are preferably adapted to provide a relation between pairs of one of the first plurality of points in time or time intervals and one of the second plurality of points in time and/or the compliance determining means are preferably adapted to provide a relation between the pairs of one of the first plurality of points in time or time intervals and a first of the second plurality of points in time occurring after the pertaining point in time of the first plurality or within the pertaining time interval of the first plurality
where the relation preferably then relates to a time difference between the pairs of the point in time or a starting time of the time interval of the first plurality and the point in time of the second interval.
[0043] Also, the compliance determining means are preferably adapted to provide a relation between a number of times wherein a point in time of the second number occurs within a time interval of the first plurality, and a number of times wherein a point in time of the second number does not occur within a time interval of the first plurality.
[0044] Again, the compliance determining means are preferably adapted to provide, as the information, one of a plurality of predetermined colours to the user, the colour being determined on the basis of the relation.
[0045] In addition, the compliance determining means may be adapted to provide, as the information:
one of a plurality of predetermined numbers to the user, the number being determined on the basis of the relation, one or more of a plurality of predetermined areas of a display visible to the user, the area(s) activated being determined on the basis of the relation, one of a plurality of predetermined sound signals to the user, the sound signal being determined on the basis of the relation, and/or one of a plurality of predetermined graphical images to the user, the image being determined on the basis of the relation,
[0050] Also, means may be provided for informing the user, if a point in time of the second plurality occurs outside a time interval of the first plurality.
[0051] A third aspect of the invention relates to a medical dispenser being adapted to hold a number of medical doses, to inform a user or patient of when to take a dose, and to determine when the user or patient accesses a medical dose, the dispenser comprising:
means for informing the user in one of a plurality of different manners, means for, a number of times, operating the informing means in order to inform the user with different manners of informing, means for, during operation of the operating means, determining which manner(s) of informing brings the user or patient to access a medical dose, means for, subsequently to the operation of the operating means, selecting a manner of informing based on the determination.
[0056] Thus, the dispenser is adapted to select a manner of informing based on knowledge of which manner(s) brings the user or patient to actually access the medication.
[0057] Normally, the informing means would be adapted to inform the user using at least one of sound, visual information, or vibration. Preferably, the informing means are adapted to provide the sound, visual information, and/or vibration with different intensities and/or frequencies.
[0058] In a preferred embodiment, the determining means are adapted to determine that a manner of informing brings the user or operator to access a medical dose, when the user or operator accesses the dose while or within a predetermined period of time after the actual manner of operating is used. The predetermined period of time after the actual manner was used provides time for the user to react to the manner.
[0059] In order for the dispenser to determine which manner is e.g. the most efficient and in order to have the user take the medication, the operating means are preferably adapted to subsequently (one after the other) use different manners of information until the user gains access to a medical dose.
[0060] Not always will the user respond to the same manner of informing. This may be due to a number of reasons. Therefore, preferably, the selecting means are adapted to select a manner, which the most often brings the user or operator to gain access to the medical dose. This may be obtained when the operating means are adapted to be operated a plurality of times, the determining means being adapted to determine, for each of the plurality of times, which manner brings the user of operator to access the medical dose, and wherein the selecting means are adapted to select the manner having brought the user or operator the most often to access the medical dose.
[0061] A number of different dispenser types may advantageously use this technology, such as:
a dispenser being adapted to hold one or more blister cards holding the number of medical doses, and being adapted to detect that the user or patient has accessed a medical dose when the blister card is removed from the dispenser, a dispenser being adapted to provide one or more medical doses to the user or patient by inhalation, the dispenser having an air passage connected to a medical output and means for covering or closing the output or air passage when not in use, and being adapted to detect that the user or patient has accessed a medical dose when the covering means is removed from the dispenser, and/or a dispenser being adapted to provide one or more medical doses to the user or patient by injection by an injection needle, the dispenser having means for covering the injection needle when not in use, and being adapted to detect that the user or patient has accessed a medical dose when the covering means is removed from the dispenser.
[0065] It is interesting to note that the detecting means, informing means, etc. may, in fact, be positioned in the cover means in the injector/inhaler, so that standard injectors (such as an injector pen) or inhalers may be used and still gain the present functionality.
[0066] A fourth aspect of the invention relates to a medical dispenser being adapted to removably hold one or more blister cards for each holding a number of medical doses, and to inform a user or patient in relation to the taking of one or more medical doses, wherein:
the blister card comprises an indentation, a hole, or a protrusion at each of one or more of a plurality of predetermined positions, the dispenser having means for detecting an indentation, a hole, or a protrusion at each of the predetermined positions, and means for operating the informing means on the basis of an output from the detecting means.
[0070] Normally, a blister card is a square card without any indentations, holes or protrusions (apart from the blisters). The card may have rounded corners but will otherwise normally have straight sides.
[0071] Thus, the mechanical features (such as indentations, holes, protrusions) of the blister card are able to actually determine the operation of the dispenser. In this manner, the same dispenser may be used for different medications in that the medication when inserted will have the dispenser function correctly. Also, different manufacturers may “code” their blister cards differently in order to obtain different manners of operation of the dispenser.
[0072] In the context of the present invention, it should be noted that a blister card is a card holding a number of medical doses on or in a sheet-shaped (with blisters) member. Any form of sheet-shaped member may be used, and it is not required that the medication actually is present in blisters. The sheet-shaped member has advantages used in a number of the present embodiments in that it may be slid into and out of the dispenser and that it may have the mechanical features detected by detecting means in a number of the present embodiments.
[0073] Preferably, the detecting means has, at each of the predetermined positions, displaceable detecting means being displaced by a protrusion at the position of the blister card, or indentation or hole exists at the position. Such detecting means may operate on any of a wide variety of detecting schemes (mechanical, magnetic, optical detection, etc.)
[0074] The dispenser may be adapted to identify, from the positions of the blister card where indentations, holes, or protrusions are detected, one or more of:
a manufacturer of the medical doses, a type of medication in the medical doses, a frequency of recommended intake of the medical doses, recommended points in time of intake of the medical doses, a dose strength of one or more of the medical doses, and a manner of informing the user or operator (such as for reminder or compliance readout).
[0081] In a preferred embodiment, the dispenser further comprises means for determining a compliance of the user's or operator's intake of the medical doses based on:
a predetermined medication schedule identified by indentations, holes, or protrusions or the lack of indentations, holes, or protrusions at predetermined positions of the blister card and information relating to points in time when the user or operator gains access to at least one of the doses of medication.
[0084] The identified medication schedule may be fully coded in the positions of the indentations etc, or may be stored in the dispenser and identified by e.g. a code or address coded in the positions of the indentations etc.
[0085] Preferably, the dispenser also comprises means for informing the user or operator to take a dose of the medication and means for determining when it is time to inform the user on the basis of:
a predetermined medication schedule identified by indentations, holes, or protrusions or the lack of indentations, holes, or protrusions at predetermined positions of the blister card and a clocking device.
[0088] An interesting aspect is one where the dispenser being adapted to receive, from the user, information relating to:
how to calculate compliance, and/or how to inform the user of compliance.
[0091] Thus, the user may himself set e.g. a compliance level which he desires to follow. The dispenser may then adapt its manners and times of informing—and may adapt a specific e.g. limit between levels of compliance (low, sufficient, high) so as to inform the user of his compliance in related to the selected compliance.
[0092] This information may be entered by the blister card(s) being adapted to have indentations, holes, or protrusions made subsequent to manufacture thereof, and wherein the dispenser is adapted to derive the information from the indentations, holes, or protrusions made subsequent to manufacture thereof. Thus, the user himself may provide the indentations etc. and thereby “code” the dispenser accordingly.
[0093] As mentioned above, the dispenser preferably comprises means for detecting or determining when the user or operator gains access to at least one of the medical doses.
[0094] Also, preferably, the dispenser comprises stationary means for introduction into further indentations at other positions of the blister card, the stationary means preventing a blister card not having the further indentations from engaging with the detecting means. In this manner, only blister cards having those further indentations will not be useable in the dispenser. This will prevent wrongful use of unoriginal blister cards in the dispenser.
[0095] In any of the above embodiments using a blister card, the dispenser may be able to hold the one or more blister card(s) in a manner so that the blister card is curved in a direction at least substantially along a longitudinal direction thereof. This curved state has a number of advantages in that the blister card is then biased against inner surfaces of the dispenser. A curved element (which in its rest position is straight) will obtain a much more stiff state across the direction of the bend. This may be used for a number of purposes, such as to maintain the blister card in the dispenser and to position the indentations etc. more precisely in the dispenser.
[0096] Preferably, the dispenser is adapted to receive the blister card(s), in a slot thereof, in a direction along the longitudinal direction of the blister card(s).
[0097] Preferably, the dispenser has a first surface and is adapted to bias an edge portion of each blister card being received thereby against the first surface. Then, the detecting means are preferably positioned a predetermined distance from the first surface and are able to detect the blister card(s) when positioned between the detecting means and the surface. The bent shape of the blister card will ensure that the positioning of the indentations etc is more precise.
[0098] A fifth aspect of the invention relates to a blister card for use in the dispenser according to the fourth aspect of the invention, the blister card has a number of blisters for each holding a medical dose, the blister card further comprising an indentation or a protrusion at each of one or more of a plurality of predetermined positions.
[0099] Normal blister cards have no protrusions, indentations or holes except for medicine blisters themselves and maybe small mechanical features used for manipulating the blister cards during manufacture or packing.
[0100] Normally the present blister card is manufactured as a normal blister card with a subsequent step of providing the indentations etc. Optionally, protrusions may, in fact, be provided at the positions during providing of the blisters for the medication.
[0101] The blister card may also comprise further protrusions, holes, or indentations at the above-mentioned other positions in order to ensure that un-original blister cards are not used in the dispenser.
[0102] A sixth embodiment of the invention relates to a method of operating a medical dispenser being adapted to hold a number of medical doses and being adapted to determine when a user or patient gains access to one or more of the medical doses, the method comprising:
determining each of a first plurality of points in time or time intervals at which the user or patient should take a medical dose, detecting each of a second plurality of points in time where the user or patient gained access to the medical doses, and providing to the user or patient information relating to a relation between the first and second pluralities.
[0106] As mentioned above, the providing step preferably comprises providing a relation between pairs of one of the first plurality of points in time or time intervals and one of the second plurality of points in time. Then, the providing step could comprise providing a relation between the pairs of one of the first plurality of points in time or time intervals and a first of the second plurality of points in time occurring after the pertaining point in time of the first plurality or within the pertaining time interval of the first plurality.
[0107] In one embodiment, the relation relates to a time difference between the pairs of the point in time or a starting time of the time interval of the first plurality and the point in time of the second interval.
[0108] In another embodiment, the providing step comprises providing a relation between a number of times wherein a point in time of the second number occurs within a time interval of the first plurality, and a number of times wherein a point in time of the second number does not occur within a time interval of the first plurality.
[0109] The providing step may comprise providing, as the information;
one of a plurality of predetermined colours to the user, the colour being determined on the basis of the relation, one of a plurality of predetermined numbers to the user, the number being determined on the basis of the relation, one or more of a plurality of predetermined areas of a display visible to the user, the area(s) activated being determined on the basis of the relation, one of a plurality of predetermined sound signals to the user, the sound signal being determined on the basis of the relation, and/or one of a plurality of predetermined graphical images to the user, the image being determined on the basis of the relation.
[0115] Also, the method may further comprise the step of informing the user, if a point in time of the second plurality occurs outside a time interval of the first plurality.
[0116] A seventh aspect of the invention relates to a method of operating a medical dispenser being adapted to hold a number of medical doses, to inform the user in one of a plurality of different manners, and to inform a user or patient of when to take a dose, the method comprising:
determining a compliance of the user taking of medical doses, and selecting a manner of informing based on the determined compliance.
[0119] Thus, the informing step may comprise informing the user using one of sound, visual information, or vibration. Then, the determining step could comprise determining a compliance selected between a predetermined number of compliances, and the selecting means could be adapted to select visual information based on a first compliance of the predetermined number of compliances, vibration based on a second compliance of the predetermined number of compliances, and sound based on a third compliance of the predetermined number of compliances.
[0120] Also, the informing step could comprise providing the sound, visual information, or vibration with different intensities and/or frequencies. Then, the determining step could comprise determining a compliance selected between a predetermined number of compliances, and the selecting means could be adapted to select an intensity and/or frequency based on the determined compliance.
[0121] Preferably, dispenser is adapted to hold a number of medical doses and is adapted to determine when a user or patient gains access to one or more of the medical doses, the method comprising:
determining each of a first plurality of points in time or time intervals at which the user or patient should take a medical dose, and detecting each of a second plurality of points in time where the user or patient gained access to the medical doses,
wherein the compliance determining step comprises determining the compliance as a relation between the first and second pluralities.
[0124] As mentioned above, the compliance determining step preferably comprises providing a relation between pairs of one of the first plurality of points in time or time intervals and one of the second plurality of points in time. Also, the compliance determining step could comprise providing a relation between the pairs of one of the first plurality of points in time or time intervals and a first of the second plurality of points in time occurring after the pertaining point in time of the first plurality or within the pertaining time interval of the first plurality.
[0125] Then, the relation could relate to a time difference between the pairs of the point in time or a starting time of the time interval of the first plurality and the point in time of the second interval.
[0126] Also, the compliance determining step could comprise providing a relation between a number of times wherein a point in time of the second number occurs within a time interval of the first plurality, and a number of times wherein a point in time of the second number does not occur within a time interval of the first plurality.
[0127] In any case, the compliance determining step preferably comprises providing, as the information:
one of a plurality of predetermined colours to the user, the colour being determined on the basis of the relation, one of a plurality of predetermined numbers to the user, the number being determined on the basis of the relation, one or more of a plurality of predetermined areas of a display visible to the user, the area(s) activated being determined on the basis of the relation, one of a plurality of predetermined sound signals to the user, the sound signal being determined on the basis of the relation, and/or one of a plurality of predetermined graphical images to the user, the image being determined on the basis of the relation.
[0133] The method preferably also comprises the step of informing the user, if a point in time of the second plurality occurs outside a time interval of the first plurality.
[0134] An eighth aspect of the invention relates to a method of operating a medical dispenser being adapted to hold a number of medical doses, to inform a user or patient of when to take a dose, inform the user in one of a plurality of different manners, and to determine when the user or patient accesses a medical dose, the method comprising:
a number of times, operating the informing means in order to inform the user with different manners of informing, during operation of the operating means, determining which manner(s) of informing brings the user or patient to access a medical dose, subsequently to the operation of the operating means, selecting a manner of informing based on the determination.
[0138] Preferably, the informing step comprises informing the user using one of sound, visual information, or vibration. Then, the informing step could comprise providing the sound, visual information, or vibration with different intensities and/or frequencies.
[0139] The determining step preferably comprise determining that a manner of informing brings the user or operator to access a medical dose, when the user or operator accesses the dose while or within a predetermined period of time after the actual manner of operating is used.
[0140] Also, preferably, the operating step comprises subsequently using different manners of information until the user gains access to a medical dose.
[0141] In the preferred embodiment, the selecting step comprises selecting a manner, which the most often brings the user or operator to gain access to the medical dose. Preferably, the operating step is operated a plurality of times, the determining step comprising determining, for each of the plurality of times, which manner brings the user of operator to access the medical dose, and wherein the selecting step comprises selecting the manner having brought the user or operator the most often to access the medical dose.
[0142] In a preferred embodiment of any of the sixth, seventh or eighth aspects, the method comprises the steps of the dispenser holding one or more blister cards holding the number of medical doses, and detecting that the user or patient has accessed a medical dose when the blister card is removed from the dispenser.
[0143] In another embodiment, the dispenser is adapted to provide one or more medical doses to the user or patient by inhalation, and the dispenser has an air passage connected to a medical output and means for covering or closing the output or air passage when not in use, the method comprising the step of detecting that the user or patient has accessed a medical dose when the covering/closing means is removed from the dispenser.
[0144] In a third embodiment, the dispenser is adapted to provide one or more medical doses to the user or patient by injection by an injection needle, and the dispenser has means for covering the injection needle when not in use, the method comprising the step of detecting that the user or patient has accessed a medical dose when the covering means is removed from the dispenser.
[0145] A ninth aspect of the invention relates to a method of operating a dispenser being adapted to removably hold one or more blister cards for each holding a number of medical doses, the blister card comprises an indentation, hole, or a protrusion at each of one or more of a plurality of predetermined positions, and to inform a user or patient in relation to the taking of one or more medical doses, the method comprising:
detecting, using detecting means of the dispenser, at each of the predetermined positions any indentation, hole, or a protrusion at that position, and operating the informing means on the basis of an output from the detecting means.
[0148] Then, the detecting step could comprise, at each of the predetermined positions having a protrusion or if no hole or indentation is present at the position, displacing a displaceable detecting means.
[0149] The method preferably comprises the step of identifying, from the positions of the blister card where indentations, holes, or protrusions are detected, one or more of:
a manufacturer of the medical doses, a type of medication in the medical doses, a frequency of recommended intake of the medical doses, recommended points in time of intake of the medical doses, a dose strength of one or more of the medical doses, and a manner of informing the user or operator.
[0156] Also, the method may comprise the step of determining a compliance of the user's or operator's intake of the medical doses based on:
a predetermined medication schedule identified by indentations, holes, or protrusions or the lack of indentations, holes, or protrusions at predetermined positions of the blister card and information relating to points in time when the user or operator gains access to at least one of the doses of medication.
[0159] Further, the method may comprise the steps of informing the user or operator to take a dose of the medication and of determining when it is time to inform the user on the basis of:
a predetermined medication schedule identified by indentations, holes, or protrusions or the lack of indentations, holes, or protrusions at predetermined positions of the blister card and a clocking device.
[0162] In an interesting embodiment, the method comprises the step of the dispenser receiving, from the user, information relating to:
how to calculate compliance, and/or how to inform the user of compliance.
[0165] Then, the blister card(s) may have indentations, holes, or protrusions made subsequent to manufacture thereof, and wherein the dispenser derives the information from the indentations, holes, or protrusions made subsequent to manufacture thereof.
[0166] Preferably, the method of this aspect further comprises the step of detecting or determining when the user or operator gains access to at least one of the medical doses.
[0167] In any of the embodiments of the sixth, seventh, eighth and ninth aspects incorporating a blister card, the method preferably comprises the step of the dispenser holding the one or more blister card(s) in a manner so that the blister card is curved in a direction at least substantially along a longitudinal direction thereof. Then, the method may comprise the dispenser receiving the blister card(s), in a slot thereof, in a direction along the longitudinal direction of the blister card(s).
[0168] The method also preferably comprises the step of biasing an edge portion of each received blister card against a first surface of the dispenser. Then, the detecting means could be positioned a predetermined distance from the first surface and detect the blister card(s) when positioned between the detecting means and the surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0169] In the following, preferred embodiments of the invention will be described with reference to the accompanying drawing, where
[0170] FIG. 1A-1F illustrate a first preferred embodiment of a device according to the invention, and with means for monitoring the position of a blister card,
[0171] FIG. 2A-2G illustrate a second embodiment of a device according to the invention, and with means for monitoring the position of a covering part,
[0172] FIG. 3A -D illustrate a blister card and the use thereof, the blister card having holes, indentations or protrusions,
[0173] FIG. 4A-4B are timelines showing possible ways of administering drugs utilising a device according to the invention,
[0174] FIG. 5 illustrates an embodiment of the invention used in an injector, and
[0175] FIG. 6 illustrates an embodiment of the invention use in an inhaler.
DETAILED DESCRIPTION OF THE INVENTION
[0176] FIG. 1A-1F show a first embodiment of a device 1 for holding a blister card B. In FIG. 1F , the device is shown with a blister card B inserted into the device. The device 1 has a closed surface 2 and oppositely thereto a partly open surface 3 . The partly open surface 3 has a slot 4 extending partly down the surface. The slot 4 is intended for inserting a finger for sliding the blister card B into and out of the device. The one end 5 of the device has an inlet 6 for inserting the blister card into and taking the blister card B out of the device. The other end of the device 1 has monitoring means (See FIG. 3 ) for registering the position of the blister card B.
[0177] The monitoring means is intended for registering a first position of the blister card B within the device, said first position being a position where the blister card is fully or almost fully inserted into the device (See FIG. 3B ). Fully or almost fully inserted is a position where the closed surface 2 covers all of the tablets in the blister card B, so that not even one tablet can be taken from the blister card.
[0178] The monitoring means is preferably also intended for registering another position (See FIG. 3A ) of the blister card B in relation to the device, said other position being a position where the blister card B is fully or partly pulled out of the device. Fully or partly pulled out is a position where the closed surface 2 does not cover the tablets T in the blister card B, or at least does not cover outer tablets in the blister card, so that at least one tablet can be taken.
[0179] In the embodiment shown the device also comprises a small signalling means 7 such as an LED or other lighting means placed in another end 8 of the device. The signalling means 7 may have different functions. The signalling means may be for signalling to the user when the blister card is in the first position or not, i.e. in the position, where tablets cannot be taken from the blister card.
[0180] The signalling means 7 may also be a means for reminding the user of when to take a tablet according to information from a dosage plan stored in an electronic memory (See FIG. 3 ) of the device. The signalling means 7 may also be a means for displaying to the user a level of compliance. A first level may be a level of compliance where the dosage of tablets to be taken and the time at which the tablets are to be taken have been fulfilled according to the dosage plan. In this situation, the signalling means 7 may show a steady green light. A second level of compliance may be a level of compliance, where the dosage of tablets to be taken and/or the time at which the tablets are to be taken, have not been fulfilled according to the dosage plan, but where satisfactory compliance still may be established if the dosage of tablets are taken now. In this situation the signalling means may show a steady yellow light. A third level of compliance may be a level of compliance where the dosage of tablets to be taken and/or the time at which the tablets are to be taken, have not been fulfilled according to the dosage plan, and where satisfactory compliance cannot be established, even if the dosage of tablets are taken now. In this situation, the signalling means may show a blinking red light, or a steady red light. Other ways of signalling may be established depending on other defined intermediate levels of compliance according to the information of dosage plan stored in the device.
[0181] The device is designed (See FIG. 1B ) so that the closed surface 2 and the opposite surface 3 are curved. This has the advantage that when the blister card B is inserted through the inlet 6 into the device, the blister card B will be slightly bent compared to the planar configuration of the blister card B before insertion into the device. The slight bending of the blister card B will lead to the blister card B being wedged in the device, thereby holding the blister card B in the device without any elements as such for holding the blister card B within the device.
[0182] Thus, when the blister card B is inserted into the device through the inlet and is pushed all the way to the first position, where the blister card B is fully inserted in the device, the blister card B cannot drop out of the device. The curvature of the closed surface and the partly open surface 3 may have any rise H of the curvature in relation to a length of the blister card B. The only demand of the rise H of the curvature is that the blister card B must be so hardly wedged as not to drop out of the device by accident, perhaps when the inlet 6 of the device is directed downwards.
[0183] The device is also so designed that the one end 5 and the other end 6 of the device have flattened parts 9 . The flattened parts 9 enable the placement of the device at a supporting surface such as a table. The device also has a shape and a size making it possible easily to bring the device along during the day, either in a bag, even a small lady's handbag, or in a pocket of a shirt or of a pair of trousers. The size of the device is not much larger than the size of the blister card B contained in the device. Thus, the device itself will not be limiting the compliance of the user, only the “discipline” of the user will determine the compliance.
[0184] FIG. 2A-2G show a second embodiment of a device for holding a blister card B. In FIG. 2G , he device is shown with a blister card B inserted into the device. The device has a movable covering part 10 ; in the embodiment shown, a hinged covering part 10 . In an alternative embodiment, the covering part 10 may be slidable along grooves in the device instead of being rotated as shown. In yet another embodiment, the covering part may just be liftable from a lowered closed state on top of the device to a raised open state separated from the device.
[0185] The covering part 10 is intended for covering a compartment 11 for holding the blister card B within the device. In an open state of the covering part 10 , both the compartment 11 and control buttons 12 of the device are covered. In the embodiment shown, the covering part 10 has an aperture 13 for allowing viewing of a display 14 , even if the covering part 10 is in the closed state. A small signalling means 15 is situated to the right of the covering part 10 , and the covering part 10 does not cover this signalling means 15 either, even if the covering part 10 is in the closed state.
[0186] As mentioned above, in the embodiment shown the device also comprises a small signalling means 15 such as a LED or other lighting means such as the one shown in the first device of FIG. 1A-1F . The function and purpose of the signalling means 15 of the second embodiment shown in FIG. 2A-2G may be any one of the same purposes and functions as the ones described in relation to the first embodiment. Accordingly, the description related to the first embodiment of FIG. 1A-1F regarding the function and the purpose of the signalling means is hereby, by reference, incorporated into the description of the signalling means of the second embodiment shown in FIG. 2A-2G .
[0187] Apart from the signalling means 15 , as mentioned, the second embodiment of the device also has a display 14 . The display 14 may be used for many purposes and may include different functions. A display increases the amount of and the kind of information which may be given to the user apart from the information given by the previously described signalling means 15 . Also, apart from the display 14 , as mentioned, the second embodiment of the device has control buttons 12 . Control buttons 12 may be used for different purposes. The control buttons 12 may be used for entering data into an electronic memory of the device. The control buttons may also be used for scrolling between different data or different sets of date, all capable of being shown in the display 14 .
[0188] A bottom part 16 of the device shown in FIG. 2A-2G is provided with holes 17 intended as outlets for tablets from the blister card B contained in the compartment 11 of the device. The outlets 17 may have an orifice 18 planar with surface 19 of the bottom part 16 . This will however necessitate holding the device in the hands of the user, when having to dispense one or more tablets from the blister pack in the compartment.
[0189] Therefore, in an alternative embodiment of the device, the outlets may have an orifice 18 being situated at a level above a level of the bottom surface 19 . This leads to the advantage that the device may be placed at a supporting surface such as a table, when dispensing the tablets from the blister pack. In order for this function to be realised, the level at which the orifices of the outlets are situated must be situated above the level of the bottom surface in a distance being the same as or larger than a height of the tablets to be dispensed.
[0190] Thus, due to the possibility of orifices of the outlets situated in a plane above a level of the bottom surface, and thus above the supporting surface, there is room for the tablets between the orifice of the outlets and the supporting surface, when the device is placed with the bottom surface on the supporting surface. Being able to place the device on the supporting surface when dispensing the tablets, makes it very much easier to dispense the tablets from the blister pack, especially for elderly people or others having only a limited amount of strength in hands and fingers.
[0191] The bottom surface has a small cover (not illustrated). This cover is intended as cover for batteries for powering the signalling device, the display and any electronic memory storage means of the device. The batteries may also be used for powering possible means for transmitting data from the device or receiving data to the device from to a remote data receiving or data transmitting apparatus for storing, or in any other way handling data related to the usage and the monitoring facilities of the device.
[0192] The one side of the device has a plug 21 . One or more plugs may be provided for different purposes. One purpose of a plug may be to provide the device with electrical power from an external power source, either as an alternative to the batteries, or as a supplement to the batteries. Another purpose of one or more plugs may be to provide the device with a wired link to an external data receiving and/or data transmitting apparatus. The number of plugs may also be intended for a telecommunication means such as modem or the like for providing the device with a wireless link to an external data receiving and/or data transmitting apparatus. Finally, the plug may be used for transmitting data to other devices related to the use of the device according to the invention, such other devices perhaps being a sound alarm, a lighting alarm or a tactile alarm in the vicinity of the device and of the user and having the purpose of alerting the user of when to take a tablet from the device in order to maintain or in order to obtain satisfactory compliance.
[0193] Monitoring the actual direct status of the dispenser and monitoring the compliance may take place by any suitable means. The display may, as shown in FIG. 2 , constitute a part of the dispenser. However, alternatively the display may be connected to the dispenser either physically by a permanent or detachable wiring, or non-physically by means of wireless signals either to a separate display unit or perhaps to a mobile phone, or any other means of receiving wire-less signals.
[0194] Using wire-less signals to transmit the monitoring of compliance has the advantage that means for receiving messages that may be more frequently used than the dispenser, such as a mobile phone, will constitute the display means. This will increase the safety of the user taking the tablets at the prescribed times of drugs, and thereby maintain proper compliance. Furthermore, it will be possible for others than the user to monitor the compliance of the user, perhaps a doctor or other supervisor related to the dosage plan.
[0195] At least the device shown in FIG. 1 , and possibly also the device shown in FIG. 2 may be provided with a mechanical switch which is engaged when a blister card B is stored in the device. Referring to the embodiment shown in FIG. 1 , when the blister card B is removed from the first position, the switch is disengaged, this being monitored by a timer in the device. When the blister card B is moved to the first position again, the timer monitors this as a dosage of drugs having been taken.
[0196] In a possible functionally extended embodiment, the timer may compute when the next dosage of drugs has to be taken according to a drug dosage plan, and the user may be reminded according to this drug dosage plan. When the switch is disengaged again, this is monitored as the blister card B having been removed from the first position, and compliance having been fulfilled if the removal complies with the drug dosage plan.
[0197] To avoid a user to achieve a misleading good compliance by pulling the card from and to the first position a number of times, the removal of the card could be registered as a tablet taken, only if it happens during an active alarm. This reduces the risk of a misleading compliance indication by failed operation, and makes it more cumbersome to cheat the device. This way of detecting the consumption of tablets is rather simple and inexpensive, but still relatively reliable and valuable as a new tool to optimise a treatment, and enable distinction between non-compliers and non-responders.
[0198] Referring to the embodiment shown in FIG. 2 , the same functionality as above may be incorporated in a functionally extended embodiment. However, the monitoring is not a monitoring of a removal of the blister card B, but is a monitoring of lifting the covering part from the first and closed position to another and open position. In this way, exactly the same function as described above with reference to the embodiment of FIG. 1 may be obtained just by monitoring the covering part in stead.
[0199] Alternatively to a mechanical switch used for monitoring at least when the blister card B or the covering part is in the first position or not, other means of monitoring could be used. Thus, a capacitive monitoring may be used where the blister card B or the covering part introduces a change in a capacitor, when being placed in the first position compared to not being in the first position. Also magnetic means or optical means may be used to monitor when the blister card B or the covering part is in the first position or not. Additionally, seeing that the blister card B often have a back foil made of aluminium foil or perhaps another metal foil, electrical means sensing a conductivity of the foil of the blister card B may be used to monitor whether the blister card B is in the first position or not.
[0200] FIGS. 3A and B illustrate a dispenser 1 of the type illustrated in FIG. 1 . The illustrated dispenser is flat but may also be curved as that of FIG. 1 in order to obtain the advantages thereof.
[0201] In FIG. 3A , the blister card B and the dispenser 1 are slightly separated in that the blister card B has been sided a little outwardly of the dispenser 1 . In FIG. 3B , the blister card B is fully inserted into the dispenser 1 .
[0202] The blister card B has two indentations or cut-away parts 40 which mate with corresponding protrusions 41 of the dispenser 1 . These protrusions and indentations serve the purpose of preventing an unoriginal blister card from being fully inserted into the dispenser 1 .
[0203] The reason for this may be seen in the detector 42 , which, when the blister card B is fully inserted into the dispenser 1 (so that the indentations 40 and protrusions 41 mate) will be able to detect a feature of the blister card B at the position of the detector 42 . Such a feature may be another indentation (not illustrated) as the indentations 40 , a protrusion as is illustrated at 43 in FIG. 3C , or a hole as illustrated at 44 in FIG. 3D .
[0204] Another embodiment is indicated in FIG. 3E , where the indentations 46 (which may just as well be protrusions or holes) are positioned not at the bottom of the blister card B but at sides thereof so that a detector positioned in the slot receiving the card may be able to detect the features as the card is inserted—or when it is inserted.
[0205] Any number of detectors 42 may be used.
[0206] The detector may be based on optical, magnetical, or mechanical principles.
[0207] The dispenser 1 has electronics 45 to which the detector(s) 42 are coupled. These electronics furthermore comprise batteries, timer/clock, the reminding means (light emitter, vibrator, sound provider), a processor or CPU, and memory for storing data, such as medication schedules or programs for the CPU.
[0208] The features ( 40 , 43 , 44 , 46 ) may be provided for informing the dispenser 1 of a number of different things, such as
a manufacturer of the medical doses, a type of medication in the medical doses, expiration date of the medical doses, a frequency of recommended intake of the medical doses, recommended points in time of intake of the medical doses, a dose strength of one or more of the medical doses, a manner of informing the user or operator (which type of reminder does the user prefer for reminder and compliance readout) and What compliance level does the user himself wish to have (be informed of)
[0217] This information is detected (using the detector(s) 42 ) by the electronics 45 and may be used in the operation of the dispenser 1 .
[0218] Thus, in fact, the user may himself provide indentations or other features in order to actually program the dispenser himself.
[0219] The blister card B may be provided from manufacture with score lines, weakenings, perforations or merely demarcations for providing such indentations for e.g. informing the electronics of the level of compliance to which the user wishes to be kept or which compliance levels should give which outputs by the dispenser 1 (see below).
[0220] Naturally, the blister card B would normally be provided with features from manufacture, such features informing the electronics of how the medical doses should be dispensed. Such features may be used for identifying one of a number of dispensing schemes kept in the memory of the electronics.
[0221] An optical fit as a recognising means between dispenser 1 and blister card B may be a an optically readable feature of the blister card B and a corresponding optical reader of the device, so that it is not possible at all to gather any information form the blister card B as to a dosage plan, if the optical reader of the device cannot read a corresponding optical readable feature of the blister card B. The optical fit may be correlated to perforations, a breaking off of a corner of the blister pack or the like physical entities of the blister card B, or the optical fit may be an optical entity such as a hologram, a certain printing, a bar code or the like. Perhaps the blister card B may be provided with a coding intended for a chosen drug dosage plan, said coding being selected by the user initial to introducing the blister card B in the device. One of a number of possible optical features fits may be indicative of the coding chosen by the patient, similarly to the more mechanical feature, where different levels of e.g. 85%, 90% and 95% compliance may be chosen, however optically by perhaps providing a hole at a chosen location of the blister card B, and a corresponding reader such as a photo cell provided in the device. In FIG. 3 , a feature is used for electronic/mechanical coding, however similarly, the photo cell recognising light through a hole in the blister card B may be used for optical coding.
[0222] Any coding of the blister card B itself may be directly related to the drugs, the number of tablets contained in the blister card B and other conditions which are essential for proper and correct drug administration of the drugs in the blister card B in question.
[0223] An embodiment and functionality as the one described above, where the blister card B is provided with encoding may be beneficial for a manufacturer of drugs in blister cards B, because the manufacturer before handing over to the user the drugs in the blister card B can be sure of the encoding ensuring a proper compliance if complied with. Thus, the manufacturer does not have to rely on a doctor or other exterior medical personnel coding the device with the risk of wrongful coding of the device.
[0224] As mentioned, perhaps the encoding of the blister card B may be made by means of visually or electronically readable and tamper-proof means such as a hologram, a perforation or a small electronic circuit resembling or in any other way utilising trademarks solely used by the manufacturer. Thereby, it will be not be possible to use drugs and blister cards from other manufacturers. Also, the user can be sure that the drugs in the blister card B and the encoding with a drug dosage plan are mutually compatible, and that the drugs, if taken according to the drug dosage plan, will ensure proper compliance according to the prescribed manufacturer of the drugs. Even alternatively, the blister card B may be provided a special design only used by the manufacturer, and having the same purpose of individualisation as described above.
[0225] Also as mentioned, another alternative way of implementing variable compliance targets for the users would be to implement the break-off tabs on the blister card B itself. This means that the device is manufactured to reward a certain compliance. After a while, the user can set higher targets by breaking off tabs, which will cause the device to give rewards at a higher level of compliance.
[0226] All the devices shown may have one or more signalling means capable of reminding the user of taking the drugs either by a visual, an audible or a tactile signal. The visual signal is a lamp lighting red or other colour, when the time for delivering the drugs arises. The audible signal may be a siren sounding a warning-like signal. The siren may be adjustable, both in relation to the sound level and in relation to the sound produced. The sound produced may also differ depending on when the drugs is taken along a time interval after the time of delivering has been reached. At the beginning of the time interval, after the time of delivering has been passed, the audible sound is “pleasant” and/or at a low level. As long as the drugs is not taken and depending on how long time after the time of delivering that the drugs is still not taken, then the audible sound will be less “pleasant”, i.e. it will start being more alert-like or alarm-like, and/or the audible sound level will increase either stepwise or gradually. The sound may be a beeping sound or it may be a recording of a voice or an exclamation.
[0227] Such an adaptive reminding could also be implemented with visual alarming means, such as light emitting diodes, where a flashing pattern changes over time, as the interval since the start of the alarm gets longer. The light produced may also differ depending on when the drugs is taken along a time interval after the time of delivering has been reached. At the beginning of the time interval, after the time of delivering has been passed, the light could be a flashing green light, different from a steady green light, or an alternating green and yellow flashing.
[0228] As long as the drugs is not taken and depending on how long time after the time of delivering that the drugs is still not taken, then the light could change to alternating yellow and red flashing and further to a constant and steady red light perhaps even to a flashing red light. The light could be a single light with the above-mentioned pattern of alarming, or it could be a plurality of lights each having their distinct colour and either not lighting or lighting steadily or flashing depending on the level of compliance at a certain time, either during or after the drugs should have been taken according to a drug dosage plan stored in a memory of the device. If the device, as shown in FIG. 2 , is provided with a display, the level of compliance may also or in stead be displayed by for example a percentage.
[0229] Alternatively, a display may be used for informing the user of his/her compliance in the form of a number, a pictogram (happy/sad face) or other manners which will lead the user to know his/her compliance.
[0230] In the latter case, either a voice or an exclamation, the sound may be added some humour or a command-like tone so that the sound is personalised in relation to the user utilising the device for taking drugs. By personalising the sound, then the initiative for taking the drugs may be increased. If the sound is a voice it may the voice of a doctor, preferably the user himself or the user's own doctor, motivating the user to take the drugs, and the command being more and more harsh along with the drugs not being taken after the time of delivering has been exceeded. If the sound is added humour it may be one exclamation at the beginning of the time interval, after the time of delivering has been exceeded, and being another exclamation late in the time interval if the drugs are still not taken.
[0231] Any personalised voice and command or any personalised exclamation which the user chooses will add to the personalising of the device, and thus to impel to handle the device and the taking of the drugs seriously. Such sounds could also be attached to the achieved compliance, so that a good compliance causes a positive or rewarding sound to be played and a poor compliance causes a motivating sound to be played.
[0232] Compliance may be determined in a number of manners, and the user may, e.g., select a specific manner by providing a feature of the blister card B. Compliance may be determined as how long after the optimum time (as defined by e.g. a medication schedule) the user actually takes the medication. Alternatively, time may be divided into intervals, and the compliance may be determined as the frequency at which the user takes the medication in a given interval or after a predetermined period of time after the optimum point in time.
[0233] Compliance may be determined as a mean over a period of time depending on e.g. a feature of the blister card B or depending on the type of medication. For some types of medication, compliance should be determined over a time interval of at least a month, and for others, a few days would suffice.
[0234] The specific manner of informing the user that it is time to take a dose of medication may vary with the users present compliance. If the user is compliant to the medication scheme, a pleasant manner of informing the user may be selected, whereas a non-compliant user may be informed in a less pleasant manner. More pleasant manners may be the emission of light, a light vibration of a pleasant sound, whereas less pleasant manners may be more aggressive vibration and/or sounds.
[0235] Another situation where different manners of informing the user may be relevant is one where the dispenser determines that a given manner of informing the user has no effect or that a given manner has a particularly high effect. A situation of that type would be to rule out audio information for a user who turns out to be deaf of light or vibration information when the dispenser is normally placed in a hand bag.
[0236] Thus, the dispenser may be able to test different manners of informing and to determine which manners are the most useful—and to thereafter predominantly use these. The determination of whether a manner of informing is useful may be made on the basis of whether the user takes the medication during or shortly after that manner of informing has been used.
[0237] FIG. 4A -B shows how drugs could be administered with a device according to the invention, and it visualizes the different administration rules a device is capable of supporting. Basically, a prescription of medicine for example from a doctor to a patient comprises a specification of a drug to be taken and an ideal dosage of the drug to be taken at a certain moment of time, or within a certain time interval. The dosage is related to a certain dosage of drugs (e.g. two tablets) with a certain interval (for example every 24 hours). Therefore the administration is related to a calendar ( 100 ), where a number of ideal dosages ( 110 ) should be taken at a certain moment of time during the day or within a certain time interval during the day.
[0238] In the example shown, the patient is supposed to take one tablet every day at 8 AM. If this administration scheme is followed precisely, the patient compliance is at a maximum. Deviations from the ideal scheme can be interpreted as varying lack of, or a decreased level of compliance. The purpose of the device according to the present invention is to monitor this compliance by application of different rules dependent on the actual function of the relevant drug. Further, the purpose of the device according to the invention is to improve the compliance, both by providing the patient with information about the actual level of compliance and by reminding the patient when to take the drug in order to maintain a certain level of compliance.
[0239] The total time can by way of example be subdivided into two main categories, described in the following. Allowed periods ( 117 ): The patient is allowed to take a dosage. The period starts at or before the ideal dosage time or reminding time. It seizes when a dosage is taken, when all previous dosages have been taken, or when the next ideal dosage is close-by. Prohibited periods ( 118 ): The patient is not allowed to take a dosage. The purpose of the prohibited periods is to avoid over-dosage or to avoid risky high drug concentrations within the patient. The prohibited period starts when a dosage is taken, when the right average dosages have been reached, or when the next ideal dosage is close-by. It seizes when a new ideal dosage is close-by. These periods can be divided into a number of relevant sub-periods for more detailed monitoring information.
[0240] For example, this more detailed information could be: Early intake ( 125 ), ideal intake ( 126 ), delayed intake ( 127 ), intake prohibited (caused by dosage taking), next dosage prohibited ( 128 ) etc. The number and the kind of sub-periods depends on the therapy, the kind and amount of drug and on the patients, and might be related to any relevant information in relation to timing of dosages or use of the device.
[0241] The term “allowed” and the term “prohibited” refer to periods of time of a drug dosage plan. Allowed is when drug intake according to the drug dosage plan is recommended, i.e. where drug dosage should take place in order to obtain a certain state or a certain level of compliance according to the drug dosage plan. Prohibited is when drug intake according to the drug dosage plan is not recommended, i.e. where drug dosage, if taking place, perhaps will lead to over-dosage, or where drug dosage, if taking place, perhaps will lead to an incorrect follow-up of the drug dosage plan, and a non-existent possibility of reestablishment of compliance according to the drug dosage plan.
[0242] The allowed and prohibited periods ( 117 , 118 ) are the default status of the device. However, dependent on the patient's interaction with the device, the device can change its actual status. For example, the prohibited period ( 130 ) is initiated by the device activation ( 131 ), as the device is trying to make the patient follow the rule that tablets should not be taken too close to each other in order to avoid too high drug concentration, i.e. a over-dosage. The prohibited period ( 135 ) is initiated by the default status, as the dosage was not taken in the allowed period and the next alarm is approaching. The device activation ( 136 ) is therefore causing a warning signal ( 121 ).
[0243] The device can be programmed with the dosage information and can therefore remind the patient at or linked to the ideal dosage time. This is done by a reminder or an alarm ( 120 ), which informs the patient that it is time to take the prescribed dosage. An alarm can continue to be activated until a dosage is taken, or it can be cancelled or changed from an audio signal to a visual signal after a certain period of time. In the example shown, the alarm is cancelled either by an activation of the device (blister card B is taken out or the covering of the device is lifted), or because the allowed period ends and the device enters a prohibited period, where dosage taking is not recommended, because the next alarm is coming soon. If the device is activated in a prohibited period, the device could give the patient an acoustical warning signal ( 121 , 122 , 123 ) indicating that it is not recommended to take a dosage.
[0244] Dependent on the function of the drug taken, different rules for administration can be relevant. Events that influence the way of administration could for example be the time before the active substance in the tablet is transferred from the tablet to the blood, the time before the active substance is influencing the relevant site in the body, the half-time period of the active substance etc. If the consequences of a high concentration of drugs within the patient is harmless and/or the half-time period is longer than the period between taking of drug dosages, the timing is relative uncritical, and good compliance is achieved by taking, in average, the acquired number of dosages. For example, it may be acceptable to take two dosages at the same time if the previous dosage was forgotten. A device for such drug could therefore add up the number of reminders, so that previously forgotten dosages still are reminded to the patient.
[0245] For drugs with a very critical upper limit of active substance concentration, for example drugs for anticoagulation treatment, other rulers might be implemented in the device. In this example, the device will give the patient a warning if a dosage is taken too close to the previous dosage taken, or too close to the next ideal dosage to be taken.
[0246] FIGS. 5 and 6 illustrate other embodiments than pill dispensers holding blister cards.
[0247] In FIG. 5 , the dispenser is an injection pen 50 having a syringe 52 for injection of medication present in a first part 53 of the pen 50 . When not in use, the syringe 52 is not in use, it is covered by a cover 54 which comprises the detecting means, CPU, memory, informing means, providing means etc (in general denoted 55 ) desired to obtain th3e desired functionality according to the invention.
[0248] In this manner, no changes are required for the pen 50 in order to obtain the desired functionality.
[0249] Thus, when removing the cover 54 in order to gain access to a medication dose, the detecting means ( 54 ) will detect that, and the dispenser 50 act accordingly.
[0250] FIG. 6 illustrates another embodiment having an inhaler. The dispenser 60 has the inhaler 63 having a medication output 62 for the user to inhale through, and a base 63 . The inhaler has an air passage passing through the output 62 and a bottom of the inhaler. This bottom is blocked by the base 63 , when the inhaler 63 is not in use and positioned in the base 63 .
[0251] As is the case for the pen of FIG. 5 , the base 63 of the inhaler comprises all means and functionalities required (denoted 65 >) in order to gain the advantages of the present invention. Again, no changes are required in the actual inhaler 63 .
[0252] In this aspect, it should be noted that even further manners of delivery may be altered in order to obtain the advantages of the invention: nasal sprays, transdermal deliveries, rectal delivery, etc. | A medical dispenser adapted to inform a user of when to take medication, detect when the user accesses the medication and inform the user of his/tiers compliance to a medication schedule. The dispenser may inform the user with differing manners of informing (sound, light, vibration, higher of lower frequency or intensity) depending on the users compliance. Blister cards for use in the dispenser may be coded in order to inform the dispenser of a medication schedule, a desired compliance level, etc. The user may himself code the blister card. The dispenser may hold a blister card or may be adapted for providing medical doses for inhalation or injection. | 0 |
This is a continuation, of application Ser. No. 708,784 filed on July 26, 1976.
BACKGROUND OF THE INVENTION
Heretofore there have been a variety of proposals involving apparatus for the purification of water, especially for the desalinization of the existing water supply which is available from the ocean depths. However, the various attempts at such purification have proven to be overly costly and expensive as they contemplate the use of large cumbersome machinery and equipment for the transportation of the water to be purified over large distances whereby the proposals have become somewhat impractical for use where it is necessary. It is, in fact, known that some of the greatest shortages of available drinking and potable water are in the vicinity of water which is available but impossible to utilize because of the great impurities therein. It is, of course, well-known that steam or the vapors which emanate from heated or boiling water is a source of pure water supply upon the condensation thereof. However, little, if any, equipment has been proposed to reclaim and purify this available water in situ absent in expensive cumbersome and difficult to maintain machinery.
SUMMARY OF THE PRESENT INVENTION
The present invention is designed to overcome these difficulties by providing apparatus and systems for obtaining highly potable water from salt water for water which would otherwise be impossible to ingest. In accomplishing this result, the present invention contemplates the use of the natural heat generated by the sun and therefore requires little, if any, machinery which could provide a drain on energy sources. The concept of the invention involves the provision of a system comprising a tank into which salt water or impotable water normally flows or settles, such as a tank into which sea water can flow or a settling tank.
The top of this tank will be covered by a plastic cover which, for economy's sake, may be made of conventional plastic or other suitable material which is able to accommodate and pass the heating rays of the sun. The sun's rays passing through this plastic cover will cause the water captured within the tank portion to vaporize at an astonishingly rapid rate. As a result, the water within the settled tank or from the sea will become vaporized within the upper portion of the cover and above the sea water or settling material arising in the form of moisture-laden air.
This moisture-laden air is then conveyed by a blower arrangement utilizing only a modest amount of energy into a pipe line of any suitable material. In the settling tank arrangement the normal cold water aerator means which are present in the form of a fountain in most such units is used to condense the water as it passes through the line so arranged as to take maximum benefit from the line of travel of the aerated water.
A fluid pump is provided in the line from the condenser and pumps the pure water into a fresh water storage tank where it can be stored pending transportation to the source using the fresh water.
The system thus provided in effect uses only two modest amounts of energy to accomplish a potable water from salty or unclean sources, i.e. the fan arrangement necessary for the blower which would require little horsepower as it is only moving moisture-laden air and the pump arrangement used to transport the water from the condenser to the fresh water tank. Where necessary, as for example, in connection with utilization of sea water, an outlet from the condenser may be provided for the emission of any fumes emanating within the condenser as the vapor is being converted to water. The escape of the fumes need only be a pipe extending above the sea level.
The entire unit may be a supported float arrangement in which parts are suspended above the sea level while others are anchored below the sea. Alternatively, it may comprise a series of supported apparatus disposed in tandem on land whereby vapors emanating from an existing settling tank can pass through a condenser utilizing part of presently existing aerating fountains during its transformation into fresh potable water. While the invention will be described in relation to two embodiments thereof, it is to be understood at the outset that these embodiments are not to be considered to be limitations upon the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram of the water purification sytem of the present invention used to desalinate salt water.
FIG. 2 is a block diagram of the water purification system of the present invention used in conjunction with an existing settling tank.
FIG. 3 is a block diagram top view of a modified form of the invention used to desalinate salt water.
FIG. 4 is a block diagram side view of the modified form of the invention of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
It is of paramount importance in various sections of the world at the present time to provide means for increasing the supply of potable water. It is also of great importance that these means do not constitute an inordinate drain upon presently available energy sources. The present invention presents an effective and economic solution to the first problem, viz. providing a fresh or potable water supply while not presenting any great imposition upon available energy means.
In the drawings, FIG. 1 illustrates one phase of the invention which shows the apparatus of the system having portions disposed partially above the level of the sea or ocean in which the water purification system is located. It will thus be seen from the drawings that the system is integral and is preferably located in situ i.e. where the impure water exists in its natural state. The system comprises a tank 10 having a valve 11 in the enclosing liquid retaining wall 10a to permit the entry and containment of a certain amount of sea water maintaining it filled only to a certain level. The invention provides for the continuous processing of the sea water into potable water and for the retention in the tank 10 of a predetermined amount of sea water which will be available for such processing.
A cover 12 is disposed over the top of the tank 10. Preferably this cover 12 is of a flexible inflatable plastic material which will remain in the form of an encasing dome while the processing is proceeding. It will be understood, however, that any material which would permit the build-up of natural heating forces sufficient to vaporize the sea water contained within the tank would be suitable for the purposes of this invention. As illustrated, the rays of the sun itself may be used to provide a more than sufficient heat source, although it has been found that enough vaporization will take place under the appropriate enclosure even absent in extensive heat from the source of the sun.
The vaporized water will rise toward the top of the tank 10 under the cover 12. According to this invention, this vapor is not permitted to settle downwardly but rather as it is formed is constantly moved in the direction of the arrow by a directional blower 13 using only a modest amount of horsepower. This unique induced flow pattern maintains a constant area for the formation of new vapors while the old vapors are being moved for processing. As illustrated, the vapors are moved toward and into the pipe line 14 which extends into relative depth below the surface of the sea 15. The vapor as it passes down the pipe line 14 starts to condense into droplets of water without any need for an independent power source. The apparatus of this invention thus uses the changes in temperatures which exist between the temperature at the surface of the sea and that which exists at greater depth for the condensing effect. The reconstituted water which is pure then passes into the final condenser located on the surface of the bottom of the sea or is anchored by any suitable means (not shown).
A fluid pump 17 is used to continually pump the potable water from the condenser 16 through pipe 18 into a fresh water storage tank 19 where it may remain for any desirable period of time and will be subject to being moved or transported at will.
There are means for the escape of any fumes from the condensing apparatus via the pipe line 20 which rises to and above the surface of the sea.
The various sections of the water purification system of the present invention are linked together into one integral and integrated unit. The inter-connecting pipes may be of heavy duty solid plastic material or any other suitable material may be used which can safely and efficiently accommodate the transport of liquid passing therethrough. Thus the present invention contemplates using free heating sources such as the sun or heat generated under any containment preventing access from wind or rain, etc. This accomplishes the vaporization and purification of the sea water which then with a very minor energy expenditure is caused to move to a pipe line leading to a condensing area. The formation of droplets in the pipe line and the movement of the vapors therein are assisted by the forces of gravity and the condensing uses only the natural drop in temperature from the temperature existent near the crest of the sea to that which exists at the bottom. Thereafter fluid pumps are usable to transport the water from the condenser to the fresh water containing tank. The logistics of the system are such that it has been shown that enormous amounts of fresh water are obtainable in the circulating system from relatively small areas of salt or brackish water each day that the system is utilized.
FIG. 2 shows a modified form of the present invention for the specific purpose of purifying and reclaiming water from an existing raw sewage settling tank. It is well known that such areas include water aeration spraying means insitu.
As shown in the drawings, there is an existing settling tank 30 having an enclosing retaining wall 30a into which raw sewage and the like 31 is normally conveyed for settling purposes on a continual basis. In accordance with this invention, a dome 32 is provided as a cover for the tanks. This dome may comprise the inflatable plastic material heretofore discussed or any suitable material for the intended purpose. The rays of the sun or the heat generated by the containment itself, causes the water in the settling tank to vaporize and rise towards the top of the container.
In accordance with the invention in order to provide a continuous processing of the impure water into potable water, a fan or blower 33 is disposed in one portion of the tank to move the vapors in the direction of the arrow to a pipe 34 which, as aforesaid, may be made of any suitable material for the safe, efficient and economic transportation of the vapor and liquid. The pipe is so constructed as to allow the vapors to pass over an extended period of time through the pipe which is being cooled by an existing aeration fountain 35. At this point, the lowering of the temperature caused by the coolness of the water in the aeration fountain, causes the vapors to be converted into droplets and ultimately into a body of water in the final condenser 36 after passing through the preliminary condenser formed by a sinesoidal section 37 of the pipe 34.
Thereafter, the water may be moved into a fresh water storage tank 38 by means of a pump 39 urging the water through and section of the pipe 40 to the storage tank. The fresh water may then be stored or transported at will.
In this version of the present invention, it is possible to store the fresh water in an underground tank, if desired, whereby the water from the condenser 36 may be fed into the tank without utilizing any pump means but simply by gravity feed from the condenser into the underground fresh water storage tank. In the modified forms of the invention shown in FIGS. 3 and 4 the water evaporation tank 10 is of the same construction as that set forth in FIG. 1 as are the pipe line and the like. However, as shown in the drawings means are provided to increase the evaporating area. Such means are illustrated in the form of cloth covered baffles 50 dispersed at random throughout the tank. These can serve as additional supports for the transparent covering. Primarily, however, when the baffles are covered with the porous material such as nylon cloth or burlap, they become saturated as a result of the capillary action by the sea water. As a consequence, without enlarging the space involved there is an increase in the evaporating area and a consequent increase in the rate of evaporation.
As also shown in FIGS. 3 and 4 the pump and blower arrangement illustrated with regard to FIG. 1 which does use some external energy although of a minimum type, is replaced by a driving arrangement 51 which is maintained in the direction of the prevailing winds. A fan 54 (shown in phantom) internally of the vane 51 is activated by the force of the prevailing winds coming into the vane 51. This causes the circulation of the flow of the air derived only from wind forces over the surface of the solar energy system. The air passes through duct 52 across the surface of the tank in the same fashion as described with relation to the blower 13 in FIG. 1. The entire unit is maintained in floating position on support 53 although, of course, it may be otherwise secured if desired.
Thus, in FIGS. 3 and 4 structure is presented in accordance with the present invention which provides for evaporation at a greater rate in a confined area with the use of cloth covered baffles. Also the natural wind currents are utilized to drive the air over the evaporation area either alone or as a supplement to the blower pump. In order to further conserve energy it is possible with the present invention to use waste heat gases from atomic reactors, electric generating plants or exhaust gases from internal combustion engines (not shown) which could be directed into the driving arrangement 51 in place of the prevailing winds. Such structure would somewhat enhance the yield of the system and supplement the heating from the rays of the sun.
It will thus be seen that the present invention provides an efficient, simple and yet entirely dependable method of purifying salt water, brackish water or even water from raw sewage to make it potable. The unit is an integral one and uses available heat, gravity and other means in their normal state and only a minimum amount of energy for accomplishing the beneficial purification results.
The contents of the evaporation tank of the invention, which as is clear from the foregoing are provided therein as a substantially static body of impure water during operation, may be from time to time drained into an open tank so that a final solar evaporation can occur. This will enable the reclamation of salt. Thus, the concentrated brine resulting from the primary evaporation may therefore be used for any suitable commercial purpose.
Of course, if desired, a regulatory system (not shown) of the conventional type may be used to sense the level of the humidity in the tank and thereby regulate the speed of the blower fan used to move the molecules of water emerging above the surface of the water. Furthermore, the system of the present invention operates during the night as well as during daylight hours to purify the water passing therethrough. In addition, various surface tension breaking chemicals may be used to reduce the surface tension of the sea water being processed and thus accelerate the evaporation process.
It is to be understood of the term "potable" water is used herein to describe the very pure water obtainable with the use of the system of the present invention. However, the term "potable" is not to be considered as a restriction but rather is to be interpreted as meaning a form of processed water which can also be used for irrigation and similar non-drinking purposes.
It will also be understood that while examples of the present invention have been described in detail, various changes and modifications may be made while not departing from the spirit and scope of the present invention which is to be limited only by the scope of the appended claims. | An integral water purification system including a tank for containing unclean water located at the source with continual replenishment of said water in the tank, a cover for the tank to accumulate natural heat by the elimination of any disturbances by the elements and to aid such accumulation by the rays of the sun in order to vaporize the unclean water, a blower for moving the vapor to a pipe leading from an area of one temperature to an area of another and lower temperature such as from the crest to the depth of the sea, whereby the vapor is condensed into droplets and accumulated in a condensing unit as pure water and a pump to force the water from the final condenser to a fresh water storage tank for later use whereby potable water is obtained from unclean water with the use of natural forces and with a minimum of expenditure of artificial energy sources. | 8 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates to fishing devices. More specifically, the present invention relates to a novel and improved snap ring fishing net connector.
II. Description of Related Art
In the fishing industry, various types of line connectors are used for assembling seines used in the harvesting of fish. Among the many types of connectors, snap ring connectors are commonly used for making connections between the fish net (the seine) and the draw cable. These snap ring connectors are generally curved, ring-shaped members made of heavy metallic material. When a snap ring connector is used to connect two or more lines, a stationary line is attached to one end of the connector for connection with the net, while the remaining line(s) are run through the opening of the connector to slidably engage the snap ring connector along its inner surface.
In a typical fish harvesting application, a number of snap ring connectors are individually tied to the perimeter of the seine. A tow line (draw cable) goes through the center opening of each of the connectors and is used by for towing the fish net. Concurrent with the release of this main line, the fish net is dropped into the water from a fishing vessel to allow it to spread over a wide area of water upon the target school of fish. Under its own weight and the weight of the attached connectors, the net slowly descends in the water and the harvesting of the fish begins.
Upon achieving a suitable depth where fish are expected to be present, the fishermen begin to draw the tow line by pulling in its two ends. With this action, the snap rings along the perimeter of the fish net slide along the main line and are drawn close in with each other thereby causing the net to close and to contain the fish.
Previously used fish net line connectors are shown in FIGS. 1 and 2. These connectors are commonly made of steel material. Some are zinc-coated to enhance their corrosion resistance.
FIG. 1 shows a line connector consisting of a generally O-ring member for line engagement. Connection with the net is made with a stationary line tied to one portion of the ring. The draw cable, which is used for the closing of the net opening, is seen threading through the ring. A cross bar extends across the O-ring to separate the two lines which are to be engaged.
FIG. 2 shows a snap ring connector represented by a continuously curved member having a pear shape with a curved small upper portion, a relatively longer curved lower portion and two relatively straight side portions connecting the upper and lower portions. The stationary line, which is used to attach the ring to the fish net, is shown tied to the smaller upper portion of the ring. A draw cable, for towing or closing the net, is shown engaged along the inner circumference of the ring. This draw cable is allowed to slide along the line engaging surface of the ring's inner circumference.
The snap ring connector of FIG. 2 also shows a spring-loaded trap door on a straight side portion of the ring for opening and closing so as to facilitate the engagement of the draw cable without having to thread it in order through each of the connectors. The trap door is opened to allow the draw cable to be engaged by the connector. Contained within this spring-loaded trap door is a spring for releasably closing the trap door after the draw cable has been placed into the snap ring.
Similar to the O-ring shaped line connector as shown in FIG. 1, the snap connector has a cross bar which extends across the opening of the ring to create two spaces for separating the stationary line from the draw cable to reduce the possibility of line tangling. One of these spaces lies between the cross bar and the smaller curved portion, the other between the longer curved portion and the cross bar.
A major problem encountered in the use of these prior art line connectors is that they are highly susceptible to wear along the inner surface of the rings where contact is made between the draw cable and the connector. The draw cable is typically of braided steel construction; and prior art connectors are fabricated from steel stock or pipe and have smooth rounded surfaces. Thus, even though that they may be zinc coated for increased corrosion resistance, they are not capable of withstanding the abrasions generated by the draw cable when it is engaged upon the inner surface of the rings. This results in an average useful life time of six months for such prior art ring connectors. Frequent replacements of these rings are thus required resulting in high repair or equipment costs for seine fishing rings. In addition, the materials used in the manufacture of the snap ring connector make it vulnerable to corrosion, particularly after prolonged periods of immersion in seawater. This problem necessitates periodic fresh water cleaning of the snap ring connectors which is both inconvenient and costly, particularly on long fishing expeditions where fresh water is always a scarce commodity.
SUMMARY OF THE INVENTION
It is the object of the present invention to provide a snap ring connector with increased resistance to wear and corrosion. According to the present invention, a snap ring connector is provided to comprise a curved pear-shaped member having an improved wear-resistant surface along the inside portion of its circumference where it engages the draw cable, and an spring-loaded trap door for the opening or closing of the snap ring connector for the placement of the draw cable.
In a preferred embodiment of the invention, the snap ring connector basically comprises a ovate shaped member made of stainless material to reduce the corrosive effects of sea water on the snap ring, a surface material deposited along the inner surface of the connector to provide a suitable hardened surface of contact between the draw cable and the connector, and a cross-bar extending from one side of the connector to provide separate line engagement spaces for the stationary line and the tow line, and a spring-loaded trap door. The spring-loaded trap door is made of two piece construction having interfitting threads for connecting each other and with suitable inner diameter to accommodate the diameter of the ring connector.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, objects and advantages of the present invention will become more apparent from the detailed description set forth below, when taken in conjunction with the drawings in which like reference characters correspond throughout and wherein;
FIG. 1 is a front elevation view of a prior art O-ring;
FIG. 2 is a front elevation view of a prior art ovate snap ring connector;
FIG. 3 is a front elevation view of the snap ring connector of the present invention;
FIG. 4 is an enlarged sectional view taken on line 4--4 of FIG. 3; and
FIG. 5 is an enlarged sectional view taken on line 5--5 of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 3, 4 and 5 of the accompanying drawings show a preferred embodiment according to the invention. In FIG. 3 the ovate shaped connector of the present invention is shown having an upper arcuate portion 4 and a lower arcuate portion 6 connected by an extension member 8.
The upper arcuate portion has a relatively smaller radius and length than the lower arcuate portion. For example, in one preferred embodiment of the invention, the upper and lower arcuate members have an inner radii of approximately 3/4" and 21/2" respectively. Of course, the radii and the arcuate lengths of both portions can be suitably varied so as to accommodate the size of the lines to be engaged or connected. The arcuate members are connected by extension member 8 forming a C-shaped configuration. The combined configuration can be made by round welding the pieces together, or it can be fabricated from steel stock by cold bending. A suitable length of this member can be in the order of 25". The material used for the fabrication of this C-shaped configuration is preferably stainless steel, for example 11/4" diameter #T-304L stainless steel, or any other materials which possess good structural strength and exhibit corrosion resistant characteristics when subject to salinity.
A cross bar 20 extends from point 22 along extension piece 8 across the snap ring connector in a slightly upwardly direction and is welded to point 24 of the connector to define two confinement areas 9 and 11 within the connector. The main purpose of this cross bar is to provide separate spaces for the lines so as to minimize the possibility of line entanglement in fishing operations. The upward orientation for cross bar 20 is to permit a greater travel for the trap door mechanism 30 to result in a larger opening for the C-configuration to accept draw cables with larger diameter size.
A stationary line 42 is connected to the upper portion of the connector. The connection can be made with any convention means. Draw cable or line 44 threads through area 11. In fishing operations this draw cable is intended to engage upon hardened surface 50 formed upon the inner surface of lower arcuate portion 6 of the connector (FIG. 5). Hardened surface 50 consists of a material deposit having a physical property capable of withstanding the abrasive effect of the line when it is drawn or pulled. In a preferred embodiment of this invention, this material is composed of preferably a 5/32" chrome-manganese welding rod welded at a welder setting of 300 volts/120 amperes, upon the inner line-engaging surface of lower arcuate portion 6 of the connector. Although chrome-manganese material is preferred, other types of materials may be utilized to form the hardening of the inner surface.
Line 44 is placed into the larger confinement area either by inserting its open end through confinement areas 11 of the connector; or by passing it through the trap door mechanism 30.
Referring to FIG. 4, trap door mechanism 30 comprises a cylindrical member members 32 and 34 and spring 38, disposed between the respective elongated portions 10 and 12 of the upper and lower arcuate portions 4 and 6. In this preferred embodiment of the invention, the material used for the cylindrical member is stainless steel, typically #T-304 stainless steel pipe, or other material having corrosion resistant characteristics. Furthermore, it is preferred that spring 38 be formed of stainless steel #302 wire having a 1/8" diameter. The trap door mechanism slidably engages within its inner diameter the elongated portions 10 and 12 for opening and closing of the larger confinement area so as to facilitate the placement of the draw cable. FIGS. 3 and 4 illustrate trap door mechanism 30 in the closed position which is effected by a spring 38 located within trap door mechanism 30 to resist against its opening.
Spring 38 is a helical compression spring located within cylindrical members 32 and 34 to act against end surface 46 of elongated portion 10 of upper arcuate portion 4 and spring stop 40 located at the lower portion of trap door mechanism 30. Acting against the elongated portion, spring 38 urges spring stop 40 toward the lower elongated portion 12 of lower arcuate portion 6, thereby closing the larger confinement area 11 of the snap connector.
When trap door mechanism 30 is slid towards the upper arcuate portion 10, trap door mechanism 30 opens the confinement area 11. The opening of confinement area 11 enables the placement of the draw cable into the confinement area 11 for line engagement.
In the present embodiment of the invention, trap door mechanism 30 consists of two hollow cylindrical members 32 and 34 having interfitting male and female threads for connecting with each other. However, cylindrical members 32 and 34 may be integrally formed and positioned upon elongated portion 10 during the bending of upper accurate portion 10. Disposed within the interior of mated cylindrical members 32 and 34 is spring 38. Cylindrical member 34 contains spring stop 40 affixed within its inner diameter at a distance from end opposite engagement with cylindrical member 32, to securably engage the end surface 42 of elongated portion 12 of lower arcuate portion 6. It is also preferred that spring stop 42 be formed from stainless steel, such as a stainless steel washer welded to the interior of cylindrical member 34. To install the trap door mechanism onto the elongated portions, the two cylindrical members 32 and 34 are first disconnected and the spring removed. The upper member 32 is then slid onto the elongated portion 46 toward upper arcuate portion 4. Next, spring 38 is inserted into the inner diameter of cylindrical member 32. The relative lengths of cylindrical member 32 and spring 38 are such that when cylindrical member 32 is slid toward the upper arcuate portion, part of the spring will be exposed. This exposed portion of the spring is engaged in compression by cylindrical member 34 which allows cylindrical member 34 to clear into the space between the elongated portions of upper and lower arcuate members 4 and 6. The spring then is held compressed until interfitting male and female threads 36 and 37 come into contact with each other for connecting cylindrical members 32 and 34. Thereafter, the unitary trap door mechanism is released to allow the compression spring to close. To enhance handling, the exterior surface of the trap door mechanism is roughened, or knurled to enable a firmer grip by the fish net operator.
Although the preferred embodiment of the present invention is constructed primarily of stainless steel, is envisioned that other types of non-corrosive, high-strength resilient materials may be utilized. Stainless steel is a preferred material due to its inherent ability to withstand corrosion from salt and other corrosive agents. It is further envisioned that materials such as hot-rolled steel may be utilized to form the snap ring connector of the present invention. If such materials as hot-rolled steel is used, it is preferred that the snap ring connector be plated or galvanized to reduce corrosion due to moisture and salt.
The previous description of the preferred embodiments are provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without the use of the inventive faculty. Thus, the present invention is not included to be limited to the embodiment shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | An apparatus having a curved member in a substantially closed configuration so as to define an ovate shaped confinement area wherein the curved member is formed from a material having a first hardness. A cross piece is connected to the curved member within the confinement area. A snap release mechanism disposed upon the curved member is movable between a first position for opening the configuration and a second position for closing the configuration. The curved member has a line engaging surface facing the confinement area having a material deposit thereon. The material deposit has a second hardness relatively greater than the first hardness. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to adjustable-height ladders, and to adjustable-height stepladders in particular.
BACKGROUND OF THE INVENTION
[0002] Ladders have long been used throughout the world for a variety of purposes. Fixed, single-section ladders may be conveniently used where the top of the ladder can be stabilized against a wall or other structure. Where no stabilizing structure is conveniently available, it is often desirable to use a stepladder having a ladder section and a prop section, the tops of these sections being hinged together so that they can be spread apart to form an inherently stable stepladder.
[0003] The desirable height of a ladder or stepladder depends on how high the object or space sought to be accessed is above the ground or working surface. For example, a 6-foot high ladder or stepladder may be satisfactory for gaining access as high as 10 feet or so above ground, but a considerably taller ladder would be needed if access must be had 20 feet above ground. However, such a taller ladder will not necessarily be suitable for convenient access to locations closer to the ground. If a particular project requires access to locations at a variety of heights, one option is to have available two or more ladders or stepladders of varying heights. This is not a preferred option, as it entails the extra expense of multiple ladders, the need to transport multiple ladders to and from the project site, and the need for an increased amount of space to store the ladders when they are not being used.
[0004] To address these problems, a number of adjustable ladders and stepladders have been developed over the years. There are numerous examples of extension ladders in the prior art, typically featuring an upper ladder section overlapping a lower ladder section. The two sections may slide relative to each other to create a ladder of a desired height, up to nearly double the height of a single section. By providing utility over a larger range of heights, and being collapsible for compact storage, extension ladders of this type have enjoyed widespread acceptance as a solution to the noted problems.
[0005] However, the mechanisms of conventional extension ladders typically work only for ladders having parallel rails. It is well known that a given structure, having a given top width, will have greater lateral stability if its base width is greater than at its top width, as compared to the case where the width is constant. This principle has often been applied to fixed ladders, especially tall ladders; i.e., it is well known to construct fixed ladders with flared rails, in order to enhance the ladders' lateral stability and therefore the safety of persons using the ladders. However, attempts to create an extension ladder having flared rails have not been successful.
[0006] The prior art discloses numerous examples of adjustable stepladders. U.S. Pat. No. 534,463, issued Feb. 19, 1895 to Bowser, U.S. Pat. No. 1,670,653, issued May 22, 1928 to Cummins, and U.S. Pat. No. 5,000,289, issued Mar. 19, 1991 to Sanchez, all disclose a stepladder featuring an upper ladder section and a slidable lower ladder section, plus an upper prop section and a slidable lower prop section. A disadvantage common to all of these inventions is that each requires one or both of the ladder sections to have parallel rails; i.e., they will not work where both the upper ladder section and the lower ladder section have the desirable feature of flared rails. Furthermore, in each of these inventions, the width of the upper ladder section must be controlled within close tolerances to suit the configuration of the lower ladder section.
[0007] For the foregoing reasons, there is a need for a stepladder which is conveniently adjustable in height when the rails of the ladder sections are flared as well as when they are parallel, and wherein the ladder section can be adjusted independently of the prop section. In addition, there is a need for an extension ladder which is conveniently adjustable in height when the rails of the ladder sections are flared, as well as when they are parallel. The present invention is directed to these needs.
BRIEF SUMMARY OF THE INVENTION
[0008] In general terms, the present invention is an adjustable stepladder, each section of which has either flared rails (i.e., the rails being farther apart at the bottom that at the top) or parallel rails. The height of the stepladder can be adjusted, even in embodiments having flared rails, by means of a slide mechanism which permits upper and lower ladder sections to be moved longitudinally relative to each other, while adjusting itself to accommodate the variable width between the rails, and at the same time keeping all sections of the stepladder substantially aligned on a common centerline.
[0009] Accordingly, in one aspect, the present invention is an adjustable stepladder comprising:
[0010] (a) an upper-front frame having:
[0011] two elongate upper-front rails, each having an elongate front slide track running substantially parallel thereto, and each having a top end and a bottom end; and
[0012] a plurality of upper steps spanning between the upper-front rails;
[0013] (b) a lower-front frame positioned rearward of the upper-front frame and having:
[0014] two elongate lower-front rails, each having a front slide mechanism slidingly engageable with the front slide track of a corresponding upper-front rail, and each having a top end and a bottom end; and
[0015] a plurality of lower steps spanning between the lower-front rails;
[0016] (c) front locking means, for disengageably locking the lower-front frame in a desired position relative to the upper-front frame;
[0017] (d) an upper-rear frame having:
[0018] two elongate upper-rear rails, each having an elongate rear slide track running substantially parallel thereto, and each having a top end and a bottom end; and
[0019] one or more upper struts spanning between the upper-rear rails;
[0020] (e) a lower-rear frame positioned forward of the upper-rear frame and having:
[0021] two elongate lower-rear rails, each having a rear slide mechanism slidingly engageable with the rear slide track of a corresponding upper-rear rail, and each having a top end and a bottom end; and
[0022] one or more lower struts spanning between the lower-rear rails;
[0023] (f) rear locking means, for disengageably locking the lower-rear frame in a desired position relative to the upper-rear frame; and
[0024] (g) a top member interconnecting the top ends of the of the upper-front rails and the top ends of the upper-rear rails;
[0025] wherein:
[0026] (h) the upper-front frame, the lower-front frame, the upper-rear frame, and the lower-rear frame are substantially symmetrical about a common centerline;
[0027] (i) the lower-front frame may be selectively positioned relative to the upper-front frame by moving the front slide mechanisms within their corresponding front slide tracks;
[0028] (j) the lower-rear frame may be selectively positioned relative to the upper-rear frame by moving the rear slide mechanisms within their corresponding rear slide tracks;
[0029] (k) in all configurations of the stepladder, and as measured in any plane perpendicular to said centerline and intersecting both the upper-front frame and the lower-front frame, the upper-front frame is narrower than the lower-front frame; and
[0030] (l) in all configurations of the stepladder, and as measured in any plane perpendicular to said centerline and intersecting both the upper-rear frame and the lower-rear frame, the upper-rear frame is narrower than the lower-rear frame.
[0031] In the preferred embodiment, each front slide mechanism comprises:
[0032] (a) a front swing arm hingingly connected to the corresponding lower-front rail;
[0033] (b) front spring means for biasing the front swing arm to swing away from said lower-front rail; and
[0034] (c) a front slide member swivellably and rotatably connected to the front swing arm, said front slide member being slidingly engageable with the front slide track of the corresponding upper-front rail;
[0035] and wherein each rear slide mechanism comprises:
[0036] (d) a rear swing arm hingingly connected to the corresponding lower-rear rail;
[0037] (e) rear spring means for biasing the rear swing arm to swing away from said lower-rear rail; and
[0038] (f) a rear slide member swivellably and rotatably connected to the rear swing arm, said rear slide member being slidingly engageable with the rear slide track of the corresponding upper-rear rail.
[0039] In another aspect, the invention is an extension ladder comprising:
[0040] (a) an upper frame having:
[0041] two elongate upper rails, each having an elongate slide track running substantially parallel thereto, and each having a top end and a bottom end; and
[0042] a plurality of upper steps spanning between the upper rails;
[0043] (b) a lower frame positioned rearward of the upper frame, said lower frame being wider than the upper frame and having:
[0044] two elongate lower rails, each having a slide mechanism slidingly engageable with the slide track of a corresponding upper rail, and each having a top end and a bottom end; and
[0045] a plurality of lower steps spanning between the lower rails; and
[0046] (c) locking means, for disengageably locking the lower frame in a desired position relative to the upper frame;
[0047] wherein:
[0048] (d) the upper frame and the lower frame are substantially symmetrical about a common centerline;
[0049] (e) the lower frame may be selectively positioned relative to the upper frame by moving the slide mechanisms within their corresponding slide tracks; and
[0050] (f) in all configurations of the extension ladder, and as measured in any plane perpendicular to said centerline and intersecting both the upper frame and the lower frame, the upper frame is narrower than the lower frame.
BRIEF DESCRIPTION OF THE DRAWINGS
[0051] Embodiments of the invention will now be described with reference to the accompanying figures, in which numerical references denote like parts, and in which:
[0052] [0052]FIG. 1 is an side elevational view of the preferred embodiment of an adjustable stepladder in accordance with the invention.
[0053] [0053]FIG. 2 is a perspective view of the slide mechanism of the preferred embodiment.
[0054] [0054]FIG. 3 is an side elevational view of the preferred embodiment of an extension ladder in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0055] As illustrated in FIG. 1, the adjustable stepladder of the present invention, generally represented by reference numeral ( 10 ), has an upper-front frame ( 20 ), a lower-front frame ( 30 ), an upper-rear frame ( 40 ), and a lower-rear frame ( 50 ). The upper-front frame ( 20 ) includes a pair of elongate upper-front rails ( 22 ) lying substantially in a common plane, and the upper-front rails ( 22 ) are spaced apart by a plurality of upper steps ( 24 ) spanning therebetween. Each upper-front rail ( 22 ) has a top end ( 22 a ) and a bottom end ( 22 b ). Connected to and running substantially parallel to each upper-front rail ( 22 ) is an elongate front slide track ( 26 ). In the preferred embodiment, the upper-front frame ( 20 ), when viewed from the front, will be wider at the bottom than at the top, as this configuration provides enhanced lateral stability compared to a frame having a lower width equal to its top width. However, the upper-front frame may be of constant width (i.e., having parallel upper-front rails) without departing from the fundamental concept of the invention.
[0056] The lower-front frame ( 30 ) includes a pair of elongate lower-front rails ( 32 ) plus a plurality of lower steps ( 34 ) spanning therebetween. Each lower-front rail ( 32 ) has a top end ( 32 a ) and a bottom end ( 32 b ). When the stepladder ( 10 ) is assembled, the lower-front frame ( 30 ) is positioned rearward of the upper-front frame ( 20 ) and shares therewith a common centerline (as viewed from the front or the rear of the stepladder). In the preferred embodiment, the lower-front frame ( 30 ) will be wider at the top than at the bottom, as viewed from the front, but may be of constant width if desired.
[0057] Attached to each lower-front rail ( 32 ) near the top thereof is a front slide mechanism ( 60 ) which is engageable with the front slide track ( 26 ) of the corresponding upper-front rail ( 22 ). Referring to FIG. 2, the front slide mechanism ( 60 ) in the preferred embodiment includes a front swing arm ( 62 ) hingingly mounted on the inner face of the lower-front rail ( 32 ) so that the front swing arm ( 62 ) can pivot inwardly from the lower-front rail ( 32 ); i.e., toward the centerline. A spring means ( 64 ) disposed between the front swing arm ( 62 ) and the lower-front rail ( 32 ) biases the front swing arm ( 62 ) to swing inwardly from the lower-front rail ( 32 ). The front swing arm ( 62 ) is configured such that its free end ( 62 a ) may be aligned with the front slide track ( 26 ) of the corresponding upper-front rail ( 22 ). A front slide member ( 66 ) is attached to the free end ( 62 a ) of the front swing arm ( 62 ) in such fashion that it is free to swivel and rotate in all directions relative to the front swing arm ( 62 ).
[0058] When the stepladder ( 10 ) is assembled, each front slide member ( 66 ) is positioned in the corresponding front slide track ( 26 ) so that it may slide therein. Because the front slide members ( 66 ) are free to swivel and rotate, the lower-front frame ( 30 ) may articulate relative to the upper-front frame ( 20 ) without impeding the ability of the front slide members ( 66 ) to slide within the front slide tracks ( 26 ). In the preferred embodiment, the front slide tracks ( 26 ) are configured such that the front slide members ( 66 ) may be conveniently disengaged therefrom, thereby entirely disengaging the lower-front frame ( 30 ) from the upper-front frame ( 20 ).
[0059] The upper-rear frame ( 40 ) includes a pair of elongate upper-rear rails ( 42 ) lying substantially in a common plane, and the upper-rear rails ( 42 ) are spaced apart by one or more upper struts ( 44 ) spanning therebetween. Each upper-rear rail ( 42 ) has a top end ( 42 a ) and a bottom end ( 42 b ). Connected to and running substantially parallel to each upper-rear rail ( 42 ) is a rear slide track ( 46 ). In the preferred embodiment, the upper-rear frame ( 40 ), when viewed from the rear, will be wider at the bottom than at the top, but may be of constant width if desired.
[0060] The lower-rear frame ( 50 ) includes a pair of elongate lower-rear rails ( 52 ) plus a plurality of lower struts ( 54 ) spanning therebetween. Each lower-rear rail ( 52 ) has a top end ( 52 a ) and a bottom end ( 52 b ). When the stepladder ( 10 ) is assembled and viewed from the rear, the lower-rear frame ( 50 ) is positioned forward of the upper-rear frame ( 40 ) and shares therewith a common centerline. In the preferred embodiment, the lower-rear frame ( 50 ) will be wider at the top than at the bottom, but may be of constant width if desired.
[0061] Attached to each lower-rear rail ( 52 ) near the top thereof is a rear slide mechanism ( 70 ) which is engageable with the rear slide track ( 46 ) of the corresponding upper-rear rail ( 42 ). Referring to FIG. 2, the rear slide mechanism ( 70 ) in the preferred embodiment includes a rear swing arm ( 72 ) hingingly mounted on the inner face of the lower-rear rail ( 52 ) so that the rear swing arm ( 72 ) can pivot inwardly from the lower-rear rail ( 52 ); i.e., toward the centerline. A spring means ( 74 ) disposed between the rear swing arm ( 72 ) and the lower-rear rail ( 52 ) biases the rear swing arm ( 72 ) to swing inwardly from the lower-rear rail ( 52 ). The rear swing arm ( 72 ) is configured such that its free end ( 72 a ) may be aligned with the rear slide track ( 46 ) of the corresponding upper-rear rail ( 42 ). A rear slide member ( 76 ) is attached to the free end ( 72 a ) of the rear swing arm ( 72 ) in such fashion that it is free to swivel and rotate in all directions relative to the rear swing arm ( 72 ).
[0062] When the stepladder ( 10 ) is assembled, each rear slide member ( 76 ) is positioned in the corresponding rear slide track ( 46 ) so that it may slide therein. Because the rear slide members ( 76 ) are free to swivel and rotate, the lower-rear frame ( 50 ) may articulate relative to the upper-rear frame ( 40 ) without impeding the ability of the rear slide members ( 76 ) to slide within the rear slide tracks ( 46 ). In the preferred embodiment, the rear slide tracks ( 46 ) are configured such that the rear slide members ( 76 ) may be conveniently disengaged therefrom, thereby entirely disengaging the lower-rear frame ( 50 ) from the upper-rear frame ( 40 ).
[0063] Referring again to FIG. 1, the stepladder ( 10 ) also features a top member ( 27 ) spanning across the upper ends of the upper-front frame ( 20 ) and the upper-rear frame ( 40 ). In order to enhance the stability of the stepladder ( 10 ) when in use, the top member ( 27 ) is rigidly connected to either the upper-front frame ( 20 ) or the upper-rear frame ( 40 ), or to both. In the preferred embodiment, the top member ( 27 ) is rigidly connected to the upper-front frame ( 20 ) only, and is hingingly connected to the upper-rear frame ( 40 ), thereby facilitating folding and compact storage of the stepladder ( 10 ). Alternatively, the top member ( 27 ) may be rigidly connected to the upper-rear frame ( 40 ) only, and hingingly connected to the upper-front frame ( 20 ), to achieve essentially the same foldability.
[0064] Also in the preferred embodiment, bracing means is provided to hold the assembly of the upper-front frame ( 20 ) and the lower-front frame ( 30 ) in a substantially fixed relationship relative to the assembly of the upper-rear frame ( 40 ) and the lower-rear frame ( 50 ). As illustrated in FIG. 1, the bracing means may be conveniently provided in the form of a hinged brace ( 29 ) of a type well known in the art of stepladders, with the hinged brace ( 29 ) being pivotally connected to the upper-front frame ( 20 ) at one end and to the upper-rear frame ( 40 ) at the other end. It will be readily appreciated that the hinged brace ( 29 ) must be detachable from either or both of the upper-front frame ( 20 ) and the upper-rear frame ( 40 ), in order to permit full-range movement of the lower-front frame ( 30 ) and the lower-rear frame ( 50 ) relative to the upper-front frame ( 20 ) and the upper-rear frame ( 40 ) respectively.
[0065] To further enhance the stability of the stepladder ( 10 ) when in use, the upper-front frame ( 20 ) has front locking means ( 28 ), and the upper-rear frame ( 40 ) has rear locking means ( 48 ). In the preferred embodiment, the front locking means ( 28 ) will include a pair of brackets, one rigidly connected to and projecting rearwardly from each of the upper-front rails ( 22 ) near the lower end thereof, as illustrated in FIG. 1. Similarly, the rear locking means ( 48 ), will include a pair of brackets, one rigidly connected to and projecting frontwardly from each of the upper-rear rails ( 42 ) near the lower end thereof. When the lower-front frame ( 30 ) has been positioned as desired relative to the upper-front frame ( 20 ), by sliding the front slides ( 66 ) within the front slide tracks ( 26 ) and pivoting the lower-front frame ( 30 ) relative to the upper-front frame ( 20 ) as appropriate, the brackets of the front locking means ( 28 ) may be positioned to engage one of the lower steps ( 34 ) so as to prevent the lower-front frame ( 30 ) from sliding or articulating relative to the upper-front frame ( 20 ). Similarly, when the lower-rear frame ( 50 ) has been positioned as desired relative to the upper-rear frame ( 40 ), by sliding the rear slides ( 76 ) within the rear slide tracks ( 46 ) and pivoting the lower-rear frame ( 30 ) relative to the upper-front frame ( 20 ) as appropriate, the brackets of the rear locking means ( 48 ) may be positioned to engage one of the lower struts ( 54 ) so as to prevent the lower-rear frame ( 50 ) from sliding or articulating relative to the upper-rear frame ( 40 ).
[0066] The stepladder ( 10 ) of the present invention may be conveniently adjusted in height by sliding the lower-front frame ( 30 ) to a desired position relative to the upper-front frame ( 20 ), sliding the lower-rear frame ( 50 ) to a desired position relative to the upper-rear frame ( 40 ), and then engaging the front locking means ( 28 ) and the rear locking means ( 48 ) as previously described. This procedure may entail pivoting lower-front frame ( 30 ) relative to the upper-front frame ( 20 ) and pivoting the lower-rear frame ( 50 ) relative to the upper-rear frame ( 40 ), to avoid interference of the front locking means ( 28 ) with the steps and interference of the rear locking means ( 48 ) with the struts as the lower-front frame ( 30 ) and the lower-rear frame ( 50 ) are moved to their desired positions.
[0067] In all configurations of the stepladder, and at any location where the upper-front frame is overlapping the lower-front frame, the upper-front frame is narrower than the lower-front frame, as measured in a plane perpendicular to the common centerline. Similarly, at any location where the upper-rear frame is overlapping the lower-rear frame, the upper-rear frame is narrower than the lower-rear frame, as measured in a plane perpendicular to the centerline. By virtue of this configuration, the front slide mechanisms ( 60 ) are always outboard of the front slide tracks ( 26 ) such that each front slide member ( 66 ) may engage its corresponding front slide track ( 26 ). Because the front swing arms ( 62 ) are hinged and the front slide members ( 66 ) are swivellably and rotatably connected to their respective front swing arms ( 62 ), the front slide members ( 66 ) remain engageable with the front slide tracks ( 26 ) even though the lateral distance between a given lower-front rail ( 32 ) and its corresponding upper-front rail ( 22 ) may vary depending on the relative positions of the upper-front frame ( 20 ) and the lower-front frame ( 30 ). Similarly, because the rear swing arms ( 72 ) are hinged and the rear slide members ( 76 ) are swivellably and rotatably connected to their respective rear swing arms ( 72 ), the rear slide members ( 76 ) remain engageable with the rear slide tracks ( 46 ) even though the lateral distance between a given lower-rear rail ( 52 ) and its corresponding upper-rear rail ( 42 ) may vary depending on the relative positions of the upper-rear frame ( 40 ) and the lower-rear frame ( 50 ).
[0068] Accordingly, the stepladder ( 10 ) of the present invention is fully adjustable not only when the upper-front frame ( 20 ), the lower-front frame ( 30 ), the upper-rear frame ( 40 ), and the lower-rear frame ( 50 ) are each of constant width, but also when each is wider at the bottom than at the top. The front spring means ( 64 ) cooperate with the front swing arms ( 62 ) such that the centerline of the upper-front frame ( 20 ) remains substantially coincident with the centerline of the lower-front frame ( 30 ) regardless of their relative positions. Similarly, the rear spring means ( 74 ) cooperate with the rear swing arms ( 72 ) such that the centerline of the upper-rear frame ( 40 ) remains substantially coincident with the centerline of the lower-rear frame ( 50 ) regardless of their relative positions.
[0069] It will also be readily seen that the stepladder ( 10 ) may be adjusted for use on uneven surfaces by differential positioning of the lower-front frame ( 30 ) and the lower-rear frame ( 50 ). It may further be seen that, in the preferred embodiment of the invention, the lower-front frame ( 30 ) and the lower-rear frame ( 50 ) may be disengaged completely from the upper-front frame ( 20 ) and the upper-rear frame ( 40 ) such that the assembly of the upper-front frame ( 20 ), the top member ( 27 ), and the upper-rear-frame ( 40 ) may be employed as a conventional non-adjustable stepladder.
[0070] In a further embodiment, as illustrated in FIG. 3, the invention is an extension ladder ( 110 ) comprising an upper-front frame ( 20 ) and a lower-front frame ( 30 ) and all associated components as herein previously described in connection with the adjustable stepladder embodiment of the invention ( 10 ). When assembled in accordance with the preceding description, the upper-front frame ( 20 ) and the lower-front frame ( 30 ) form the extension ladder ( 110 ), which may be deployed as shown in FIG. 3; i.e., resting on a supporting surface ( 120 ) and leaning against a stabilizing surface ( 130 ). Like the stepladder ( 10 ), the extension ladder ( 110 ) is fully adjustable not only when the upper-front frame ( 20 ) and the lower-front frame ( 30 ) are each of constant width, but also when each is wider at the bottom than at the top. In the preferred embodiment, the upper-front frame ( 20 ) and the lower-front frame ( 30 ) may be disengaged from each other entirely, allowing either to be used independently as a fixed ladder.
[0071] In a yet further embodiment, the invention is a convertible adjustable stepladder comprising all of the components herein previously described in connection with the adjustable stepladder embodiment of the invention ( 10 ), with the additional feature that the upper-front rails ( 22 ) may be detached from the top member ( 27 ), thereby detaching the upper-front frame ( 20 ) and the lower-front frame ( 30 ) and associated slide mechanisms completely from the remainder of the assembly. The upper-front frame ( 20 ) and the lower-front frame ( 30 ) may then be used as an extension ladder, and subsequently reattached to the top member ( 27 ) for further use as an adjustable stepladder.
[0072] The foregoing is a description of a preferred embodiment of the invention which is given here by way of example only, and the invention is not to be taken as limited to any of the specific features described. It will be readily seen by those skilled in the art that various modifications of the invention may be devised without departing from the essential concept of the invention, and all such modifications are intended to be included in the scope of the claims appended hereto. | An adjustable-height stepladder has an upper-front frame and an upper-rear frame interconnected by a top member. The upper-front frame and the upper-rear frame each have an elongate slide track. A lower-front frame, wider than the upper-front frame and positioned centrally rearward thereof, has a pair of rails, each having a slide mechanism slidingly engageable with the slide track of the corresponding upper-front frame rail. A lower-rear frame, wider than the upper-rear frame and positioned centrally forward thereof, has a pair of rails, each having a slide mechanism slidingly engageable with the slide track of the corresponding upper-rear frame rail. Each slide mechanism has a hinged swing arm and a biasing spring, the combination of which allows the slide mechanisms to engage the slide tracks although the lateral distance between the upper-frame rails and their corresponding lower-frame rails may vary. Accordingly, the stepladder is height-adjustable when the rails of the various frames are flared as well as when they are parallel. | 4 |
[0001] This non-provisional application is based upon and claims priority from Provisional Application No. 60/042,874 filed Mar. 31, 1997.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to oral care products comprising citrus-masked phenolics. Oral compositions including mouthwashes and dentifrices containing phenolic compounds have been formulated using one or more of the following: menthol, methyl salicylate, eucalyptol and thymol are well known (U.S. Pat. No. 4,945,087; PCT Int. Appl. Nos. WO 94 16,674; WO 94 07,477; WO 94 18,939). These compositions are characterized by their relatively high alcohol levels (20-27 volume %) which causes them to have negative aesthetics, including excessive “bite” and “burn”. These compositions often have an unpleasant medicinal taste which can be unattractive to consumers. In particular, thymol is the ingredient which contributes most to the unpleasant, medicinal and harsh taste of these compositions although the combination of several phenolics imparts greater negative taste attributes to these compositions than any one phenolic by itself.
[0003] Triclosan (2,4,4′-trichloro-2′-hydroxydiphenyl ether) is a phenolic, nonionic antimicrobial agent used in various soap and toiletry products. In the oral care area, triclosan has been used as a plaque-inhibitory agent in various toothpastes and mouthrinses. Triclosan can have an unpleasant, medicinal taste and at sufficient concentration can cause numbing of the tongue and other mucosal and gingival tissues.
[0004] Citrus-flavored mouthwashes or dentifrices have been formulated, as well as methods for preparing clear citrus-flavored mouthwashes including for example, U.S. Pat Nos. 3,876,759 and 4,420,471.
[0005] The use of limonene and its derivatives has been used to improve flavor impact and flavor stability in chewing gum compositions (U.S. Pat. No. 4,157,401) as well as in cleaning compositions (U.S. Pat. Nos. 4,511,488 and 4,620,937). Limonene and its derivatives has been shown to have anti-bacterial effects (Zuckerman, I. “Effect of oxidized d-limonene on micro-organisms” Nature, No. 4273, pp. 517, 1951; Yousef C. A. 91 #151896b (1979), Antimicrobial activity of volatile oil components (limonene)). In the oral care area, limonene has been used as a stabilizer to prevent the loss by adsorption of triclosan on the interior surfaces of packaging containers (U.S. Pat. Nos. 5,167,951; 5,135,738; 5,279,813; 5,273,741).
SUMMARY OF INVENTION
[0006] The present invention relates to an oral rinse, dentifrice, or oral gel composition comprising:
[0007] a) about 0.01 weight % to about 5 weight % of citrus flavor, citrus flavor ingredient, or mixtures thereof;
[0008] b) about 0.01 weight % to about 5 weight % of a phenolic, said phenolic selected from the group consisting of menthol, eucalyptol, methyl salicylate, thymol, triclosan, and mixtures thereof; and
[0009] c) an orally acceptable carrier.
[0010] A preferred embodiment of the present invention relates to an oral rinse, dentifrice, or oral gel composition comprising:
[0011] a) about 0.01 weight % to about 5 weight % of a citrus flavor, citrus flavor ingredient, or mixtures thereof;
[0012] b) about 0.01 weight % to about 5 weight % of a phenolic, said phenolic selected from the group consisting of menthol, eucalyptol, methyl salicylate, thymol, triclosan, and mixtures thereof;
[0013] c) about 0.1 weight % to about 70% of a polyol, said polyol selected from the group consisting of glycerol, sorbitol, propylene glycol, butylene glycol, xylitol, cyclodextrin and its derivatives, and mixtures thereof;
[0014] d) about 0.01 weight % to about 10 weight % of an oral acceptable surfactant; and
[0015] e) an orally acceptable carrier.
[0016] A more preferred embodiment of the present invention relates to an oral rinse, dentifrice, or oral gel composition comprising:
[0017] a) about 0.01 weight % to about 5 weight % of citrus flavor selected from the group consisting of orange, grapefruit, lemon, mandarin orange, lime, tangerine, and tangelo; citrus flavor ingredient selected from the group consisting of limonene, citral, cadiene, decylaldehyde, linalool, terpineol, linalyl esters, terpinyl acetate, citronellal, α-terpinene, γ-terpinene, 2-dodecanal, α-pinene, β-pinene, 2-pentenal, decanal, and C 8 to C 10 and C 12 aldehydes, acids, and esters found in citrus flavors; and mixtures thereof;
[0018] b) about 0.01 weight % to about 5 weight % of a phenolic, said phenolic selected from the group consisting of menthol, eucalyptol, methyl salicylate, thymol, triclosan, and mixtures thereof;
[0019] c) about 0.1 weight % to about 70% of a polyol, said polyol selected from the group consisting of glycerol, sorbitol, propylene glycol, butylene glycol, xylitol, cyclodextrin and its derivatives, and mixtures thereof;
[0020] d) about 0.01 weight % to about 10 weight % of an oral acceptable surfactant; and
[0021] e) an orally acceptable carrier.
[0022] The present invention also relates to a method for retarding development of plaque on a dental surface in the oral cavity of a mammal, comprising administering to said dental surface an amount of said oral rinse, dentifrice, or oral gel composition effective in retarding said development of plaque.
[0023] The present invention also relates to a method of treating gingivitis, comprising administering to a mammal in need of such treatment an amount of said oral rinse, dentifrice, or oral gel composition effective in treating gingivitis.
[0024] The present invention also relates to a method of treating the presence of microorganisms in the oral cavity of a mammal, comprising administering to the mammal in need of such treatment an amount of said oral rinse, dentifrice, or oral gel composition effective in reducing the viable population of said micro-organisms.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The dental formulations in this invention comprise oral rinses (e.g. mouthrinses or washes), dentifrices, and oral gels having an effective concentration of phenolic compounds where the unpleasant taste of the phenolics is masked by the addition of citrus flavor oils, aromatics, oleo resins, extracts, or ingredients thereof.
[0026] Citrus flavors that may be employed in this invention include natural and synthetic citrus oils, for example, orange, grapefruit, lemon, mandarin orange, lime, Mexican lime, tangerine, tangelo and blends thereof, as well as citrus aromatics, natural oleo resins, and extracts. Examples of products with synthetic flavors include Carrubba A9047 (an orange flavor) and Noville AN110099 (a citrus mint flavor). These flavors typically contain one or more citrus flavor ingredients including, for example, the following: d-limonene, l-limonene, dl-limonene, alpha-citral and beta-citral (geranol), α-terpinene, γ-terpinene, 2-dodecanal, α-pinene, β-pinene, 2-pentenal, cadiene, decylaldehyde, linalool, terpineol, linalyl esters, terpinyl acetate, citronellal, decanal, as well as C 8 to C 10 and C 12 aldehydes, acids, and esters found in citrus flavors, and mixtures thereof. Either the natural or synthetic form of these ingredients could be used in the composition of the present invention. Certain of these ingredients may provide a better masking effect of the phenolics in these compositions either alone or in combination with other citrus oil components. For example, terpenes found in citrus flavors may be particularly effective in masking the unpleasant phenolic taste found in these compositions. Limonene is the most abundant terpene in citrus flavor and can be found at levels of approximately 90-95% in citrus flavors. It is possible that this terpene could be an important contributor to the masking effect of unpleasant phenolics by citrus oils. One hypothetical mechanism for the masking ability of citrus oils is that the chemical structure of d-limonene and its isomers is similar to several of the phenolics (e.g. thymol, menthol and eucalytol). Thus, limonene may act as an antagonist to phenolic compounds for taste receptors on the tongue.
[0027] Phenolics useful in the present invention include menthol, methyl salicylate, eucalyptol, thymol and triclosan, all of which have an antimicrobial activity. Thymol and triclosan are generally considered to have the best antimicrobial activity. Thymol is also an anthelmintic and an antiseptic. For oral rinses of the present invention, phenolics can be employed at concentrations of from about 0.01 weight % to about 0.5 weight %, preferably about 0.05 weight % to about 0.3 weight % of phenolic compounds selected from a group consisting of menthol, eucalyptol, methyl salicylate, thymol, triclosan, and mixtures thereof. For dentifrices and oral gels of the present invention, the aforementioned phenolic compounds can be useful at concentrations of from about 0.05 weight % to about 5 weight %, preferably about 0.25 weight % to about 3 weight %. The ratio of limonene to phenolic is preferably at least about 0.05:1.
[0028] Humectants in dental products of the present invention impart to the mouth a moist and elegant feel and, if incorporated at sufficient concentration, may further inhibit the harshness of the phenolics in these compositions. Some humectants, for example, can provide sweetness to the composition, as well. Suitable humectants include edible polyhydric alcohols such as glycerin, sorbitol, propylene glycol, butylene glycol, xylitol and cyclodextrins, including their derivatives. A humectant generally is present in an amount ranging from about 0.1 weight % to about 30 weight % for oral rinses and from about 10 weight % to about 50 weight % for dentifrice and oral gel compositions.
[0029] Oral surfactants useful in the present invention include certain nonionic, anionic and amphoteric surfactants. The preferred oral surfactants include block co-polymers of polyoxyethylene and polyoxypropylene such as the Pluronics from BASF. Other oral surfactants include soluble alkyl sulfonates having 10 to 18 carbon atoms and sulfates of monoglycerides of fatty acids having 10 to 18 carbon atoms or sarcosinates (including salts and derivatives) such as sodium-N-lauroyl sarcosinate. Amphoteric surfactants that can be used include betaines, sulfobetaines and amidobetaines such as the TEGO betaines from Goldschmidt Chemical Corporation. Mixtures of anionic, nonionic and amphoteric surfactants can be used. These ingredients are generally present from about 0.01 weight % to about 10 weight %, preferably from about 0.01 weight % to 1 weight % for oral rinses and from about 0.5 weight % to about 2 weight % for dentifrices and oral gels.
[0030] The orally acceptable carrier of the invention generally includes mixtures of water and ethanol for oral rinses, although the carrier can be alcohol-free, especially in dentifrices and oral gels. For oral rinses, the amount of water can range up to about 25 weight %. The amount of alcohol for oral rinses ranges from about 0 weight % to about 25 weight %, preferably from about 0 weight % to about 15 weight %. For oral gels and dentifrices, the amount of water ranges from about 0 weight % to about 60 weight %, preferably from about 0 wt % to about 40 weight %.
[0031] The oral rinse compositions are usually stable so as to be substantially clear and substantially free of precipitation, flocculation, or crystal formation at about room temperature (about 25° C.) as well as at low temperatures of at least about 5° C. for at least about 1 week. The low temperature stability of these compositions is determined by cooling the compositions to about 5° C., storing for at least seven days and determining whether any precipitate, crystallized or flocculated material is formed in the clear compositions (solutions and oral gels).
[0032] For dentifrice and oral gel compositions, abrasives may also be added. Suitable abrasives include precipitated silica or silica gels which have an average particle size ranging from about 0.1 to about 50 microns. Preferred silica abrasives include those marketed under the tradename “Sylodent” or “Syloid” by the W. R. Grace & Co. and those marketed under the tradename “Zeodent” by the J. M. Huber Corp. Other suitable abrasives, having a suitable particle size as described above, include β-phase calcium pyrophosphate, alumina and calcium carbonate. The amount of abrasive in a dentifrice composition ranges up to about 60 weight %, preferably from about 10 weight % to about 40 weight %.
[0033] Oral rinse, dentifrice, and oral gel compositions of the present invention may also contain a suitable fluoride source. Typical sources include soluble salts of the fluoride ion (e.g. sodium fluoride, potassium fluoride, stannous fluoride, stannous fluorozirconate) or, soluble salts of the monofluorophosphate ion (e.g. sodium monofluorophosphate). The preferred fluoride source is sodium fluoride. The fluoride ion source should provide from about 50 ppm to about 2,500 ppm fluoride, preferably from about 250 ppm to about 1500 ppm for dentifrice and oral gel compositions, and from about 50 ppm to about 250 ppm fluoride for oral rinses.
[0034] Antiplaque agents can also be optionally added to the compositions of the present invention. These include cetyl pyridinium chloride and related quaternary salts such as chlorhexidine, zinc salts such as zinc chloride, stannous salts such as stannous chloride, or stannous fluoride and peroxygens such as hydrogen peroxide, carbamide peroxide, sodium percarbonate, magnesium perphthalate or sodium perborate. These optional antiplaque agents are generally present at levels ranging from about 0 weight % to about 5 weight %.
[0035] Anticalculus agents can also be optionally added to the compositions of the present invention. These include tetra-alkali metal pyrophosphate salts and zinc salts, such as zinc chloride. These optional anticalculus agents are generally present at levels ranging from about 0 weight % to about 5 weight % for pyrophosphate salts and from about 0 weight % to about 3 weight % for zinc salts.
[0036] In compositions of the present invention, preservatives may be used, especially in non-alcohol or low alcohol compositions. These include benzoic acid, sodium benzoate, methylparaben, propylparaben, sorbic acid and potassium sorbate. These preservative agents are generally present at levels ranging from about 0 weight % to about 2 weight %.
[0037] In compositions relating to the invention, buffering systems may be used to stabilize the pH in the product. The pH of the oral rinse, dentifrice, and oral gel compositions can range from about 3.5 to about 8.5. Typical buffering systems include, but are not limited to, citrate, benzoate, gluconate and phosphate. Buffering systems are present in concentrations from about 0.01 weight % to about 1 weight %.
[0038] Thickening agents or binders are an optional component of the compositions. Typical thickening include, xanthan gum, carragenan,.carboxyvinyl polymers, carbomers, cellulose gums such as carboxymethyl cellulose, cellulose derivatives such as hydroxyethylcellulose and silicas. Thickeners are usually present in the compositions from about 0 weight % to 2 weight % in oral rinses, in which xanthan gum is the preferred thickener. In dentifrices and oral gels, silica-based thickeners can be used at concentrations from about 0 weight % to about 20 weight %. “Sylox” or “Sylodent” by W. R. Grace & Co. are the tradename of the preferred silica-based thickener.
[0039] Orally acceptable sweetening agents such as saccharin, lactose, maltose, aspartame, sodium cyclamate, and polydextrose can be added to the compositions. Sweetening agents generally are present in an amount ranging from about 0.001 to about 5 weight % for oral rinse, dentifrice and oral gel compositions. Orally acceptable coloring agents generally are present in an amount ranging from about 0 weight % to about 0.01 weight %.
EXAMPLE 1
[0040] The following dental rinse was formulated: Sodium citrate, citric acid, sodium saccharin, sorbitol solution 70% and dye were dissolved in water, at room temperature (which is generally between about 20 and 25° C.), using a mixer with high-lift blade rotating at approximately 200-300 rpm to give a clear aqueous solution. Poloxamer 407, benzoic acid, menthol, thymol, methyl salicylate, eucalyptol and d-limonene were added to the 190° alcohol to give a clear alcoholic solution. The alcoholic phase was added slowly to the aqueous phase which was continually agitated until the addition was complete. The resulting orange product was mixed for a further 30 minutes. The solution had a pH of approximately 4.0.
INGREDIENT WEIGHT PERCENT Sodium Saccharin 0.0500 Sodium Citrate 0.0400 Citric Acid 0.0100 Sorbitol Solution 70% 22.0000 FD&C Red No. 40 0.0008 D&C Yellow No. 10 0.0002 Poloxamer 407 0.5000 Alcohol 190 Proof 17.9000 Benzoic acid 0.1500 Thymol 0.0640 Eucalyptol 0.0920 Menthol 0.0420 Methyl Salicylate 0.0600 d-Limonene 0.1000 Purified Water 58.9910 Total 100.0000
EXAMPLE 2
[0041] The following dental rinse was formulated: Sodium citrate, citric acid, sodium saccharin, sorbitol solution 70%, hydroxypropyl β-cyclodextrin and dyes were dissolved in water, at room temperature, using a mixer with high-lift blade rotating at approximately 200-300 rpm to give a clear aqueous solution. Poloxamer 407, benzoic acid, menthol, thymol, methyl salicylate, eucalyptol and flavor were added to the 190° alcohol to give a clear alcoholic solution. The alcoholic phase was added slowly to the aqueous phase which was continually agitated until the addition was complete. The resulting orange product was mixed for a further 30 minutes. The solution had a pH of approximately 4.0.
INGREDIENT WEIGHT PERCENT Sodium Saccharin 0.0500 Sodium Citrate 0.0400 Citric Acid 0.0100 Sorbitol Solution 70% 22.0000 FD&C Red No. 40 0.0008 D&C Yellow No. 10 0.0002 Hydroxypropyl β-Cyclodextrin 1.0000 Alcohol 190 Proof 12.0000 Poloxamer 407 0.5000 Benzoic Acid 0.1500 Thymol 0.0640 Eucalyptol 0.0920 Menthol 0.0420 Methyl Salicylate 0.0600 Citrus Mint Flavor (Noville 0.1000 AN110099) Purified Water 63.8910 Total 100.0000
EXAMPLE 3
[0042] The following dental rinse was formulated: Sodium citrate, citric acid, sodium saccharin, sorbitol solution 70%, sodium lauryl sulfate and dye were dissolved in water using a mixer with high-lift blade rotating at approximately 200-300 rpm to give a clear aqueous solution. Poloxamer 407, benzoic acid, triclosan (Irgacare MP-Ciba Geigy) and flavor were added to the 190° alcohol to give a clear alcoholic solution. The alcoholic phase was added slowly to the aqueous phase which was continually agitated until the addition was complete. The resulting orange product was mixed for a further 30 minutes. The solution had a pH of approximately 4.0.
INGREDIENT WEIGHT PERCENT Sodium Saccharin 0.0500 Sodium Citrate 0.0400 Citric Acid 0.0100 Sorbitol Solution 70% 22.0000 FD&C Red No. 40 0.0003 D&C Yellow No. 10 0.0009 Sodium Lauryl Sulfate 0.2500 Poloxamer 407 0.5000 Alcohol 190 Proof 8.0000 Benzoic Acid 0.1500 Triclosan 0.1000 Orange Flavor (Carrubba A9047) 0.1000 Purified Water 68.7988 Total 100.0000
EXAMPLE4
[0043] A oral gel dentifrice was formulated by dispersing the carboxymethyl cellulose in the glycerin and polyethylene glycol using a Hobart mixer. The NaF was dissolved separately in the water. The remainder of the water and sorbitol were added to the NaF/water solution and mixed for 25 minutes. Sodium saccharin and hydroxypropyl β-cyclodextrin were then added and mixed for another 10 minutes. Separately the phenolics were mixed together, i.e. eucalyptol, methyl salicylate, thymol and menthol, to make a phenolic phase and the flavor was added to the phenolic phase. The Sylodent 750, Sylodent 15, and dyes were added to the cellulose/sorbitol/cyclodextrin/water phase. Then the phenolic phase, sodium lauryl sulfate and xantham gum were added and mixed thoroughly for 30 minutes. The resulting opacified orange oral gel was deaerated to remove air bubbles.
INGREDIENT WEIGHT PERCENT Xanthan Gum 0.300 Glycerin 14.000 Sorbitol Solution 70% 21.171 Carboxymethyl Cellulose, 9M8 1.000 Polyethylene Glycol, PEG-8 3.000 Purified Water 14.000 FD&C Red No. 40 0.003 D&C Yellow No. 10 0.003 Hydroxypropyl β-Cyclodextrin 15.000 Sodium Saccharin 0.500 NaF 0.243 Sylodent 750 12.000 Sylodent 15 10.000 Thymol 0.640 Eucalyptol 0.920 Menthol 0.420 Methyl Salicylate 0.600 Sodium Lauryl Sulfate 30% 5.000 Orange Flavor (Carrubba A9047) 1.200 Total 100.000 | An oral rinse, dentifrice, or oral gel composition comprising:
a) about 0.01 weight % to about 5 weight % of a citrus flavor, citrus flavor ingredient, or mixtures thereof;
b) about 0.01 weight % to about 5 weight % of a phenolic, said phenolic selected from the group consisting of menthol, eucalyptol, methyl salicylate, thymol, triclosan, and mixtures thereof; and
c) an orally acceptable carrier.
The claimed composition is useful in retarding the development of plaque, treating gingivitis, and reducing the viable population of micro-organisms in the oral cavity of a mammal. | 0 |
TECHNICAL FIELD
This invention relates to a hand-held electronic game.
BACKGROUND
The game Operation by Milton Bradley is well known. In that game, a player holds a pair of tweezers and tries to grab and remove misplaced anatomy parts from a simulated human body cavity without touching the body cavity. If the player touches the body cavity or drops an anatomy part, the game buzzes and flashes a light.
SUMMARY
The invention provides a hand-held electronic game that includes a housing, a display mounted on the housing, the input device mounted within the housing, and a processor positioned in the housing and connected to the display and the input device. The processor is programmed to cause the display to display (1) a body cavity, (2) one or more hazardous cells in the body cavity, (3) one or more anatomy parts in the body cavity, and (4) a game piece that moves relative to the body cavity in response to signals from the input device, and, when positioned near an anatomy part, removes the anatomy part from the body cavity.
Embodiments may include one or more of the following features. For example, the housing may be shaped like a human body.
The game may include a second input device (e.g., a laser button). The game piece may destroy hazardous cells in response to signals from the second input device. Furthermore, the game may include special cells in the body cavity that replenish, when the game piece is maneuvered over them, an ability for the game piece to destroy hazardous cells.
Hazardous cells may remain stationary or move relative to the body cavity. Hazardous cells may block movement of the game piece. An anatomy part may remain in the body cavity until a hazardous cell overtakes and destroys it. The body cavity may scroll across the housing.
The housing may include a light connected to the processor and controlled by the processor. The processor may be programmed to flash the light when hazardous cells strike the game piece. Furthermore, the light may protrude from the housing. The housing may include a mechanism that permits retraction of the light when the light is pushed.
The display may be a liquid crystal display screen.
The processor also may be programmed to display a game update that provides game information to a player. The game update may display the amount of time that the player has played the game. The game update also may display a tally of anatomy parts that have been removed from the body cavity. The game update also may display a number of laser shots that are available for use by the game piece to destroy hazardous cells in the body cavity.
An anatomy part may remain in the body cavity until a player removes it, or for a predetermined time period.
The game piece may be displayed as tweezers.
The processor may be programmed to remove one of a player's lives when a hazardous cell strikes the game piece. The game may include a vibrator mounted in the housing, connected to the processor, and controlled by the processor. The processor may be programmed to vibrate the game using the vibrator when a hazardous cell strikes the game piece.
The game may further include a speaker mounted in the housing, connected to the processor, and controlled by the processor. The processor may be programmed to play one or more sounds from the speaker when an anatomy part is removed from the body cavity, when the game piece moves through the body cavity, or when all anatomy parts are removed from the body cavity.
Other features and advantages will be apparent from the following description, including the drawings, and from the claims.
DESCRIPTION OF DRAWINGS
FIG. 1 is a front view of a hand-held electronic game.
FIG. 2 is a block diagram of operating components of the game of FIG. 1.
FIG. 3 is a flow chart of game play using the game of FIG. 1.
FIG. 4 is a detail of a display screen of the game of FIG. 1.
FIGS. 5-7 are details of elements displayed by the display screen of FIG. 4.
DETAILED DESCRIPTION
Referring to FIG. 1, a hand-held, electronic game 100 includes a housing 105 in the shape of a human body. The housing 105 may be made of a rigid plastic material and formed of two pieces that fit together to form a hollow volume to house components of the game. A liquid crystal display (LCD) screen 110 is positioned at the front of the housing 105. The LCD screen 110 displays both a body cavity 115 (designed to simulate a human body cavity) and a game update 120. Control buttons 125-150 are positioned on the housing 105 at easy-to-reach locations. For example, an operate button 125 is positioned at a portion of the housing 105 corresponding to a hand such that use of the operate button 125 is eased when a player holds and plays the game 100. An indicator light 155 (for example, a light-emitting diode) is positioned at and acts as the nose of the human body represented by the housing 105.
Briefly, game play consists of moving a pair of tweezers 160 depicted on the LCD screen 110 through the body cavity 115. The body cavity 115 may scroll to simulate movement of the tweezers 160 through the body cavity 115. The tweezers 160 are moved (for example, up, down, right, or left) by the player using the operate button 125. The player's goals are to avoid touching hazardous cells 165 which are depicted in the body cavity 115 of the LCD screen 110, and to obtain "funatomy" parts 170, such as a "rubber band" or a "funny bone", left in the body cavity 115. Points, designated as money, are awarded for collecting the funatomy parts 170.
Referring also to FIG. 2, the housing 105 contains an electronic controller 200 which connects to and controls other game components. A power source 205 (for example, a battery) is contained by the housing 105 and provides electrical power for the controller 200. Switches 210-250, which connect to the control buttons 125-150, provide inputs from the player to the controller 200.
Using input from the switches 210-250, the controller 200 controls the image displayed on the LCD screen 110. As game play requires, the controller 200 also may flash the indicator light 155, vibrate a vibrator 255 contained by the housing 105 and configured to shake the game 100, or send an audio signal to a speaker 260 contained by the housing 105. The controller 200 performs these tasks using additional information obtained from a processor 265, memory 270, a clock 275, and a counter 280.
Referring also to FIG. 3, game play proceeds according to a procedure 300 that is initiated when the player presses a start/laser button 130 (step 305) to turn on the game 100. Game play 300 initially defaults to a demonstration mode which helps the player get acquainted with the game 100. A reset button 150 may be pressed at this time to place the game 100 in game mode. Additionally, the reset button 150 may be pressed at any time if the game 100 malfunctions. A sound button 135 may be pressed at any time during game play to turn off or turn on the sound from the speaker 260.
A skill level is set to zero when a new game button 145 is pressed (step 310). The skill level ranges from zero (easy play) to a maximum level L max (difficult play). As a player completes each skill level, an increasingly more difficult skill level is introduced. For example, difficulty may be altered by changing a funatomy part appearance time or adding hazardous cells 165 to the body cavity 115. As a player advances to higher skill levels, the game update 120 saves information until the new game button 145 is pressed again and a new game begins. The game update 120 includes a time indicator 170 and a tally 175 of collected funatomy parts 170. When a high score button 140 is pressed at any time during game play 300, the time indicator 170 displays the money earned by the player for that game. Furthermore, at higher skill levels, the time indicator 170 may display accumulated laser shots which are used in the higher-skilled games to destroy hazardous cells 165.
When the player presses the start/laser button 130 another time, the controller 200 begins a game of basic OPERATION (step 315) with the player having a fixed number of lives. Referring also to FIG. 4, during basic OPERATION, the player moves the tweezers 160 through a stationary body cavity 115 using the operate button 125 on the game body 105. The body cavity 115 includes hazardous cells 165 that must be avoided by the tweezers 160. When funatomy parts 170, such as a "butterfly in the stomach" shown in the body cavity 115 or a "broken heart" shown in the tally 180, appear along edges of the body cavity 115 and between the hazardous cells 165, the player maneuvers, using the operate button 125, the tweezers 160 to "operate" on that funatomy part 170. A successful operation causes the part 170 to be removed from the body cavity 115 and placed in the tally 180. Every time the player removes a funatomy part 170, money is accumulated and the controller 200 causes the speaker 260 to play a brief song. If the tweezers 160 strike a hazardous cell 165 at any time during the game, the controller 200 vibrates the game 100 using the vibrator 255, flashes the indicator light 155, and removes one of the player's lives.
Referring again to FIG. 3, the controller 200 next determines if the player has successfully completed the game (step 320). The player successfully completes the basic game by collecting all of the available funatomy parts while still retaining at least one life. Lack of success causes the controller to return game play to the game of basic OPERATION (step 315).
If success has been achieved, the controller 200 increments the skill level (step 325) to a more difficult skill level. The controller 200 then determines if the skill level is at a first threshold L 1 (step 330). If the skill level has not reached the first threshold, the controller 200 returns game play to the game of basic OPERATION at step 315.
If the skill level has reached the first threshold, the controller 200 advances to a game of moving OPERATION (step 335). This new game incorporates all the aspects of basic OPERATION in addition to new features which make the game more difficult. Referring also to FIG. 5, the hazardous cells 165 begin to scroll in a direction indicated by double arrows 505. Thus, a funatomy part 170, which appears in the body cavity 115 and remains "stationary", will disappear if the player fails to operate on the part 170 before it is captured by the hazardous cells 165. For example, after the funatomy part 170 appears in the body cavity 115, the player advances the tweezers 160 to operate on the part 170. If, however, the hazardous cell 510 reaches the part 170 (since the hazardous cells are scrolling) before the tweezers 160 arrive, then the part is captured by the cell 510 and the player cannot operate on that part 170 until the part 170 reappears at a later time. If the tweezers 160 strike a hazardous cell 165 at any time during the game of moving OPERATION, the controller 200 vibrates the game 100 using the vibrator 255, flashes the indicator light 155, and removes one of the player's lives.
Referring again to FIG. 3, the controller 200 then determines if the player has successfully completed the game of moving OPERATION (step 340) by collecting all of the funatomy parts 170 while retaining at least one life. Lack of success causes the controller 200 to return game play to the game of moving OPERATION (step 335).
If success has been achieved, the controller 200 increments the skill level (step 345) to a more difficult skill level. The controller 200 then determines if the skill level is at a second threshold L 2 (step 350). If the skill level has not reached the second threshold, the controller 200 returns game play to the game of moving OPERATION at step 335.
If the skill level has reached the second threshold, the controller advances to a game of basic laser surgery OPERATION (step 355). Basic laser surgery OPERATION incorporates all the aspects of moving OPERATION in addition to new features which make the game more difficult. Referring also to FIG. 6, the player may now fire (using the start/laser button 130) laser shots 600 from the tweezers 160 at hazardous cells 165 to destroy them. The player begins with a preset number of laser shots 600. Additional laser shots may be obtained by capturing special cells 605 that flash and remain stationary during basic laser surgery is OPERATION. When the player maneuvers the tweezers 160 to a flashing cell 605, a supply of laser shots is replenished by a preset number of laser shots 600. Laser shots 600 are used to clear a way through crowded areas of hazardous cells 165. For example, each laser shot 600 may be able to destroy one hazardous cell 165. A number 610 of laser shots 600 collected by the player is displayed in the time indicator 175. The controller 200 may be configured to hold a maximum number 610 of laser shots. Thus, the player should attempt to conserve laser shots 600 to use at just the right time. Furthermore, the player must be careful not to destroy, using a laser shot 600, flashing cells 605 which appear during the game. If the tweezers 160 strike a hazardous cell 165 at any time during the game of basic laser surgery OPERATION, the controller 200 vibrates the game 100 using the vibrator 255, flashes the indicator light 155, and removes one of the player's lives.
Referring again to FIG. 3, the controller 200 then determines if the player has successfully completed basic laser surgery OPERATION (step 360) by collecting all of the funatomy parts 170 while still retaining at least one life. Lack of success causes the controller 200 to return game play to basic laser surgery OPERATION (step 355).
If success has been achieved, the controller 200 increments the skill level (step 365) to a more difficult skill level. The controller 200 then determines if the skill level is at a third threshold L 3 (step 370). If the skill level has not reached the third threshold, the controller 200 returns to the game of basic laser surgery OPERATION at step 355.
If the skill level has reached the third threshold, the controller 200 advances to a game of advanced laser surgery OPERATION (step 375). Advanced laser surgery OPERATION incorporates all the aspects of basic laser surgery OPERATION in addition to new features which make the came more difficult. The hazardous cells 165 may now completely block a path of the tweezers 160 and thus require the player to fire at least one laser shot 600 to avoid touching the hazardous cells 165. If the tweezers 160 strike a hazardous cell 165 at any time during the game of advanced laser surgery OPERATION, the controller 200 vibrates the game 100 using the vibrator 255, flashes the indicator light 155, and removes one of the player's lives.
Referring again to FIG. 3, the controller 200 determines if the player has successfully completed advanced laser surgery OPERATION (step 380) by collecting all of the funatomy parts 170 while still retaining at least one life. Lack of success causes the controller 200 to return game play to the game of advanced laser surgery OPERATION (step 375).
If success has been achieved, the controller 200 increments the skill level (step 385) to a more difficult skill level. The controller 200 then determines if the skill level is at a fourth threshold L 4 (step 390). If the skill level has not reached the fourth threshold, the controller 200 returns to the game of advanced laser surgery OPERATION at step 375.
If the skill level has reached the fourth threshold, the controller 200 advances to a game of avoid virus OPERATION (step 395). Avoid virus OPERATION incorporates all the aspects of advanced laser surgery OPERATION in addition to new features which make the game more difficult. Referring also to FIG. 7, virus cells 700 begin moving through the body cavity 115 in a free-floating manner; that is, they don't scroll with the hazardous cells 165. Initially, a virus cell 700 briefly flashes as a warning to the player. Then the virus cell 700 detaches from the rest of the scrolling hazardous cells 165 and tries to attack the tweezers 160. The player must try to get the tweezers 160 away from the virus cell 700 quickly. If the tweezers 160 "catch" a virus (that is, if the tweezers 160 are struck by a virus cell 700), the player loses a life. The player may use laser shots 600 to blast the virus cells that move in the tweezers'path to ensure success. If the tweezers 160 strike a hazardous cell 165 at any time during the game of avoid virus OPERATION, the controller 200 vibrates the game 100 using the vibrator 255, flashes the indicator light 155, and removes one of the player's lives.
Referring again to FIG. 3, the controller 200 determines if the player has successfully completed avoid virus OPERATION (step 400) by collecting all of the funatomy parts 170 while still retaining at least one life. Lack of success causes the controller 200 to return game play to the beginning of avoid virus OPERATION (step 395).
If success has been achieved, the controller 200 determines if the skill level is at the maximum value L max (step 405). If the skill level has not reached the maximum value, the controller 200 increments the skill level (step 410) to a more difficult skill level and returns game play to the game of avoid virus OPERATION at step 395. Otherwise, the controller 200 returns game play 300 to the game of avoid virus OPERATION at step 395.
Other implementations also are contemplated. For example, the game 100 may be timed by the clock 275, so that the player is required to remove all funatomy parts 170 from the body cavity 115 within a preset interval. At the end of the preset interval, the player's money is determined from the number of parts 170 removed and placed in the tally 180. Alternately, if the player removes all the funatomy parts 170 within the preset interval, the player's money may be determined from the time remaining in the preset interval.
Funatomy parts 170 may have different monetary prizes for removal. For example, the player may receive $30 for removing an "Adam's apple" and $60 for removing a "wishbone." Prizes may be based on a location in the body cavity 115 in which the funatomy part appears. For example, a "bread basket" which appears in a lower corner of the body (cavity 115 may be more difficult to operate on than a "funny bone" which appears in an upper corner of the cavity 115. Therefore, the prize would be greater for the "bread basket" than for the "funny bone." A player may receive bonus money based on how many laser shots 600 remain at the end of a skill level.
The game may default to a maximum number of lives. When a player loses the last life during a game, the controller 200 may be configured to take all money and laser shots 600 from the player, and to end the game.
The game 100 may be configured to automatically shut off after a predetermined interval of inactivity. Then, to finish a previous level, the player may press the start/laser button 130. Alternately, the player may start back at skill level zero by pressing the new game button 145.
The indicator light 155 is configured to protrude like a nose from the housing 105. The light 155 may be mounted internally on springs to permit the light 155 to be pushed into the housing 105. This configuration serves to prevent breakage which may occur if the light 155 is accidentally struck by, for example, dropping the game.
Other embodiments are within the scope of the following claims. | A hand-held electronic game includes a housing shaped like a human body, a display mounted on the housing, an input device mounted within the housing, and a processor positioned in the housing. The processor is connected to the display and the input device. The processor is programmed to cause the display to display a body cavity, one or more hazardous cells in the body cavity, one or more anatomy parts in the body cavity, and a game piece in the body cavity. The game piece moves relative to the body cavity in response to signals from the input device, and, when positioned near an anatomy part, removes the anatomy part from the body cavity. | 0 |
[0001] The present application is a continuation of U.S. application Ser. No. 15/076,294 filed Mar. 21, 2016 (Publication No. 2016/0277556), which is pending; which claims benefit of Provisional Application Nos. 62/136,272 filed Mar. 20, 2015 and 62/194,780 filed Jul. 20, 2015; all of which are incorporated by reference herein.
BACKGROUND
[0002] According to the World Health Organization, over 5% of the world's population—360 million people—have disabling hearing loss (328 million adults and 32 million children). Approximately one-third of people over 65 years of age are affected by disabling hearing loss. Disabling hearing loss refers to hearing loss greater than 40 dB in the better hearing ear in adults and a hearing loss greater than 30 dB in the better hearing ear in children.
[0003] Hearing aids are electrical devices that assist in optimizing perception of speech or other sounds. Most hearing aids are designed for hearing impaired individuals, of which there are approximately 37 million in the United States. Hearing aid unit sales in 2013 came very close to topping the 3-million unit mark for the first time in industry history. Industry experts are projecting 4 million unit sales by 2020.
[0004] Even though hearing aids can have a substantial impact on mitigating hearing loss, use of hearing aids with mobile or cordless telephones can be problematic. The configuration of Behind the Ear (BTE) or Receiver in the Canal (RIC) hearing aids can impede transfer of the sound from the voice emitting speaker (or receiver) of telephones thereto. For example, the position of the microphones of BTE hearing aids is often removed from the traditional placement of the voice emitting speakers of such telephones adjacent the ear. To illustrate, a user of a BTE hearing aid can oftentimes hear the phone ring, but cannot clearly hear callers due to the BTE hearing aid ear mold obstruction preventing the transfer of sounds from the voice emitting speaker.
[0005] Therefore, there is a need for a device facilitating the transfer of sounds from the voice emitting speaker of a telephone to a hearing aid.
[0006] The assistive hearing device described herein is designed to improve communication on telephones, including cordless or mobile phones, for people who wear BTE or RIC hearing aids. The assistive hearing device eliminates the need to place a phone receiver behind the ear to obtain the clearest sound. The assistive hearing device redirects telephonic sound via an acoustical accumulator and director to the microphone of the hearing aid located behind the ear or in the ear canal of the user. The acoustical accumulator and director extends beyond the top of the phone whereby it redirects the telephonic sound from the phone closer to where the BTE or RIC microphone is located.
SUMMARY OF THE INVENTION
[0007] In its simplest form, the assistive hearing device consists of a small outer case having opposite top and bottom ends, with a sound entrance aperture proximate the bottom end of the assistive hearing device, which is coupled (preferably with an elastic band, an adhesive material, or a hook and loop fastener) to the phone and a sound exit aperture located proximate the top end of the assistive hearing device. The two apertures are located approximately 1.5 to 2 inches apart. The assistive hearing device does not require a power source and is easy to install. The assistive hearing device adheres to the receiver end of a phone via a small O-Gasket creating a secure and soundproof seal. The O-Gasket material used to adhere the device to the phone can be, for example, a custom made high-density polyethylene film with double-sided synthetic rubber adhesive or a high friction rubber material.
[0008] In accordance with the present invention, an assistive hearing device having a sound entrance aperture on a first side, the sound entrance aperture placed against a voice emitting speaker (or receiver) of the telephone, a sound egress aperture on a second side opposite the first side, and the sound egress aperture located within closer proximity to a hearing device relative to the sound entrance aperture and the speaker to facilitate transmission of sound from the speaker to the hearing device located nearby is provided. The assistive hearing device includes a hollow interior, which connects the sound entrance and sound egress apertures, and allows sound waves entering the sound entrance aperture to travel through the hollow interior and exit the sound egress aperture. The sound entrance aperture of the assistive hearing device surrounds the speaker of the mobile device to capture sound waves transmitted from the speaker. The transmitted sound waves enter the sound entrance aperture, traverse through the hollow interior of the assistive hearing device and exit the sound egress aperture, which is located within closer proximity to the hearing device microphone relative to the sound entrance aperture and to the telephone speaker.
[0009] While most telephone speakers are designed to be placed against the ear of a user adjacent to the ear opening leading to the ear canal, the assistive hearing device takes into account that many hearing devices are worn behind the ear, which is at the opposite side of the ear opening. Specifically, the sound egress aperture is located on an opposite side of the sound entrance aperture to direct sound waves that enter the sound entrance aperture to the sound egress aperture, which is in closer proximity and oriented on the same side with respect to the BTE hearing aid microphone.
[0010] The assistive hearing device may include an adhesive portion that contains an adhesive material that is bonded to a surface surrounding the sound entrance aperture of the assistive hearing device. A removable strip can be removably attached to the adhesive material bonded to the first adhesive containing portion. The removable strip covers the adhesive material until it becomes desirable to attach the assistive hearing device to the mobile phone. The assistive hearing device may be connected to a strap, which straps the assistive hearing device to the mobile device. The assistive hearing device also may be connected to the mobile device by an elastic/silicone band or a band securable by hook and loop that fastens at its ends. The band may be adjusted to fit a variety of phone sizes and shapes.
[0011] The assistive hearing device of the present invention can be constructed from a variety of materials, including but not limited to plastic, metallic, compound materials, etc. Furthermore, the assistive hearing device may be constructed into a variety of shapes and sizes to account for the distance between the phone speaker and the input/microphone of the hearing device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings, which are included to provide further understanding of the present invention disclosed in the present disclosure and are incorporated in and constitute a part of this specification, illustrate aspects of the present invention and together with the description serve to explain the principles of the present invention. In the drawings:
[0013] FIG. 1 is a front perspective view of a telephone with a first embodiment of an assistive hearing device of the present invention having a band for connecting to the telephone;
[0014] FIG. 2A is an exploded rear perspective view of the telephone with the first embodiment of the assistive hearing device of FIG. 1 showing the band and a spacer;
[0015] FIG. 2B is a perspective view of a hook and loop fastener for connecting the assistive hearing device to the telephone;
[0016] FIG. 3 is a side elevational view of the telephone with the first embodiment of the assistive hearing device of FIG. 1 ;
[0017] FIG. 4 is a partial side elevational view of the telephone with a partial cross-sectional view taken along line 4 - 4 of the first embodiment of the assistive hearing device of FIG. 1 , the arrows illustrating a direction of sound generated from the voice emitting speaker of the telephone traveling into a sound entrance aperture, through a hollow interior of the assistive hearing device, out of a sound egress aperture, and to a Behind the Ear (BTE) or Receiver in the Canal (RIC) hearing aid of a user also depicted therein;
[0018] FIG. 4A is a top plan view of the first embodiment of he assistive hearing device of FIG. 1 coupled with the band;
[0019] FIG. 4B is a front elevational view of the first embodiment of the assistive hearing device of FIG. 1 coupled with the band;
[0020] FIG. 4C is a side elevational view of the first embodiment of the assistive hearing device of FIG. 1 coupled with the band;
[0021] FIG. 5A is a partial front perspective view of a telephone with a second embodiment of an assistive hearing device of the present invention with a band having sound openings;
[0022] FIG. 5B is a cross-sectional view taken along line 5 B- 5 B of the second embodiment of the assistive hearing device of FIG. 5A with a sliding cover in the closed position;
[0023] FIG. 5C is a cross-sectional view taken along line 5 B- 5 B of the second embodiment of the assistive hearing device of FIG. 5A with the sliding cover in the open position;
[0024] FIG. 6A is a front perspective view of a telephone with a third embodiment of an assistive hearing device of the present invention including a sleeve that fits over the end of the telephone;
[0025] FIG. 6B is an exploded front perspective view of the telephone with the third embodiment of an assistive hearing device of FIG. 6A including the sleeve that fits over the end of the telephone;
[0026] FIG. 7A is a front perspective view of a telephone with a fourth embodiment of an assistive hearing device of the present invention having an angled configuration;
[0027] FIG. 7B is a side perspective view of the telephone with the fourth embodiment of the assistive hearing device of FIG. 7A in use by a user wearing the BTE hearing aid, the sound emanating from an egress aperture of the assistive hearing device placed in proximity to the BTE hearing aid of the user;
[0028] FIG. 7C is a side elevational view of the telephone with the fourth embodiment of the assistive hearing device of FIG. 7A , the arrows illustrating a direction of sound generated from the voice emitting speaker of the telephone traveling into a sound entrance aperture, through a hollow interior of the assistive hearing device, out of a sound egress aperture, and to the BTE hearing aid of the user;
[0029] FIG. 8 is a front elevational view of the telephone with the fourth embodiment of the assistive hearing device of FIG. 7A ;
[0030] FIG. 9 is a side elevational view of the telephone with the fourth embodiment of the assistive hearing device of FIG. 7A ;
[0031] FIG. 10 is a rear perspective view of the telephone with the fourth embodiment of the assistive hearing device of FIG. 7A , showing the sound egress aperture positioned in proximity of the BTE hearing aid of the user;
[0032] FIG. 11 is a front perspective view of a telephone with a fifth embodiment of the assistive hearing device of the present invention;
[0033] FIG. 12 is a cross-sectional view taken along line 12 - 12 of the telephone and the fifth embodiment of the assistive hearing device of FIG. 11 ;
[0034] FIG. 13A is a side perspective view of the telephone with the fifth embodiment of the assistive hearing device having a straight configuration in use by a user wearing a BTE hearing aid, the sound emanating from a sound egress aperture of the assistive hearing device placed in proximity to the BTE hearing aid of the user;
[0035] FIG. 13B is a side elevational view of the telephone with the fifth embodiment of the assistive hearing device of FIG. 11 , the arrows illustrating a direction of sound generated from the voice emitting speaker of the telephone traveling into a sound entrance aperture, through a hollow interior of the assistive hearing device, out of the sound egress aperture, and to the BTE hearing aid of the user;
[0036] FIG. 14 is front elevational view of the telephone with the fifth embodiment of he assistive hearing device of FIG. 11 ;
[0037] FIG. 15 is a side elevational view of the telephone with the fifth embodiment of the assistive hearing device of FIG. 11 ;
[0038] FIG. 16 is another front elevational view of the telephone with the fifth embodiment of the assistive hearing device of FIG. 11 oriented in a horizontal direction relative to the telephone;
[0039] FIG. 17 is a front perspective view of a telephone with a sixth embodiment of the assistive hearing device attached to the telephone by a hook and loop strap;
[0040] FIG. 18 is a cross-sectional view taken along line 18 - 18 of the telephone and the sixth embodiment of the assistive hearing device of FIG. 17 ; and
[0041] FIG. 19 is front perspective view of the telephone with one part of a hook and loop fastener around the sound entrance aperture and a rear perspective view of the fifth embodiment of the assistive hearing device of FIG. 11 with another part of the hook and loop fastener around the voice emitting speaker of the telephone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0042] The detailed description set forth below is intended as a description of various configurations of the present invention and is not intended to represent the only configurations in which the present invention may be practiced. It will be apparent, however, to those skilled in the art that the present invention is not limited to the specific details set forth herein and may be practiced without these specific details.
[0043] Various embodiments of an assistive hearing device according to the present invention are described below. Each of these embodiments serve in redirecting telephonic sound via an acoustical accumulator and director to the microphone of a hearing aid located behind the ear or in the ear canal of the user. To that end, the embodiments of the assistive hearing device employ a sound entrance aperture, a sound egress aperture, and a sound conduit formed by a hollow interior of the devices to transmit telephonic sound to the microphone of a hearing aid.
[0044] FIGS. 1, 2A, 3, and 4 illustrate an assistive hearing device 100 in accordance with a preferred embodiment of the present invention. As shown in FIG. 1 , in accordance with a preferred embodiment, assistive hearing device 100 includes a band 110 , a sound egress aperture 104 , and a spacer 106 . Band 110 is preferably made of an elastic material such as silicone or rubber and is placed around a phone 150 to secure assistive hearing device 100 to phone 150 . In a preferred embodiment, assistive hearing device 100 has molded arcs to engage the circular portion of band 110 . Examples of phone 150 may include conventional telephone handsets, wireless handsets, or a mobile phones.
[0045] Referring to FIG. 2A , spacer 106 of assistive hearing device 100 is positioned against the surface of phone 150 surrounding a sound entrance aperture 102 of assistive hearing device 100 . When placed on phone 150 ( FIG. 4 ), spacer 106 preferably surrounds a voice emitting speaker (or receiver) 152 of phone 150 . Spacer 106 may be in the form of a donut seal, but is not limited to such a configuration.
[0046] Assistive hearing device 100 is fixed relative to phone 150 by band 110 so that sound from voice emitting speaker 152 can be conducted through spacer 106 and into sound entrance aperture 102 for transmission through a hollow interior 108 of assistive hearing device 100 . Spacer 106 is preferably made of a high friction rubber to prevent assistive hearing device 100 and phone 150 from sliding relative to each other.
[0047] In a preferred embodiment, one end of band 110 is adjustable and has a plurality of holes 120 and the opposite end has a plurality of pegs 122 projecting from band 110 . Band 110 is placed around phone 150 and the length of band 110 may be adjusted by securing pegs 122 into selected holes 120 depending on the configuration and size of phone 150 .
[0048] Referring to FIG. 2B , in another preferred embodiment, assistive hearing device 100 includes a band 170 with a hook and loop fastener at its end to removably secure assistive hearing device 100 to phone 150 . One end of band 170 having a hook part 172 is attachable to the opposite end of band 170 having a loop part 174 by positioning and pressing the two ends together. When the two ends are pressed together, band 170 fastens at its ends and binds together assistive hearing device 100 and phone 150 .
[0049] Referring to FIG. 3 , assistive hearing device 100 includes a first portion 111 and a second portion 112 . Assistive hearing device 100 is configured such that second portion 112 is offset approximately 0.25 to 0.75 inches from first portion 111 to permit sound egress aperture 104 to be position proximate a BTE hearing aid 160 . An angled transition portion 114 positioned between first and second portions 111 and 112 creates the offset position of second portion 112 relative to first portion 111 . As depicted in FIG. 4 , the offset position of second portion 112 provides for the transmission of sound from sound egress aperture 104 towards BTE hearing aid 160 in a manner that is not impeded by the user's ear or any other portion other user's head against which phone 150 is placed. The offset configuration offers the added advantage of reducing the chances of muffling the sound in the event the user presses assistive hearing device 100 against a portion of the user's ear or head to block sound egress aperture 104 .
[0050] Referring to FIG. 4 , with assistive hearing device 100 coupled to phone 150 , sound can be directed from voice emitting speaker 152 of phone 150 to a position more proximate to the microphone of BTE hearing aid 160 being worn by a user. Sound entrance aperture 102 is placed proximate the bottom of assistive hearing device 100 . Sound egress aperture 104 is placed proximate the top end of assistive hearing device 100 . Sound entrance aperture 102 and sound egress aperture 104 communicate with one another via a hollow interior 108 that extends through first portion 111 , second portion 112 , and angled transition portion 114 . Sound entrance aperture 102 of assistive hearing device 100 surrounds voice emitting speaker 152 of phone 150 to capture sound from voice emitting speaker 152 . As indicated by the arrows in FIG. 4 , sound from voice emitting speaker 152 of phone 150 enters sound entrance aperture 102 , is conducted through hollow interior 108 of assistive hearing device 100 , and exits sound egress aperture 104 proximate the microphone of BTE hearing aid 160 . As such, sound (such as the voice of a caller) can be better picked-up by BTE hearing 160 aid and the user is able to better hear the voice of the caller via BTE hearing aid 160 when using phone 150 .
[0051] Referring to FIGS. 4A-4C , various views of assistive hearing device 100 coupled with band 110 are shown. Band 110 can have a thickness B of approximately 0.08 inches, a minimum width of approximately 0.50 inches, and a maximum width E of approximately 0.98 inches. Assistive hearing device 100 can have a width A of approximately 1.19 inches at the top and a height F of approximately 2.09 inches, with the molded arcs having a width C of approximately 0.87 inches. Second portion 112 is preferably offset from first portion 111 by a distance G of approximately 0.63 inches.
[0052] Referring to FIGS. 5A-5C , alternatively, assistive hearing device 100 ′ has a band 110 ′ that includes sound openings 130 , a lever 132 , and a sliding cover 134 . Sound openings 130 are for a user without the need for BTE hearing aid 160 . Sound openings 130 can be opened or closed by moving sliding cover 134 with lever 132 . In a closed position, sliding cover 134 covers sound openings 130 . In an open position, sound from voice emitting speaker 152 of phone 150 may be transmitted through sound openings 130 and directly to the ear of a user adjacent to the ear opening leading to the ear canal.
[0053] Referring to FIGS. 6A and 6B , another preferred embodiment of an assistive hearing device is generally referred to by the number 200 . Assistive hearing device 200 includes a sleeve 202 that fits over the end of phone 150 , preferably surrounding voice emitting speaker 152 of phone 150 . Sleeve 202 is configured to form a friction fit with the end of phone 150 . Sound from phone 150 is conducted through assistive hearing device 200 to BTE hearing aid 160 in a similar manner described above in connection with assistive hearing device 100 .
[0054] Referring to FIG. 7A-7C , another preferred embodiment of an assistive hearing device is generally referred to by the number 300 . Assistive hearing device 300 includes a sound entrance aperture 302 , a sound egress aperture 304 , an adhesive portion 306 , and a hollow interior 308 . In a preferred embodiment, sound entrance aperture 302 is proximate, but spaced apart from one end of assistive hearing device 300 . Sound egress aperture 304 is proximate, but spaced apart from the opposite end of assistive hearing device 300 . Sound entrance aperture 302 and sound egress aperture 304 are on opposite facing sides of assistive hearing device 300 . Assistive hearing device 300 includes a first portion 310 , a second portion 312 , and an angled transition portion 314 . Assistive hearing device 300 preferably has an angled or offset configuration with first portion 310 adapted to be coupled to phone 150 and second portion 312 being offset from first portion 310 . Second portion 312 extends beyond phone 150 when assistive hearing device 300 is coupled to a phone 150 .
[0055] Referring to FIGS. 7B, 7C, and 10 , with assistive hearing device 300 coupled to phone 150 , sound can be directed from voice emitting speaker 152 of phone 150 to a position more proximate to the microphone of BTE hearing aid 160 being worn by a user. As indicated by the arrows in FIG. 7C , sound from voice emitting speaker 152 of phone 150 enters sound entrance aperture 302 , is conducted through hollow interior 308 of assistive hearing device 300 , and exits sound egress aperture 304 proximate the microphone of BTE hearing aid 160 . As such, sound (such as the voice of a caller) can be better picked-up by BTE hearing aid 160 and the user is able to better hear the voice of the caller via the microphone of BTE hearing aid 160 when using phone 150 .
[0056] Referring to FIGS. 8 and 9 , assistive hearing device 300 is configured such that second portion 312 is offset approximately 0.25 inches from first portion 310 to permit sound egress aperture 304 to be positioned proximate BTE hearing aid 160 . Angled transition portion 314 between first and second portions 310 and 312 creates the offset position of second portion 312 relative to first portion 310 . The offset position of second portion 312 provides for the transmission of sound from sound egress aperture 304 towards BTE hearing aid 160 in a manner that is not impeded by the user's ear or any other portion other user's head against which phone 150 is placed. The offset configuration offers the added advantage of reducing the chances of muffling the sound in the event the user presses assistive hearing device 300 against a portion of the user's ear or head to block sound egress aperture 304 .
[0057] In a preferred embodiment, assistive hearing device 300 is coupled to phone 150 by adhesive portion 306 which may be in the form of a closed cell foam “donut” seal that contains an adhesive material having an approximate thickness of ⅛ inches that bonds to a surface that surrounds sound entrance aperture 302 . When placed on phone 150 , adhesive portion 306 preferably surrounds voice emitting speaker 152 and adheres to phone 150 . In this manner, assistive hearing device 300 is fixed relative to phone 150 and sound from voice emitting speaker 152 can be conducted through the seal created by adhesive portion 306 and into sound entrance aperture 302 for transmission through assistive hearing device 300 .
[0058] Adhesive portion 306 preferably includes an adhesive material that removably bonds to a surface that surrounds sound entrance aperture 302 of assistive hearing device 300 to a surface of phone 150 that at least partially surrounds voice emitting speaker 152 of phone 150 . Preferably, adhesive portion 306 includes an open area in communication with sound entrance aperture 302 and voice emitting speaker 152 to conduct sound transmitted from voice emitting speaker 152 through sound entrance aperture 302 and into hollow interior 308 of assistive hearing device 300 . The adhesive material may be derived from any material with physical and/or chemical properties that facilitate attachment of a mobile phone surface to assistive hearing device 300 . One or more removal strips (not shown) can be removably attached to the adhesive material. The removal strip may be constructed from any material with properties that allow the removal strip to be removably attached to the adhesive material without adversely affecting the adhesive properties of the adhesive material.
[0059] In a preferred embodiment, assistive hearing device 300 has a length in the range of approximately 2.5 inches to 3.0 inches, with 3.0 inches being preferred; a width in the range of approximately 0.5 inches to 1.0 inches, with 1.0 inches being preferred; and a depth of approximately 0.15 inches to 0.25 inches, with 0.25 inches being preferred. Sound entrance aperture 302 has a maximum dimension in the range of approximately 0.25 inches to 0.5 inches, with 0.5 inches being preferred. Sound egress aperture 304 has a maximum dimension in the range of approximately 0.5 inches to 1.0 inches, with 1.0 inches being preferred. Sound entrance aperture 302 and sound egress aperture 304 being spaced apart in the range of approximately 1.75 inches, with 1.75 inches being preferred.
[0060] In a preferred embodiment, assistive hearing device 300 is shown to have a generally rectangular configuration, but is not limited to such a configuration. Other shapes and configurations providing for a sound entrance aperture 302 on one side proximate one end, a sound egress aperture 304 on an opposite side proximate an opposite end, and communication therebetween via a hollow interior 308 suitable for the intended purpose of communicating sound from voice emitting speaker 152 to BTE hearing aid 160 or RIC hearing aid are within the scope of the present invention,
[0061] Referring to FIGS. 11, 12, 13A, 13B, 14, and 15 , another preferred embodiment of assistive hearing device 400 is shown having a generally rectangular configuration similar to assistive hearing device 300 , except without the offset. Accordingly, the description herein with respect to assistive hearing device 300 is applicable to assistive hearing device 300 and is incorporated here by reference. Reference numerals identifying features of assistive hearing device 400 that correspond to like reference numerals identifying features of assistive hearing device 300 are used to denote similar features.
[0062] Referring to FIG. 16 , assistive hearing device 400 is shown in an alternative position when coupled to phone 150 . In this positioning, assistive hearing device 400 is in a generally horizontal position with sound egress aperture 404 extending from a side of phone 150 as compared to the top of phone 150 .
[0063] Referring to FIGS. 17 and 18 , assistive hearing device 400 alternatively may be secured to phone 150 via a strap 460 . One end of strap 460 is secured to a first side of assistive hearing device 400 via a first loop connected to assistive hearing device 400 . Strap 460 is then placed around phone 150 and the opposite end is secured to an opposite side of assistive hearing device 400 via a second loop connected to assistive hearing device 400 . The end of strap 410 may be secured by hook and loop fasteners such as Velcro to prevent loosening. In this embodiment, assistive hearing device 400 may be secured to phone 150 with a hook and loop fasteners 462 and 464 to hold assistive hearing device 400 in position on phone 150 .
[0064] Referring to FIG. 19 , alternatively, adhesive portion 406 need not be used, but it is appreciated that a rubber seal may be secured to assistive hearing device 400 surrounding the sound entrance aperture 402 to facilitate transmission of the sound into assistive hearing device 400 . | An assistive hearing device having a sound entrance aperture on a first side, the sound entrance aperture placed against a voice emitting speaker (or receiver) of the telephone, a sound egress aperture on a second side opposite the first side, and the sound egress aperture located within closer proximity to a hearing device relative to the sound entrance aperture and the speaker to facilitate transmission of sound from the speaker to the hearing device located nearby is provided. The assistive hearing device includes a hollow interior, which connects the sound entrance and sound egress apertures, and allows sound waves entering the sound entrance aperture to travel through the hollow interior and exit the sound egress aperture. The sound entrance aperture of the assistive hearing device surrounds the speaker of the mobile device to capture sound waves transmitted from the speaker. The transmitted sound waves enter the sound entrance aperture, traverse through the hollow interior of the assistive hearing device and exit the sound egress aperture, which is located within closer proximity to the hearing device microphone relative to the sound entrance aperture and to the telephone speaker, | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an exhaust gas measuring apparatus which obtains the emission amount of exhaust gases emitted from an engine.
2. Description of the Related Art
In an automobile, the emission amount of exhaust gases emitted from the engine is measured and evaluated in an exhaust gas test mode including acceleration and deceleration by using an exhaust gas measuring apparatus.
In the exhaust gas measuring apparatus, exhaust gases diluted with air in the atmosphere are collected by using a sampling unit, as disclosed in Jpn. UM Appln. KOKAI Publication No. 4-116620.
Most exhaust gas measuring apparatuses collect exhaust gases from the engine by using sampling units employing a method called CVS (Constant Volume Sampler).
More specifically, as shown in FIG. 5, a sampling unit a has a passage "d" interposed with a venturi b and a filter c and open to the atmosphere, a blower e for taking in air in the atmosphere into the passage d, and a passage h for introducing the exhaust gases from a test vehicle (automobile) g traveling on a chassis dynamometer f in a predetermined exhaust gas test mode into the passage d. The exhaust gases emitted from the engine are mixed in air flowing in the passage d at a predetermined flow rate with the suction force of the blower e.
The exhaust gases are collected at a portion between the passage h and the venturi b through a sampling venturi i, a passage j, and a pump (not shown), and are stored in a bag (not shown) during the test mode.
At this time, air in the atmosphere is also collected in a bag (not shown) through another passage k and a pump (not shown).
The net exhaust gas concentration is obtained with an analyzer (not shown) by subtracting regulated materials (impurities), e.g., HC, CO, and NO X , contained in the collected air from the collected, diluted exhaust gases.
The net exhaust gas concentration, the flow rate coefficient of the venturi b, and the amount of diluted exhaust gases in the standard state obtained by measurement under the temperature and pressure of the inlet port of the venturi b are subjected to calculation to measure the emission amount of exhaust gases emitted from the test vehicle g.
This allows measurement of the emission amount of exhaust gases at high precision.
However, a demand has arisen for a further improvement in this precision.
This is because air pollution caused by automotive emission products is worsening each year, leading to gradual worldwide reinforcement of exhaust gas regulations. In recent years, in some areas, strict regulations have been legislated to restrict emission of harmful substances to almost zero. California State, U.S.A. legislated strict regulations which stipulate that the emission amount of harmful substances from automobiles be set to almost zero from '97 model year vehicles.
For this reason, the influence of the diluting air to the measurement supplied to the sampling unit has become an issue.
More specifically, air in the atmosphere contains many impurities that interfere with measurement of the emission amount of exhaust gases.
When air in the atmosphere is directly supplied to a sampling unit as diluting air, high measurement precision cannot be ensured because of the influence of impurities, e.g., HC, CO, and NO X , in the atmosphere. As a consequence, it is impossible to measure exhaust gas with accuracy as high as required by the regulations.
As a countermeasure against this, it has been proposed to connect an air purifier n to diluting air inlet port m of a sampling unit a, as shown in FIG. 6.
More specifically, the air purifier n is constituted by a cleaner p and a blower fan q, and removes the impurities, e.g., HC, CO, and NO X , in air taken in from the atmosphere with the blower fan q, with the cleaner p, thereby purifying the air.
When the purified air is supplied to the sampling unit a as a diluting air in place of air in the atmosphere, the exhaust gas measuring apparatus has high exhaust gas measuring precision.
The air purifier n is an expensive and large apparatus. Further, its running cost is high because expendables such as the filters used in the cleaner p are expensive.
The cleaner p need not be used in the case where the exhaust gas measuring can meet the test requirements or the requirements stipulated by regulations or test apparatus, without measuring the exhaust gas at a high precision.
And, the exhaust gas measuring apparatuses are provided in units of a plurality of test benches, e.g., the first and second test benches, as shown in FIG. 7, so that many tests can be performed. An automobile manufacturer usually has several to ten-odd sets of test benches.
If air purifiers n are to be provided in units of sampling units a, as described above, a rather high cost is required for this purpose.
In addition, spaces for installing the air purifiers n must be maintained in units of test benches.
SUMMARY OF THE INVENTION
One object of the present invention is to provide an exhaust gas measuring apparatus in which either purified air or the air in the atmosphere is used as purified diluting air in the CVS sampling unit, in accordance with the measurement precision required, and which can measure exhaust gas with high accuracy at low cost.
Another object of the invention is to provide an exhaust gas measuring apparatus in which purified diluted air is supplied from a small number of air purifiers to a greater number of sampling units, by using the air purifiers effectively and efficiently.
According to the present invention, there is provided an exhaust gas measuring apparatus comprising:
an atmosphere introducing unit for taking in air in the atmosphere as diluting air;
an air purifier for taking in and purifying air in the atmosphere, thereby generating diluting air;
a diluting unit for diluting a portion of exhaust gases of an engine with the diluting air;
selecting means for causing either one of the atmosphere introducing unit and the air purifier to communicate with the diluting unit;
a sampling unit for collecting diluted exhaust gases; and
measuring means for obtaining an emission amount of collected exhaust gases.
Additional objects and 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. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate a presently preferred embodiment of the invention and, together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain the principles of the invention.
FIG. 1 is a diagram for explaining an exhaust gas measuring apparatus according to the first embodiment of the present invention;
FIG. 2 is a diagram showing the arrangement of the air purifier in detail;
FIG. 3 is a diagram for explaining the structure around the sampling unit of the exhaust gas measuring apparatus;
FIG. 4 is a flow chart for explaining a control operation for appropriately supplying purified diluting air supplied from an air purifier to a sampling unit in operation;
FIG. 5 is a diagram for explaining a conventional exhaust gas measuring apparatus;
FIG. 6 is a diagram for explaining an exhaust gas measuring apparatus in which an air purifier is connected to its sampling unit to dilute exhaust gases, so that the measurement precision is improved; and
FIG. 7 is a diagram for explaining a facility in which a plurality of sampling units each having the air purifier are provided.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described by way of an embodiment shown in FIGS. 1 to 4.
FIG. 1 shows the overall schematic arrangement of an exhaust gas measuring apparatus to which the present invention is applied, in which reference numeral 1 denotes an air purifier installed in, e.g., the machine room of a building.
A main body 1a of the air purifier 1 has an air inlet port 2 open to the atmosphere and an air outlet port 3.
A blower fan 4 and a cleaner 5 are disposed in the main body 1a. The blower fan 4 takes in air in the atmosphere from the air inlet port 2 and supplies it to the air outlet port 3 with a variable air blowing performance. The cleaner 5 removes impurities, e.g., HC, CO, and NO X , contained in the intake air.
The arrangement of the air purifier 1 will be described in detail with reference to FIG. 2. In FIG. 2, a pipe 51 connected to an inlet port 2 is connected to a suction fan 4. Air in the atmosphere is drawn by the suction fan 4. The downstream side of the suction fan 52 is connected to an electric heater 54 and a catalyst 55 through a U-shaped pipe 53. The electric heater 54 heats the atmosphere drawn by the suction fan 52 to about 400° C.
The catalyst 55 is an oxidizing catalyst for generating H 2 O and CO 2 by complete combustion of HC and CO. Since the electric heater 54 also serves to activate the catalyst, it is placed on the upstream side of the catalyst 55.
The downstream side of the catalyst 55 is connected to a cooling unit 57 through an L-shaped pipe 56. Air is cooled by the cooling unit 57.
The downstream side of the cooling unit 57 is connected to an activated carbon adsorption layer 59 through a pipe 58. NO X is removed by the activated carbon adsorption layer 59.
The air outlet port 3 is connected to a main duct 7 (corresponding to the main passage) disposed on, e.g., the ceiling of the first floor of the building, through a connecting duct 6.
The main duct 7 is connected to sampling units 11, 11a, . . . provided in units of test benches (to be described later) installed on the floor of the first floor. Air purified by the air purifier 1 is sent to the respective sampling units 11, 11a, . . . through the main duct 7.
For example, one end portion of the main duct 7 is closed with a detachable blind cover 8 to allow extension of the main duct 7.
The air purifier 1 is provided with a controller 1b (comprising a microcomputer and its peripheral circuits and corresponding to a flow rate controller) for supplying purified air at an appropriate flow rate in accordance with the number of sampling units 11, 11a, . . . in operation.
More specifically, the controller 1b is connected to the blower fan 4. The controller 1b is also connected to a sensor 7a for detecting a pressure P 1 in the main duct 7 and a sensor 7b for detecting an atmospheric pressure P 2 .
The controller 1b has a function of controlling the rotation speed of the blower fan 4 in order to set a difference ΔP between the pressures P 1 and P 2 at a substantially constant value, so that a necessary supply gas volume can always be ensured.
With this function, a necessary amount of diluting air is automatically adjusted in accordance with the number of sampling units 11, 11a, . . . in operation and supplied to the main duct 7.
A plurality of test benches, e.g., two sets of test benches A and B (the first and second test benches) are disposed on the floor surface of the first floor.
The first and second test benches A and B employ the same structure.
FIG. 3 shows the structure around one of the test benches, e.g., the test bench A.
The structure around the test bench A will be described. Reference numeral 9 denotes a chassis dynamometer for driving a test vehicle 10 (corresponding to the automobile) while the vehicle body stands still.
The sampling unit 11 is installed near the chassis dynamometer 9.
The sampling unit 11 employs, e.g., a CVS (Constant Volume Sampler).
The sampling unit 11 will be described. A main body 12 of the sampling unit 11 has an inlet port 13 for taking in diluting air and an outlet port 14 open to the atmosphere.
The inlet port 13 is connected to a branch duct 15 (corresponding to a branch passage) branching from the main duct 7 for each sampling unit. Air purified by the air purifier 1 can be taken in as the diluting air through the inlet port 13.
A passage 16 (corresponding to the first passage portion) is provided in the main body 12 so that the inlet port 13 and the outlet port 14 communicate with each other.
A mixing unit 18, and a cyclone 19 for removing dust are disposed in the passage 16 from the upstream side in this order. A turbo blower 20 (corresponding to a suction unit) for drawing air to the downstream side is disposed on the downstream side of the passage 16. The turbo blower 20 draws diluting air from the inlet port 13.
A connecting pipe 23 (corresponding to the second passage portion) which is to be detachably connected to an exhaust pipe 21 (through which exhaust gases from an engine 22 mounted on the test vehicle 10 are emitted into the atmosphere) extends from the mixing unit 18. Thus, the exhaust gases emitted from the engine 22 are diluted by mixing with diluting air flowing through the passage 16.
A venturi unit 24 for setting an appropriate diluting rate is inserted at a passage portion between the turbo blower 20 and cyclone 19 on the downstream side of the cyclone 19.
More specifically, the venturi unit 24 has a venturi setting portion 25 arranged where the venturi unit 24 is set, and a plurality of types of venturis attachable on and detachable from the venturi setting portion 25. The plurality of types of venturis are, e.g., three types of venturis, including a large venturi 26, a medium venturi 27, and a small venturi 28 that are classified in accordance with the specific flow rate performance.
The turbo blower 20 has such a suction force that sufficiently maintains a critical flow regardless of which one of the venturis 26 to 28 is selected. When one of the venturis 26 to 28 is selected, a gas mixture (a mixture of the exhaust gases and the diluting air) flows through the passage 16 at a predetermined flow rate determined by the selected venturi.
In other words, the necessary supply amount of diluting air is adjusted by setting a venturi selected from the large, medium, and small venturis 26 to 28 to the venturi setting portion 25.
Hence, an appropriate diluting rate is selected by properly using the three types of venturis 26 to 28 in accordance with the exhaust gas test mode and the size (test conditions) of the engine 22.
A measuring system 40 for measuring the amount of diluted exhaust gases is provided on the upstream side of the venturi setting portion 25 which is maintained at a predetermined flow rate.
The measuring system 40 is constituted by, e.g., a sensor unit 41, an arithmetic unit 42, and a flow rate display unit 43. The sensor unit 41 measures the temperature and pressure at the inlet port of the venturi. The arithmetic unit 42 calculates the amount of diluted exhaust gases in the standard state based on the information on the temperature and pressure, the flow rate coefficient of the venturi, and the time. The flow rate display unit 43 displays the calculation result.
Hence, a diluted exhaust gas amount necessary for obtaining the emission amount of exhaust gases can be obtained.
Furthermore, a collecting unit 30 is provided on the upstream side of the venturi setting portion 25.
In the collecting unit 30, diluted exhaust gases (a gas mixture of the exhaust gases and diluting air) are collected from a sampling venturi 32 disposed on the upstream side of the venturi setting portion 25 at a predetermined flow rate with the suction force of a suction pump 31 disposed outside the passage, and is stored in a bag 33.
With this collecting structure, in the exhaust gas test mode, the diluted exhaust gases are stored in the bag 33, so that information on the average concentration of the exhaust gas in the exhaust gases test mode can be obtained.
A collecting unit 36 for the diluting air is interposed on the upstream side of the mixing unit 18. In the collecting unit 36, only the diluting air is collected with a Suction pump 34 and stored in a bag 35 through a passage 38.
With this collecting unit 36, in the exhaust gas test mode, the regulated materials (impurities), e.g., HC, CO, and NO X , remaining in the purified air (diluting air) are stored.
Gases in the bags 33 and 35 are analyzed by an analyzer 37 (constituting a measuring means together with the measuring system 40), so that the net exhaust gas concentration can be obtained.
More specifically, the analyzer 37 has a function of obtaining the net exhaust gas concentration by subtracting the regulated materials (impurities), e.g., HC, CO, and NO X , contained in the purified air collected in the bag 35 from the diluted exhaust gases collected in the bag 33, and a function of obtaining the emission amount of exhaust gases by calculation of the net exhaust gas concentration and the prescribed diluted exhaust gas amount in the standard state.
Hence, the emission amount of exhaust gases emitted from the test vehicle 10 is obtained.
As shown in FIG. 1, a duct 44 (corresponding to a passage for taking in air in the atmosphere) extending to the machine room is connected to the outlet port of the branch duct 15 to communicate with it.
The distal end portion of the duct 44 is connected to an atmosphere introducing unit 45 installed on, e.g., the rooftop of the building and incorporating a filter.
The duct 44 and the branch duct 15 are respectively provided with valve units, e.g., motor-driven first and second valves 46 and 47 (switching valve units; corresponding to valve units) for opening/closing the ducts 44 and 15.
The purified air from the air purifier 1 or air in the atmosphere is selectively supplied to the sampling unit 11 as diluting air through the first and second valves 46 and 47, or purified air is supplied to the sampling unit 11 at a flow rate corresponding to the diluting rate.
More specifically, the first and second valves 46 and 47 are connected to a controller 48 (comprising, e.g., a microcomputer and its peripheral equipment) provided to each sampling unit 11.
An operating unit 49 provided to each controller 48 has various types of operation button portions, e.g., a power button portion for turning on/off the sampling unit 11, a button portion for setting an exhaust gas test mode which uses air in the atmosphere as the diluting air, a button portion for setting an exhaust gas test mode which uses purified air as the diluting air, and a venturi selection button portion (not shown) for inputting which venturi is used.
The controller 48 has the following functions:
The function of stopping the operation of the sampling unit 11 and driving the first and second valves 46 and 47 to fully close them when the power button portion is turned off.
The function of driving the first and second valves 46 and 47 to fully open and fully close, respectively, when the button portion of an exhaust gas test mode which uses air in the atmosphere as the diluting air is turned on.
The function of driving the first valve 46 to fully close and the second valve 47 to fully open, semi-open, or slightly open it in accordance with which one of the large, medium, and small venturis 26 to 28 is selected by the venturi selection button portion when the button portion of an exhaust gas test mode which uses purified air as the diluting air is turned on.
The function of operating the sampling unit 11 in accordance with the exhaust gas test mode when the power button portion is turned on.
With these functions, only by operating the operating unit 49, purified air from the air purifier 1 or air in the atmosphere is used as the diluting air, or purified air at a predetermined flow rate corresponding to the selected one of the large, medium, and small venturis 26 to 28 is taken in from the air purifier 1.
The second test bench B also employs this structure. Necessary purified air can be supplied to a plurality of sampling units, e.g., two sampling units 11 and 11a in this case, with one air purifier 1, which is a necessary minimum number.
Regarding information output upon operation of the operation buttons of the operating unit 49, a signal output from the operation unit (not shown) of the sampling unit 11 or from an automatic measuring apparatus (not shown), which is of the same type as that output from the operating unit 49, may be directly connected to the controller 48.
The air purifier 1 can purify and blow a maximum diluting air amount necessary for the plurality of sampling units.
Referring to FIG. 1, suffix "a" is added to the reference numeral of each component around the second test bench B, so that the first and second test benches A and B can be discriminated from each other.
The operation of the exhaust gas measuring apparatus having the above arrangement will be described.
In this case, assume that the emission amount of exhaust gases of each of the test vehicles 10 and 10a in the exhaust gas test mode is to be measured by using both of the first and second test benches A and B and using purified air as the diluting air.
As a preparation for this, for example, in the first test bench A, the connecting pipe 23 is connected to the exhaust pipe 21 of the test vehicle 10 placed on the chassis dynamometer 9. An appropriate venturi, e.g., the small venturi 28, is selected from the three venturis 26 to 28 in accordance with the exhaust gas test mode and the size (test conditions) of the engine 22 of the test vehicle 10, and is set in the venturi unit 24, so that an appropriate diluting ratio (the ratio of exhaust gas amount emitted from the test vehicle 10 to the amount of diluting air) is obtained. In this selection, a consideration is made so that the water content in the exhaust gases will not be condensed and the measuring precision will not become low (the exhaust gas measurement concentration will not become excessively low).
When the small venturi 28 is set, the necessary supply amount of diluting air for the sampling unit 11 is determined.
Similarly, in the second test bench B, a connecting pipe 23a is connected to an exhaust pipe 21a of a test vehicle 10a placed on a chassis dynamometer 9a, and an appropriate venturi is selected from three venturis 26 to 28 and set in the venturi portion of the sampling unit 11a, so that an appropriate diluting ratio (the ratio of exhaust gas amount emitted from the test vehicle 10 to the amount of diluting air) is obtained.
Subsequently, the operating units 49 and 49a provided in units of test benches are operated.
This operation is done when the type of venturi selected with the venturi selection button is input, the button portion of the exhaust gas test mode which uses purified air as the diluting air is turned on, and the power button portion is turned on.
In response to this operation, the purified air draft system is set, and the air purifier 1 and the respective sampling units 11 and 11a are operated.
FIG. 4 shows the control flow chart of this purified air draft system.
How to obtain the emission amount of exhaust gases will be described by using this control flow chart. Upon reception of information input from the operating unit 49, the controller 48 of the sampling unit 11 checks whether the test is to be performed in accordance with whether the power button portion of the operating unit 49 is turned on, as shown in step S1.
Since the power button portion of the operating unit 49 is ON, the flow advances to step S2 in response to this ON signal.
In step S2, whether the test requires purified air is checked in accordance with whether the button portion of the exhaust gas test mode which uses purified air as the diluting air is turned on.
Since the button portion of the exhaust gas test mode which uses purified air as the diluting air is ON, it is determined from this ON signal that highly precise exhaust gas measurement which uses purified air is to be performed, and the flow advances to step S3.
In steps S3 and S4, which venturi is used is checked.
Since an input indicating that the small venturi 28 is set to the venturi setting portion 25 has been made in the operating unit 49, the controller 48 enters step S5 via steps S3 and S4.
In step S5, the controller 48 drives the first valve 46 to a fully closed position and the second valve 47 to a slightly opened position so that a passage for the purified air is ensured and a supply amount of diluting air corresponding to the specific flow rate of the small venturi 28 is ensured.
In this manner, the purified air draft system of the first test bench A is set.
The purified air draft system of the second test bench B is also set in the same manner under the control of a controller 48a of the sampling unit 11a.
When the sampling unit (non-operating sampling unit) is not used, i.e., is stopped, both the first and second valves 46 and 47 (46a and 47a) are fully closed by the OFF signal from the power button portion which is input through the controller 48 (48a) (step S8).
By these control operations, a preparation for supplying only necessary amounts of diluting air to the sampling units 11, 11a is done.
Thereafter, the air purifier 1 and the sampling units 11 and 11a are operated.
Upon operation of the air purifier 1, air in the atmosphere is taken in by the blower fan 4, and any impurities contained in this air are removed by the cleaner 5, thereby purifying the air. This purified air is supplied from the connecting duct 6 to the respective branch ducts 15 and 15a through the main duct 7.
In the sampling unit 11, the turbo blower 20 is activated to draw air in the passage 16 to be exhausted to the atmosphere.
Then, the flow velocity of the gas flowing through the small venturi 28 is maintained at a critical flow, and the gas in the passage 16 flows while it maintains a predetermined flow rate determined by the small venturi 28.
With the suction force generated at this time, the purified diluting air is taken in from the inlet port 13 and reaches the mixing unit 18.
At this time, on the chassis dynamometer 9 of the first test bench A, the test vehicle 10 is being driven in accordance with the exhaust gas test mode.
The exhaust gases emitted from the test vehicle 10 reach the mixing unit 18 through the connecting pipe 23, and are diluted as they are mixed with the diluting air flowing through the mixing unit 18.
When this diluted exhaust gases pass through the cyclone 19, dust in the diluted exhaust gases is removed.
The diluted exhaust gases pass through the small venturi 28 and are emitted to the atmosphere from the turbo blower 20.
The temperature and pressure of the diluted exhaust gases flowing at the predetermined flow rate are detected by the sensor unit 41 at the inlet side of the small venturi 28.
The arithmetic unit 42 performs a calculation based on the information on temperature and pressure, the flow rate coefficient of the venturi, and the time, to obtain the amount of diluted exhaust gases in the standard state. The flow rate display unit 43 displays the amount of diluted exhaust gases in this exhaust gas test mode.
Meanwhile, both the sampling suction pumps 31 and 34 are in operation.
With the suction force of the suction pump 31, the sampling venturi 32 draws the diluting air maintained at a critical flow.
The diluted exhaust gases flowing in the passage 16 are collected through the sampling venturi 32 and a collection pipe 32a, and are stored in the bag 33 at a predetermined flow rate in the exhaust gas test mode.
The diluting air before being mixed with the exhaust gases is collected by the suction force of the suction pump 34, and is stored in the bag 35 in the exhaust gas test mode in the same manner.
The analyzer 37 calculates the net exhaust gas concentration by subtracting the regulated materials (impurities), e.g., HC, CO, and NO X , contained in the purified air collected in the bag 35 from the diluted exhaust gases collected in the bag 33.
The net exhaust gas concentration and the prescribed diluted exhaust gas amount in the standard state metered by the small venturi 28 are subjected to calculation by using the analyzer 37, thereby obtaining the emission amount of exhaust gases emitted from the test vehicle 10 traveling in the exhaust gas test mode.
This measurement is performed by the second test bench B as well in the same manner, thereby obtaining the emission amount of exhaust gases emitted from the test vehicle 10a.
While the sampling units 11 and 11a are operating in this manner, the controller 1b of the air purifier 1 controls the rotation speed of the blower fan 4 by detecting the pressure P 1 in the main duct 7 and the atmospheric pressure P 2 and monitoring the pressure difference Δ between them, so that necessary diluting air is supplied.
When the two sampling units 11 and 11a operate, the blower fan 4 is controlled to increase its rotation speed so that a necessary amount of diluting air is always ensured.
With this control, the exhaust gas test can be performed well in which one air purifier 1 is used and two sampling units 11 and 11a (test benches A and B) are used simultaneously.
When one of the two test benches, e.g., the test bench B, is stopped, the sampling unit 11a of the test bench B is stopped, and the first and second valves 46a and 47a are fully closed. Simultaneously, the controller 1b of the air purifier 1 decreases the rotation speed of the blower fan 4 to suppress variations in pressure-difference ΔP occurring upon closing of the branch duct 15a, thereby ensuring the diluting air amount which is necessary by only the sampling unit 11.
Hence, even when one air purifier 1 and one sampling unit 11 (test bench A) are used, the exhaust gas test can be performed well.
When an exhaust gas test is performed which does not require high precision, unlike in a case wherein purified air is used as the diluting air, and air in the atmosphere is directly used as the diluting air, the button portions of the exhaust gas test mode using air in the atmosphere as the diluting air, which are located on the operating units 49 and 49a of the test benches that are to perform this test, may be turned on, and the power button portion may be turned on.
Then, the first and second valves 46 and 47 of these test benches are respectively opened and closed (step S9 of FIG. 4), so that the ducts 44 are opened.
Upon this operation, the sampling units 11 and 11a take in air in the atmosphere as the diluting air from the atmosphere introducing unit 45.
In this manner, with the structure of supplying the purified air from the air purifier 1 to the sampling units 11 and 11a through the main duct 7, purified diluting air can be appropriately supplied, by effectively using a small number of air purifiers 1 (one in this case), to the sampling units 11 and 11a that are larger in number than the air purifiers 1.
This means that even if a plurality of sampling units 11, 11a, . . . are employed, the number of air purifiers can be a necessary minimum, leading to a rather low cost. Also, spaces necessary for installing the air purifiers 1 can be small, leading to down sizing of the exhaust gas measuring apparatus.
In addition, regarding the structure using the main duct 7, if the blind cover 8 of the main duct 7 is removed and the main duct 7 is extended, as indicated by an alternate long and two dashes line in FIG. 1, the number of test benches can be increased easily.
In measurement of the emission amount of exhaust gases, the net exhaust gas concentration is calculated by subtracting the impurities in the diluting air from the collected exhaust gases. The diluted exhaust gas amount is measured, and the net exhaust gas concentration and the diluted exhaust gas amount are subjected to calculation to obtain the emission amount of exhaust gases. As a consequence, when purified diluting air is used, a highly precise emission amount of exhaust gases can be obtained.
When the blowing flow rates of the sampling units 11, 11a, . . . for the air purifier 1 are controlled by controlling the capacity (rotation speed) of the blower fan 4 that substantially stabilizes the pressure difference ΔP between the atmospheric pressure and the internal pressure of the main duct 7, a necessary diluting air amount in accordance with the number of operating sampling units 11, 11a, . . . can be obtained from the air purifier 1 with a simple control operation.
If the branch ducts 15, 15a, . . . are controlled by the second valves 47, 47a, . . . that are opened and closed when the sampling units 11, 11a, . . . are operative and non-operative, respectively, thereby introducing the diluting air to the operating sampling units 11, 11a, . . . , then the branch ducts 15, 15a, . . . can be reliably opened/closed in accordance with the operative/non-operative states of the sampling units 11, 11a, . . . with a simple structure.
If a structure that introduces air in the atmosphere to the sampling units 11, 11a, . . . by using the ducts 44 and the first valves 46, 46a, . . . is employed, exhaust gas measurement directly using air in the atmosphere as the diluting air, which complies with the conventional exhaust gas regulations, can also be performed.
To collect the diluted exhaust gases, a structure is employed in which the diluting air is drawn with the turbo blower 20, the diluting air is mixed with the exhaust gases from the engine, and a portion of the diluted exhaust gases is collected. Therefore, a predetermined volume of diluted exhaust gas can be collected with a simple structure.
In addition, if the venturi unit 24 capable of adjusting the diluting ratio of the exhaust gases is provided on the upstream side of the turbo blower 20 and the open degree of the second valve 47 is adjusted in accordance with the present diluting ratio when the sampling units 11, 11a, . . . are in operation, the emission amount of exhaust gases can be measured for exhaust gases which are diluted with an appropriate diluting ratio.
In the above embodiment, two sampling units 11 and 11a are connected to one air purifier 1. However, the present invention is not limited to this, and more than two sampling units may be connected to one air purifier. Also, even if two air purifiers are employed and sampling units larger in number than the air purifiers, i.e., three or more sampling units, are connected to the two air purifiers through a main duct, the same effect as that of the embodiment described above can be obtained.
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 devices shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | An exhaust gas measuring apparatus includes an atmosphere introducing unit, an air purifier, a diluting unit, selecting means, a sampling unit, and measuring means. The atmosphere introducing unit takes in air in the atmosphere as diluting air. The air purifier takes in and purifies air in the atmosphere, thereby generating diluting air. The diluting unit dilutes a portion of exhaust gases of an engine with the diluting air. The selecting means causes either one of the atmosphere introducing unit and the air purifier to communicate with the diluting unit. The sampling unit collects diluted exhaust gases. The measuring means obtains the emission amount of collected exhaust gases. | 1 |
CLAIM OF PRIORITY
This application is a nonprovisional of and claims the priority benefit of commonly owned, U.S. Provisional Patent Application No. 61/881,351, to Christopher M. Sears, filed Sep. 23, 2013, and entitled “NOTCHED RADIAL GAP MAGNETIC LENS FOR IMPROVED SAMPLE ACCESS IN AN SEM” the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
Embodiments of the present invention relate to electron microscopy, and more particularly, to a modification to a common magnetic immersion lens for electron microscopy.
BACKGROUND OF THE INVENTION
Energy-dispersive X-ray spectroscopy (EDS, EDX, or XEDS), sometimes called energy dispersive X-ray analysis (EDXA) or energy dispersive X-ray microanalysis (EDXMA), is an analytical technique used for the elemental analysis or chemical characterization of a sample. It relies on an interaction of some source of X-ray excitation and a sample. Its characterization capabilities are due in large part to the fundamental principle that each element has a unique atomic structure allowing unique set of peaks on its X-ray spectrum.
An EDS system generally includes an excitation source (e.g., electron beam or x-ray beam), an X-ray detector, a pulse processor and an analyzer. An X-ray detector is used to convert the collected X-ray energy into voltage signals which are in turn sent to a pulse processor. The pulse processor measures the signals and passes them onto an analyzer for data display and analysis. The most common detector is Si(Li) detector cooled to cryogenic temperatures with liquid nitrogen. Silicon drift detectors (SDD) with Peltier cooling systems are also used.
Specifically, to stimulate the emission of characteristic X-rays from a sample, a high-energy beam of charged particles such as electrons or protons (e.g. in particle-induced X-ray emission or proton-induced X-ray (PIXE)), or a beam of X-rays, is focused into the sample being studied. At rest, an atom within the sample contains ground state (or unexcited) electrons in discrete energy levels or electron shells bound to the nucleus. The incident beam may excite an electron in an inner shell, ejecting it from the shell while creating an electron hole where the electron was. An electron from an outer, higher-energy shell then fills the hole, and the difference in energy between the higher-energy shell and the lower energy shell may be released in the form of an X-ray. The number and energy of the X-rays emitted from a specimen can be measured by an energy-dispersive spectrometer. As the energy of the X-rays is characteristic of the difference in energy between the two shells, and of the atomic structure of the element from which they were emitted, this allows the elemental composition of the specimen to be measured.
Scanning electron microscopes (SEM) systems often have a magnetic immersion lens at the front of an electron optical column proximate the sample. The magnetic immersion lens typically has two pole pieces with rotational symmetry about a central axis of the electron optical column A magnetic field is produced in the pole pieces by one or more pairs of current carrying coils. There is a gap between the two pole pieces, which form a magnetic circuit. Fringing fields in the region near the gap focus or deflect electrons from the optical column. X-rays emitted from the target can pass through the gap to the X-ray detector. In SEM systems, it is desirable to increase access to X-rays emitted from the sample.
Previous methods for increasing access to the sample include moving sample further away from the lens, or increasing the gap between the lens pole pieces. Each of these ways of increasing access to the sample has disadvantages. Moving the sample away increases the electron spot size and thus decreases imaging resolution. Increasing the gap between magnetic pole pieces increases the magnetic reluctance of the circuit, thus requiring more current to achieve the same magnetic field. This in turn increases the heat dissipation within the lens which can have further deleterious effects on system performance.
It is within this context that aspects of the present disclosure arise.
SUMMARY
Aspects of the present disclosure include a system having a charged particle optical column configured to generate a primary beam of charged particles and focus the primary beam onto a target. A magnetic immersion lens is provided at a front of the column. The immersion lens has an outer pole piece and an inner pole piece with a gap therebetween proximate a common axis of the first and second pole pieces. The outer pole piece has an opening that permits energetic particles from the target to pass through the outer pole piece to an external detector. The inner or outer pole piece has one or more notches proximate the gap, including at least one notch that expands the cone of acceptance through which the energetic particles can pass from the target to the external detector.
In some implementations, the one or more notches may include two or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column.
In some implementations, the one or more notches include three or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column.
In some implementations, the one or more notches include four or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column.
In some implementations, the notches may be made large enough to provide a desired access for the detector device to the target without increasing power needed to drive the immersion lens by more than 1%.
In some implementations, the outer pole piece may have a number of notches proximate the gap. In other implementations, the inner pole piece may have a number of notches proximate the gap. In still other implementations, both the inner pole piece and the outer pole piece have a number of notches proximate the gap.
In some implementations, the gap may be a radial gap. In other implementations, the gap may be an axial gap.
The system may optionally further comprise the external detector. In some such implementations, the external detector may be an X-ray detector. In certain particular implementations, the charged particle optical column may configured to generate a primary beam of electrons and focus the primary beam of electrons onto the target.
According to other aspects of the present disclosure a magnetic immersion lens apparatus may include an outer pole piece and an inner pole piece with a gap there between proximate a common axis of the pole pieces. The outer pole piece has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer or inner pole piece has one or more notches proximate the gap, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector.
In some implementations, the one or more notches include two or four or more notches arranged in an axially symmetric pattern with respect to the axis of the charged particle column.
In some implementations, the notches may be large enough to provide a desired access for the detector device to the target without increasing power needed to drive the immersion lens by more than 1%.
In some implementations, the outer pole piece has a number of notches proximate the gap. In other implementations, the inner pole piece has a number of notches proximate the gap. In still other implementations both the inner pole piece and the outer pole piece have a number of notches proximate the gap.
In some implementations, the gap is a radial gap. In other implementations, the gap is an axial gap.
According to other aspects, an outer pole piece for a magnetic immersion lens has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer pole piece has one or more notches proximate a central aperture, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector.
BRIEF DESCRIPTION OF THE DRAWINGS
Objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIGS. 1A-1B illustrate an example of a charged particle beam system according to an aspect of the present disclosure in the form of an Energy Dispersive X-ray (EDX) system.
FIG. 2 illustrates a close-up view of a portion of a magnetic immersion lens for a charged particle beam system in accordance with an aspect of the present disclosure.
FIG. 3A is a bottom-up view of a portion of a magnetic immersion lens in accordance with an aspect of the present disclosure.
FIG. 3B is a side view of a portion of a magnetic immersion lens in accordance with an aspect of the present disclosure.
FIG. 4A is a three-dimensional ¼ cutaway view of an interior portion of a magnetic immersion lens in accordance with an aspect of the present disclosure.
FIG. 4B is a bottom-up view of the magnetic immersion lens of FIG. 4A .
FIGS. 5A-5B are three-dimensional views along an opening in a magnetic immersion lens in accordance with an aspect of the present disclosure.
DETAILED DESCRIPTION
In the following Detailed Description, 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. The drawings show illustrations in accordance with examples of embodiments, which are also referred to herein as “examples”. The drawings are described in enough detail to enable those skilled in the art to practice the present subject matter. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and electrical changes can be made without departing from the scope of what is claimed. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. 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.
In this document, the terms “a” and “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. 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.
As used herein, the term “light” generally refers to electromagnetic radiation characterized by a frequency somewhere in a range of frequencies miming from the infrared through the ultraviolet, roughly corresponding to a range of vacuum wavelengths from about 1 nanometer (10 −9 meters) to about 100 microns.
FIG. 1A and FIG. 1B illustrate an example of a charged particle beam system 100 that incorporates certain aspects of the present disclosure. In this non-limiting example, the system 100 is configured as a scanning electron microscope (SEM) having charged particle optical column 102 with an electron source 115 , beam optics elements 135 , and an immersion lens 104 having an outer pole piece 104 A and an inner pole piece 104 B. The optical column 102 may be controlled by electronics 136 , referred to herein as a beam driver. The beam driver 136 may control the electron source 115 , beam optics elements 135 and immersion lens 104 . In this example, the beam optics 135 include two or more electrically conductive cylinders maintained at voltages that produce electric fields to extract electrons from the source 115 and form them into a primary beam 103 that travels in the direction of a target 101 . The immersion lens 104 focuses the primary beam into a narrow spot at the surface of the target.
Electrons from the electron beam column 102 are focused onto a surface of the target 101 , which may be an integrated circuit wafer or a test wafer. The target 101 is supported by a stage 118 . The electrons may be scanned across the surface of the target 101 , e.g., by magnet deflecting fields provided by one or more electrostatic deflector plates 106 . Voltages are provided to the deflector plates 106 via a beam scanner driver 108 . In some implementations, the beam scanner driver 108 may apply currents to magnetic coils to scan the electron beam across the target 101 . Alternatively, the stage 118 may include a stage scanning mechanism 111 and stage scanner driver 119 configured to move the target along X-Y plane parallel to the surface of the target 101 in one or more directions relative to the optical column 102 . In some implementations the stage scanning mechanism 111 and stage scanner driver 119 may move the stage in one direction (e.g., the X direction) as the beam scanner driver 108 scans the beam in a different direction (e.g., the Y direction). Alternatively, the stage scanner driver 119 may drive the stage in both the X and Y directions relative to the optical column 102 to scan the beam across the target while the beam remains fixed relative to the optical column.
Electrons striking the target 101 are either backscattered or initiate secondary emission. The electron beam column collects a portion of such backscattered or secondary electrons 117 (or other secondary particles) that emerge from the surface of the target 101 . Some of the secondary particles 117 may travel back up through the electron beam column and impinge on an internal secondary particle detector 110 , which generates a secondary signal that is proportional to the amount of backscattering or secondary emission.
Other types of secondary particles 117 are also emitted from the target 101 and may be collected by an external detector 140 . For example, characteristic X-rays when the electron beam removes an inner shell electron from the target, causing a higher-energy electron to fill the shell and release energy. A portion of these characteristic X-rays that are within an acceptance cone 142 of the external detector 140 are collected by the external detector, which converts the collected particle energy into voltage signals. The signals may be amplified by an amplifier 112 and analyzed by analyzer 116 for composition identification and measurement of the abundance of elements in the target 101 . The landing energy of the electrons of the primary beam 103 at the target 101 may be between about 3000 electron volts (3 keV) and about 30,000 electron volts (30 keV) depending on the desired characteristic X-ray lines of the elements of the target that are to be excited by the primary beam.
The outer pole piece 104 A and inner pole piece 104 B are substantially symmetric with respect to a common axis, which in the example shown in FIG. 1A is also an axis of symmetry z of the optical column 102 . Some variation from axial symmetry is within the scope of the present disclosure. Specifically, during some stage of the machining of the pole pieces, they may be turned on a lathe, resulting in pieces which can be considered symmetric with respect to the axis of the lathe within some degree of tolerance. In addition, subsequent machining may result in one or both of the pole pieces being somewhat non symmetric with respect to this axis in a mathematical sense. For example, according to aspects of the present disclosure, the outer pole piece 104 A may include an opening to allow secondary particles 117 in the cone of acceptance 142 to pass through the outer pole piece to the external detector 140 . The formation of such an opening on only one side of the outer pole piece 104 A does not change the common axis of symmetry of the pole pieces, however.
In alternative implementations, sources of energetic particles other than electrons (e.g., ions, neutrons, ultraviolet radiation, or X-rays) may be used as alternatives to the electron source 115 , depending on the nature of the system. By way of example and not by way of limitation, electron beam excitation is used in electron microscopes, scanning electron microscopes (SEM) and scanning transmission electron microscopes (STEM), and X-ray beam excitation is used in X-ray fluorescence (XRF) spectrometers.
As shown in the block diagram of FIG. 1B , the analyzer 116 may be part of a controller 120 . The controller 120 may be a self-contained microcontroller. Alternatively, the controller 120 may be a general purpose computer configured to include a central processor unit (CPU) 122 , memory 124 (e.g., RAM, DRAM, ROM, and the like) and well-known support circuits 128 such as power supplies 121 , input/output (I/O) functions 123 , clock 126 , cache 134 , and the like, coupled to a control system bus 130 . The memory 124 may contain instructions that the CPU 122 executes to facilitate the performance of the system 100 . The instructions in the memory 124 may be in the form of the program code 125 . The code 125 may control, e.g., the electron beam voltage and current produced by the source 115 , the focusing of the beam with the beam optics 135 and the immersion lens 104 , the scanning of the electron beam by the coils 106 , the scanning of the stage 118 by the stage scanner 111 and the formation of images with the signal from the detector 110 in a conventional fashion. The code 125 may also implement analysis of the images.
The code 125 may conform to any one of a number of different programming languages such as Assembly, C++, JAVA or a number of other languages. The controller 120 may also include an optional mass storage device, 132 , e.g., CD-ROM hard disk and/or removable storage, flash memory, and the like, which may be coupled to the control system bus 130 . The controller 120 may optionally include a user interface 127 , such as a keyboard, mouse, or light pen, coupled to the CPU 122 to provide for the receipt of inputs from an operator (not shown). The controller 120 may also optionally include a display unit 129 to provide information to the operator in the form of graphical displays and/or alphanumeric characters under control of the processor unit 122 . The display unit 129 may be, e.g., a cathode ray tube (CRT) or flat screen monitor.
The controller 120 may exchange signals with the imaging device scanner driver 108 , the e-beam driver 135 , the secondary detector 110 , the X-day detector 140 or amplifier 112 through the I/O functions 123 in response to data and program code instructions stored and retrieved by the memory 124 . Depending on the configuration or selection of controller 120 , the scanner driver 108 , detector 110 , and/or amplifier 112 , may interface with the I/O functions 123 via conditioning circuits. The conditioning circuits may be implemented in hardware or software form, e.g., within code 125 .
FIG. 2 illustrates a close-up view of a portion of an immersion lens 104 of FIG. 1A in accordance with an aspect of the present disclosure. The immersion lens 104 is provided in front of an electron optical column 102 (not shown in FIG. 2 ) proximate to the target 101 . The immersion lens 104 has two magnetically permeable axially-symmetric pole pieces, an outer pole piece 104 A and an inner pole piece 104 B. As used, herein, the term “outer pole piece” refers to the pole piece closest to the target 101 and the term “inner pole piece” refers to the other pole piece. The terms “front pole piece” and “back pole piece” are sometimes used to refer to the outer and inner pole pieces, respectively. By way of example and not by way of limitation, the pole pieces 104 A and 104 B are made of soft iron. The immersion lens 104 also include a pair of current carrying coils 150 (e.g., coils of copper wires) inside the pole pieces to produce magnetic field in the pole pieces 104 A and 104 B respectively. An axially symmetric fringing magnetic field is produced near the target 101 as a result of flux leakage due to a gap g between the inner and outer pole pieces. The gap g may be either a radial gap (as shown in FIGS. 4A-4B and FIGS. 5A-5B ) or an axial gap as shown in FIG. 1A or some combination of a radial and axial gap, e.g., as shown in FIG. 2 and FIGS. 3A-3B . The magnetic field focuses charged particles in the primary beam 103 onto the target 101 . The gap g between the two pole pieces also allows for X-rays or other secondary particles 117 emitted from the target to pass through toward the external detector 140 .
The outer pole piece 140 A includes an opening 144 that permits secondary particles 117 from the target 101 to pass through the outer pole piece 104 A and into the external detector 140 . According to an aspect of the present disclosure, the outer pole piece 104 A additionally has a number of notches 302 proximate the gap g, as seen in FIG. 3A . The notches 302 increase the acceptance cone 142 to allow better viewing of the target by the external detector 140 and reduce clipping. FIG. 3A is a bottom-up view of a portion of the immersion lens 104 of FIG. 2 , and FIG. 3B is the side view. In the example shown in FIG. 3A , the outer pole piece 104 A has four notches 302 near the axis of symmetry of the pole pieces. Portions of the magnetic material in the outer pole piece are cut as a cone projected from focus to form a notch. By way of example and not by way of limitation, notches 302 may be formed by electro discharge machines (EDM) and/or CNC machine. In other embodiments, notches 302 can be cut in the inner pole piece 104 B or both the inner and outer pole pieces 104 A and 104 B. In some implementation, notches 302 are in a cone shape.
These notches 302 allow for a greater viewing cone 142 of the target by the external detector 140 . In some embodiments the notches are sized to be large enough to provide the desired access but not so large to increase power needed to drive the lens by more than about 1%.
By way of example and not by way of limitation, the size of a cone-shaped notch 302 may be about 20 mm deep (as shown in FIG. 3A ) and about 6 mm in width at the front of the outer pole piece 104 A. The radius of the original (i.e., un-notched) aperture ( 304 of FIG. 3A ) in the middle of the outer pole piece 104 A is about 8 mm.
The conventional practice is to maintain strictly rotational symmetry of the pole pieces for magnetic immersion lenses proximate the exit aperture. The presence of notches in the inner or outer pole piece proximate the aperture 304 breaks the rotational symmetry in a way that is contrary to accepted practice by those skilled in the art. However, contrary to this conventional wisdom, it turns out to be advantageous to put the notches in the pole pieces if the notches induce relatively weak or easily correctable perturbations to the beam. One notch 302 would introduce a dipole term that would shift the beam. This may be corrected using the deflector plates 106 if the beam shift is not too large. Two notches 302 would introduce a quadrupole perturbation term that would cause astigmatism. However, astigmatism may be corrected by suitably configured beam optics 135 if the quadrupole perturbation is not too large. Three notches would introduce a hexapole perturbation which would make the primary beam spot look like a three leaf clover at the target. As more notches added, the higher order perturbation terms become weaker and thus tend to become obscured by other aberrations. In some implementations, a minimum of four notches may be added to the outer pole piece 104 A to eliminate any need for correction.
The three dimensional diagrams shown in FIGS. 4A-5B illustrate the relative configuration of the notches 302 and the opening 144 in the outer pole piece 104 A. In FIG. 4A four cone shaped notches formed in the outer pole piece 104 A of a magnetic immersion lens 104 in accordance with an aspect of the present disclosure. In this example, the immersion lens 104 was modified from a commercially available electron beam wafer defect review and classification system. FIG. 4B is a bottom up view of FIG. 4A . In the example illustrated in
FIGS. 4A-4B , an X-ray detector may be provided with a working distance about 3 mm and 5° half angle from the wafer plane. Portions of the outer pole piece near the axis of the lens are cut out to form 4 notches in a pattern similar to a four leaf clover. Elliptical holes are formed in the side walls as shown in FIG. 4A . No significant increase in the magnetic reluctance of the lens in octopole terms was observed.
FIGS. 5A-5B are three-dimensional views through an opening 144 in an immersion lens in accordance with an aspect of the present disclosure. In some embodiments the immersion lens is modified from a commercially available electron beam wafer defect review and classification system. The view depicted in FIG. 5A roughly corresponds to a view along the upper dashed line of the acceptance cone 142 in FIG. 3B . The view depicted in FIG. 5B roughly corresponds to a view along the lower dashed line of the acceptance cone 142 in FIG. 3B . The spheres are located at the intersection of the target 101 and the primary beam optical axis at two different working distances z=−2.3 mm and −3.4 mm. The working distance z is measured along the axis between the front of the outer pole piece and the target. Both spheres may be seen in FIG. 5A and FIG. 5B , which indicates that the external detector 140 can detect particles originating at the intersection of the beam axis and the target for both working distances.
In application, such immersion lens with notches added to the pole piece near the axis of rotation could be used for optical camera imaging access to a target or to provide illumination, e.g., laser illumination to a target.
It should be noted that in addition to SEM systems, many other charged particle systems may employ the above described immersion lens. Examples of systems may include systems configured to implement focused ion beam (FIB), ultraviolet photoelectron spectroscopy (UPS), X-ray photoelectron spectroscopy (XPS), Auger electron spectroscopy (AES), Helium Ion Microscopy (HIM), and Secondary Ion Mass Spectroscopy (SIMS).
The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for.” Any element in a claim that does not explicitly state “means for” performing a specified function, is not to be interpreted as a “means” or “step” clause as specified in 35 USC §112(f). In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 USC §112(f). | A magnetic immersion lens apparatus includes an outer pole piece and an inner pole piece with a gap therebetween proximate a common axis of the first and second pole pieces. The outer pole piece has an opening that permits energetic particles from a target in front of the immersion lens to pass through the outer pole piece to an external detector. The outer or inner pole piece has one or more notches near the gap, including at least one notch that expands cone of acceptance through which the energetic particles can pass from the target to the external detector. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is in the field of gas analysis and more particularly relates to a compact apparatus for measuring the absorption of light or other radiation by a gas that absorbs only weakly.
2. The Prior Art
Certain gases have absorption bands that absorb so weakly that absorption can only be detected after the radiation has traveled a relatively long distance, perhaps kilometers, through the gas. On the other hand, practical gas analyzers for commercial use, as opposed to laboratory apparatus, typically are small enough to be portable, and are definitely too small to provide path lengths thousands of meters long.
Furthermore, the amount of gas available might be insufficient to fill a sample chamber large enough to provide the necessary path lengths.
It is well-known to use mirrors to fold an optical beam so that the beam can traverse the sample cell a number of times. Although the present invention makes use of a folded optical path, that alone is not the inventive step.
A multi-path absorption cell was described by J. U. White, Journal of the Optical Society of America, Volume 32, page 285 (1942). The essential parts of the White cell consist of three spherical concave mirrors all having the same radius of curvature, and positioned to form an optical cavity. Utilizing the principle outlined in White's article, at least two companies have marketed a ten-meter multi-path cell, and one of the companies has also marketed a forty-meter multi-path cell.
The number of times the light can be passed through a White cell is limited by the spherical aberation of the mirrors. Thus, the White cell is not compatible with the present invention in which the light may be passed through the sample cell thousands of times.
SUMMARY OF THE INVENTION
A major purpose of the present invention is to provide a closed optical path on which radiation can travel repeatedly, and at least part of which path extends through a space in which a gas sample is present, so that the radiation can travel a long distance through the gas in spite of the fact that the physical dimensions of the apparatus are relatively small.
Another major purpose of the present invention is to provide means for introducing radiation into a closed optical path and, at a later time, for removing the radiation from the closed optical path.
As used herein, the word radiation refers to electromagnetic radiation without limitation as to its wavelength; however, the most interesting applications presently contemplated make use of radiation in the infrared, visible, and ultraviolet portions of the spectrum. Also, as used herein, the word path refers to a line segment or series of line segments along which radiation travels. A closed path is defined to be a path which returns to an initial starting point and direction.
In accordance with the present invention, radiation is directed into a closed path on which it travels repetiively thousands of times through a sample of gas whose absorption is to be measured. This yields the equivalent of a path length through the gas of several thousand meters, typically. At some point in time, the radiation is redirected out of the closed path and applied to a detector that permits the intensity of the recovered radiation to be measured. The intensity is similarly measured again but without the sample of gas in the optical path. Comparison of the two intensities permits the absorption caused by the gas to be determined.
The novel features which are believed to be characteristic of the invention, both as to organization and method of operation, together with further objects and advantages thereof, will be better understood from the following description considered in connection with the accompanying drawings in which several preferred embodiments of the invention are 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.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an optical diagram showing an s-polarized ray reflected from a dielectric surface;
FIG. 2 is an optical diagram showing a p-polarized ray transmitted through a dielectric plate;
FIG. 3 is an optical diagram showing mirrors interposed in the path of a p-polarized ray to provide a closed path;
FIG. 4 is an optical diagram showing an alternative way of interposing mirrors in the path of a p-polarized ray to provide a closed path;
FIG. 5 is an optical diagram showing mirrors interposed in the path of an s-polarized ray to provide a closed path;
FIG. 6 is an optical diagram showing an alternative way of interposing mirrors in the path of an s-polarized ray to provide a closed path;
FIG. 7 is an optical diagram showing an s-polarized ray reflected by a polarizing beamsplitter cube;
FIG. 8 is an optical diagram showing a p-polarized ray transmitted through a polarizing beamsplitter cube;
FIG. 9 is an optical diagram showing mirrors interposed in the path of a p-polarized ray to provide a closed path;
FIG. 10 is an optical diagram showing an alternative way of interposing mirrors in the path of a p-polarized ray to provide a closed path;
FIG. 11 is an optical diagram showing mirrors interposed in the path of an s-polarized ray to provide a closed path;
FIG. 12 is an optical diagram showing an alternative way of interposing mirrors in the path of an s-polarized ray to provide a closed path;
FIG. 13 is an optical diagram showing the path of a ray as it passes through a first preferred embodiment of the apparatus of the present invention;
FIG. 14 is an optical diagram showing the path of a beam of radiation as it passes through a second preferred embodiment of the apparatus of the present invention.
FIG. 15 is an optical diagram showing the path of a ray as it passes through a third preferred embodiment of the apparatus of the present invention;
FIG. 16 is an optical diagram showing the path of a ray as it passes through a fourth preferred embodiment of the apparatus of the present invention;
FIG. 17 is an optical diagram showing the path of a ray as it passes through a variation of the embodiment of FIG. 13;
FIG. 18 is an optical diagram showing the path of a ray as it passes through a variation of the embodiment of FIG. 14;
FIG. 19 is an optical diagram showing the path of a ray as it passes through a variation of the embodiment of FIG. 15;
FIG. 20 is an optical diagram showing the path of a ray as it passes through a variation of the embodiment of FIG. 16;
FIG. 21 is an optical diagram showing the path of a ray as it passes through another embodiment of the present invention;
FIG. 22 is an optical diagram showing the path of a ray as it passes through a variation of the embodiment of FIG. 21; and,
FIG. 23 is an optical diagram showing the path of a ray as it passes through another embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention makes use of the properties of polarized radiation, and a brief review of those properties as they apply to the present invention will be given.
It will be recalled that electromagnetic waves vibrate in a direction transverse to the direction the wave is moving, and unpolarized light is considered to contain components vibrating in all possible planes that contain the ray. Radiation that vibrates in only one plane is said to be plane-polarized or, as used herein, linearly polarized.
FIG. 1 shows a ray 12 on path 1 incident upon a plate 14 of dielectric material at the polarizing angle 16. The dots on the ray 12 indicate that the vibrations are in a plane perpendicular to the plane of incidence. The plane of incidence is defined as a plane containing both the normal 18 to the surface of the plate 14 as well as the incident ray 12. In FIG. 1, the plane of incidence coincides with the plane of the page, and the vibrations are perpendicular to the page. Because the vibrations are perpendicular to the plane of incidence, the ray 12 is referred to as s-polarized. When as s-polarized ray is incident at the (Brewster's) polarizing angle 16, the entire ray is reflected along a path 2 as indicated by the ray 20 of FIG. 1. Following conventional notation, an s-polarized ray is denoted by dots, while a p-polarized ray, in which all of the vibrations are in the plane of incidence is denoted by a series of lines transverse to the ray.
A similar result is shown in FIG. 7 where a polarizing beamsplitter cube 22 is used in place of the plate 14 of dielectric material. Both the plate 14 and the cube 22 are but examples of a class of devices that are referred to herein by the generic term "polarizing beamsplitter. " When the polarizing beamsplitter cube 22 is used, the path 2 is perpendicular to the path 1. In FIG. 2, by way of contrast, when a p-polarized ray 24 is incident upon the plate 14 of dielectric material at the polarizing angle 16, the entire ray passes through the dielectric material and emerges on path 3, as indicated by the ray 26.
The comparable situation for the polarizing beamsplitter cube is shown in the diagram of FIG. 8. It is a property of such a cube that the transmitted ray 26 has substantially the same direction as the incident ray 24.
Comparison of FIGS. 1 and 2 shows that the direction of polarization of the incident ray determines the direction of the reflected or transmitted ray. If the incident ray on path 1 is s-polarized, the reflected ray 20, on path 2, will also be s-polarized. But if the incident ray 24 on path 1 is p-polarized, the transmitted ray 26 on path 3 will also be p-polarized. The direction of polarization of the incident ray determines whether the ray exits on path 2 or on path 3. The same applies when the polarizing beamsplitter cube 22 is used, as seen by comparison of FIGS. 7 and 8.
In FIG. 3 a closed path for the p-polarized rays is formed by interposing the plane mirrors 28 and 30 in path 1 and path 3. As the arrows on the rays indicate, any p-polarized radiation that coincides with any part of the path will repetitively traverse the space between the mirrors 28, 30.
A similar closed path for the p-polarized rays on paths 1 and 3 is evident where the polarizing beamsplitter cube 22 is used, as shown in FIG. 9.
FIG. 4 shows another way of producing a closed path for the p-polarized radiation. In the arrangement of FIG. 4, four mirrors 32, 34, 36 and 38 are used, and they are positioned and oriented in such a way that the radiation circulates on the closed path shown.
Note that if the light that is traveling on the closed paths of FIGS. 3, 4, 9, and 10 were suddenly to have its polarization changed from p to s, the radiation would be deflected from the closed path and onto the path 2, as indicated in FIGS. 1 and 7.
FIG. 5 is somewhat similar to FIG. 3 except that s-polarized radiation is used. The mirrors 40, 42 are interposed perpendicular to path 1 and path 2, respectively, to produce a closed path on which the radiation travels repeatedly.
FIG. 11 shows the analogous paths for the polarizing beamsplitter cube 22.
FIG. 6 shows mirrors 44, 46 interposed in the paths 1 and 2 to produce a different shaped closed path than that shown in FIG. 5.
FIG. 12 shows the analogous situation for the polarizing beamsplitter cube 22.
It should be noted that the closed paths of FIGS. 5, 6, 11, and 12 coincide, at least in part, with the paths 1 and 2.
If the polarization of the radiation traveling the closed paths shown in FIGS. 5, 6, 11, and 12 were to be altered suddenly from s to p, the radiation would thereafter be removed from the closed path by way of the path 3, as indicated in FIGS. 2 and 8.
Thus, it has been shown in FIGS. 1-12 that polarized radiation traveling a closed path can be removed from that closed path by altering its direction of polarization by 90°. The present inventor completed his combination by interposing a pockels cell 48 in the closed path.
It is well-known that when no voltage is applied to a pockels cell, the direction of polarization of the radiation passing through it will not be altered. However, when a voltage is applied to the pockels cell, the polarization of the radiation will be rotated through an angle that depends on the magnitude of the applied voltage.
In accordance with a preferred embodiment of the present invention, the pockels cell 48 can be located at any point in the closed paths of FIGS. 3, 4, 5, 6, 9, 10, 11, and 12. In the embodiments of FIGS. 4, 6, 10, and 12, the radiation circulates in a particular sense around the closed path, and at some point in time, a sufficient voltage is applied to the pockels cell to cause a rotation of the direction of polarization by 90°.
The transmissivity of a pockels cell can be extremely high--on the order of 99.99%. Therefore, even though the radiation passes through the pockels cell many times, little loss of radiation occurs.
In the embodiments of FIGS. 3, 5, 9, and 11, the radiation travels back and forth along each particular segment of the closed path, and the radiation will pass twice through the pockels cell before being incident on the dielectric plate 14 or the polarizing beamsplitter cube 22. Accordingly, in the arrangements of FIGS. 3, 5, 9, and 11, the voltage applied to the pockels cell 48 should produce a change in the direction of polarization of 45° on each pass through the pockels cell. The pockels cell still produces a total change in the direction of polarization of 90°, but that change is produced in two steps.
FIGS. 13-23 show specific embodiments in which the above-described techniques are applied to the measurement of the absorption of radiation by a sample of gas or liquid.
In all of the following embodiments, the radiation originates in a source 50. Since spreading of the beam is one of the limiting factors in the use of the present invention, it is highly desirable that the source 50 produce a beam of radiation having the smallest practical divergence. To this end, in a preferred embodiment the source 50 includes a laser diode and a collimating optical system. As will be discussed below, such a source is capable of producing a beam of such small divergence that extremely long path lengths, on the order of kilometers, can be obtained in a relatively compact apparatus.
Also present in the embodiments shown in FIGS. 3-23 is apparatus for collecting and detecting the radiation that has passed repeatedly through the sample of gas. In the drawings, this apparatus is shown as including a collecting lens 52 that presents a large enough aperture to collect the emerging beam of radiation and to concentrate it on a detector cell 54. In the preferred embodiment, a lens is used, and the detector cell 54 consists of a silicon photodiode.
The pockels cell 48 used in the embodiments of FIGS. 13-20 is of a well-known type in which no rotation of the plane of polarization occurs unless and until a voltage is applied across the pockels cell. The magnitude of the applied voltage determines the amount of rotation of the plane of polarization produced as the radiation passes through the pockels cell. The application of voltage pulses to the pockels cell 48 is controlled by the programmable pulse generator and timer 49 of FIGS. 13-20, which permits a chosen sequence of voltage pulses of selected magnitudes to be applied to the pockels cell 48.
Also shown in each of the embodiments of FIGS. 13-23 is a volume of gas 56 located on the closed optical path that the radiation repeatedly travels. From the standpoint of operation of the invention, it is immaterial whether the gas is totally enclosed in a container, is partially enclosed in an airway through which the gas may flow, or whether the gas is unconfined. As noted above, it is also immaterial whether the sample consists of a gas, a vapor, or a liquid, or combinations thereof. However, for convenience of the discussion, the sample will be assumed to consist of a gas.
In the embodiments of FIGS. 13-22 the sample 56 could be contained in an optical device, exemplified by a White cell, in which the radiation undergoes multiple reflections. This has the advantages of causing a greater dwell time in that portion of the optical path and of greatly increasing the distance the radiation travels through the sample.
In the embodiments of FIGS. 13, 15, 17, 19, and 21-23, it is desirable to make use of a mirror 58 for directing the radiation from the source 50 onto a particular path. This is done to prevent physical interference between the radiation source 50 and the collector which consists of the lens 52 and the detector cell 54. The mirror 58, in a preferred embodiment is partially reflective and partially transmissive, and its diameter may be as large as that of the lens 52. In an alternative embodiment in which the beam of radiation emerging from the source 50 is small in diameter compared to the diameter of the lens 52, the mirror 58 is entirely reflective, but of a size that is considerably smaller than the diameter of the lens 52, whereby the mirror 58 does not block a substantial part of the area of the lens 52.
In the following paragraphs, the embodiments of FIGS. 13-23 will be described in detail.
In FIG. 13, unpolarized radiation from the source 50 is directed by the mirror 58 onto the path 60. As with all of the drawings, the paths show the direction of the centerline of a collimated beam. As in all of the drawings, the path 60 is incident on the beamsplitter at the polarizing angle. Accordingly, the s-polarized component is reflected on the path 62, while the p-polarized component is transmitted through the dielectric plate 14 and emerges on the path 64. The s-polarized component on the path 62 passes through the pockels cell 48 which rotates its direction of polarization by 45 degrees in response to an applied electrical signal (a constant voltage). The beam continues to the mirror 28 which reverses its direction. Upon passing through the pockels cell 48 a second time, the direction of polarization is again rotated 45 degrees, so that the radiation that has passed through the pockels cell 48 a second time is p-polarized. This radiation on the path 62 impinges on the plate 14 of dielectric material and is transmitted through that material and emerges on the path 66. This radiation next passes through the volume 56 of gas and is turned back upon itself by the mirror 30. Since the radiation still has the p-polarization, it is transmitted through the plate 14 again and emerges on the path 62. In the best known mode of operating the invention, the applied voltage is removed from the pockels cell 48, which causes the pockels cell to pass the radiation without changing its direction of polarization. In this manner, the radiation is trapped on the paths 62, 66 and passes through the volume 56 of gas numerous times.
At some point in time, the voltage is again applied to the pockels cell 48 which causes it to again alter the direction of polarization of the radiation passing through it. Assuming the radiation has just emerged from the plate 14 and is heading on the path 62 towards the mirror 28, the pockels cell 48 alters its direction of polarization 45 degrees on each pass through the pockels cell, so that as the radiation again approaches the plate 14, it has become s-polarized. Therefore, the radiation is not transmitted by the plate 14, but instead is reflected on the path 60, where it passes through the partially reflective mirror 58 and where it is collected by the lens 52 and concentrated onto the detector 54. As is well known in the art, the detector 54 produces an electrical signal that is related to the intensity of the radiation falling on the detector cell 54. In a preferred embodiment, the magnitude of the signal produced when a gas is present in the volume 56 is compared to the magnitude of the signal produced when the gas being analyzed is not present in the volume 56, and the reduction in the signal when the gas is present is attributed to absorption of the radiation by the gas. The effective distance the radiation has travelled through the gas is equal to the length of the volume of gas in the direction of the path 66 and the number of times the radiation passes through that volume while it is on the repetitive closed path. This number may be determined by taking into account the time interval that elapses between when the voltage is removed from the pockels cell and when the voltage is again applied to the pockels cell, taking into account the fact that the radiation travels approximately 30 centimeters per nanosecond.
The operation of the embodiment of FIG. 17 is identical to that of FIG. 13, the difference being that some of the angles are different when a polarizing beamsplitter cube 22 is used in place of the plate 14.
In the embodiment of FIG. 14, radiation from the source 50 travels on the path 68 and impinges on the plate 14 at the polarizing angle. The s-polarized component is refelected on the path 70 and redirected by the mirror 34 to the path 72 which takes it through the pockels cell 48. At this point in time, a first signal consisting of a constant voltage is being applied to the pockels cell that causes it to rotate the direction of polarization through an angle of 90 degrees, so that the radiation emerging from the pockels cell 48 is p-polarized. That radiation is redirected onto the path 74 by the mirror 36. The path 74 takes the radiation through the volume 56 of gas. Thereafter, the radiation is redirected by the mirrors 38 and 32 so that the p-polarized radiation on the path 76 impinges at the polarizing angle on the plate 14. The plate 14 transmits the p-polarized radiation, and the mirror 32 is so located that the radiation emerges from the plate 14 on the path 70. Before the radiation can again reach the pockels cell 48, a second signal, consisting of zero voltage, is applied to the pockels cell thereby to prevent the pockels cell from altering the polarization of the beam. Accordingly, the p-polarized beam circulates around the closed path, passing each time through the volume 56 of gas. After a particular amount of time has passed, the first signal is again applied to the pockels cell 48, and as the radiation passes through it, the polarization of the radiation is changed from p to s. The s-polarized radiation then continues on the paths 74 and 76, but on striking the plate 14 is not transmitted, but instead is reflected at the critical angle into the lens 52 which focuses it onto the detector cell 54.
The operation of the embodiment of FIG. 18 is the same as that of the embodiment of FIG. 14. In both FIG. 14 and FIG. 18, it is possible that some of the radiation emitted by the source 50 will pass through the beamsplitter and into the lens 52. If this becomes a problem, the unwanted radiation can be gated out since its time of arrival at the detector 54 identifies it as not having circulated on the closed path.
In the embodiments shown in FIGS. 13, 14, 17, and 18, the radiation on the repetitive closed path was p-polarized. In contrast, in the embodiments shown in FIGS. 15, 16, 19, and 20, the radiation that is traveling repeatedly on the closed path is s-polarized.
In the embodiment of FIG. 15, unpolarized radiation from the source 50 is redirected by the mirror 58 onto the path 78 which impinges on the plate 14 at the polarizing angle. The s-polarized component is reflected on the path 80, while the p-polarized component is transmitted by the plate 14 and emerges on the path 82. The p-polarized component then continues on the path 82 through the pockels cell 48 to the mirror 40 which reverses its direction and sends it back through the pockels cell 48. During this time, a first signal is applied to the pockels cell 48 that causes it to rotate the direction of polarization by 45 degrees on each of the two passes, so that following the second passage through the pockels cell 48, the radiation is s-polarized. Because the radiation is s-polarized, and because it is incident at the polarizing angle, the radiation is reflected from the plate 14 and proceeds along the path 84. This path takes the radiation through the volume 56 of gas, to the mirror 42, and back through the volume 56 of gas. At this point in time, a second signal is applied to the pockels cell 48 which causes the pockels cell to pass the radiation without affecting its direction of polarization. Therefore, the radiation travels repeatedly along the paths 82 and 84, until a desired number of passages have been made. Then a first signal is applied to the pockels cell 48 which causes the pockels cell to rotate the direction of polarization by 45 degrees on each passage through it. The radiation is thereby given a p-polarization which causes it to be transmitted through the plate 14 to emerge on the path 78, to pass through the partially reflecting mirror 58 and the lens 52 and to be concentrated upon the detector cell 54. Note that the radiation was s-polarized while it travelled repeatedly on the paths 82, 84.
The operation of the embodiment of FIG. 19 is the same as that of the embodiment of FIG. 15.
In the embodiment of FIG. 16, unpolarized radiation from the source 50 travels on the path 86 and impinges on the plate 14. The s-polarized component is reflected on the path 88, while the p-polarized component is transmitted through the plate 14 and emerges on the path 90. The mirrors 44, 46 are arranged to bring the radiation back to the point at which it emerged from the plate 14. The p-polarized radiation on the path 90 encounters the pockels cell 48. A first signal is being applied to the pockels cell 48 to cause it to rotate the direction of polarization of the radiation through 90 degrees, so that the radiation that emerges from the pockels cell 48 is s-polarized. That radiation is then reflected from the mirror 46 along the path 92 which passes through the volume 56 of gas. Thereafter, the mirror 44 directs the radiation along the beam 94, and because the radiation is s-polarized, it is reflected from the plate 14 along the path 90. At this point in time, a second signal is applied to the pockels cell 48 that causes it to permit the radiation to pass through it without change in the direction of polarization. In this manner, s-polarized radiation circulates a large number of times on a closed path consisting of the segments 90, 92, and 94. After the desired number of circuits have been completed, the first signal is again applied to the pockels cell 48 causing it to alter the direction of polarization by 90 degrees, so that the radiation emerging from the pockels cell is p-polarized. This radiation then travels on the paths 92 and 94, and passes through the plate 14, emerging on the path 96. The radiation on the path 96 is collected by the lens 52 and concentrated onto the detector cell 54.
The operation of the embodiment shown in FIG. 20 is identical to that of the embodiment of FIG. 16.
The embodiments of FIGS. 21-23 are remarkable in that both the p and s polarized components are caused to travel a closed course repetitively and simultaneously.
Turning to the embodiment of FIG. 21, it will be noted that two pockels cells 100, 102 are used. Unpolarized radiation from the source 50 is directed by the partially-reflective mirror 58 onto the path 104. The p-polarized component is transmitted through the cube 22 on the path 106, while the s-polarized component is reflected on the path 108. A first signal is applied to the pockels cells 100, 102 causing each of them to rotate the direction of polarization of any radiation passing through them by 45 degrees. The p-polarized component on the path 106 passes through the pockels cell 100, is reflected back on itself by the mirror 110 and passes a second time through the pockels cell 100 thereby being converted to s polarization. Simultaneously, the s-polarized radiation on the path 108 passes through the pockels cell 102 and is turned back upon itself by the mirror 112, and after passing through the pockels cell 102 a second time has acquired a p polarization. Accordingly, the s-polarized radiation travelling toward the cube 22 on the path 106 is reflected by the cube onto the path 114, while the p-polarized radiation approaching the cube on the path 108 is transmitted through the cube 22 and emerges on the path 114. Thus, both a p-polarized component and a s-polarzied component travel along the path 114, through the volume 56 of gas and are reflected back upon themselves by the mirror 116.
Upon interacting with the cube 22 again, the s-polarized component on the path 114 is reflected onto the path 106, while the p-polarized component on the path 114 is transmitted on the path 108. By this time, a second signal has been applied to the pockels cells 100, 102 which causes them to pass radiation without affecting the direction of polarization. In this manner, the s-polarized component is trapped and travels repeatedly on the paths 106, 114, while the p-polarized component is trapped and repeatedly travels the paths 108 and 114. After a desired number of passage have been made, the first signal is applied again to the pockels cells 100, 102, thereby altering the direction of polarization of the radiation passing through them, so that the s-polarized radiation on the path 106 is converted to p-polarized radiation and is transmitted by the cube 22 on the path 104 while the p-polarized radiation on the path 108 is converted to s-polarized radiation and is reflected by the cube 22 onto the path 104. Both components on the path 104 pass through the partially-transmissive mirror 58 and are collected by the lens 52 which concentrates them onto the detector cell 54.
The operation of the embodiment of FIG. 22 is identical to that of the embodiment of FIG. 21.
The embodiment shown in FIG. 23 is rather unique in that two s-polarized beams of radiation circulate in opposite senses around a closed path that includes a volume 56 of gas.
Unpolarized radiation from the source 120, 122 is reflected by partially-reflective mirrors onto the paths 124, 126. The s-polarized components are reflected by the cube 22 onto the paths 126, 124 respectively and are wasted. The p-polarized components are transmitted by the cube 22 and emerge on the paths 128, 130 respectively. Through the use of the mirrors 136, 138, these p-polarized components are redirected onto the path 132 which they travel in opposite directions. At some point, a first signal is applied to the pockels cell 134 which causes it to rotate the direction of polarization of radiation passing through it by 90 degrees. Accordingly, both of the p-polarized components become s-polarized. Thereafter, a second signal is applied to the pockels cell 134 which causes it to pass radiation without altering the direction of polarization of that radiation. Accordingly, the s-polarized components circulate around the closed path defined by the segments 128, 130, 132 a great number of times and in opposite senses. Thereafter, the first signal is again applied to the pockels cell 134, and this causes the s-polarized components to become p-polarized. Thereupon the component approaching the cube 22 on the path 128 is transmitted through the cube and emerges on the path 124, to be collected by the lens 136 and concentrated on the detector 140. Likewise, the p-polarized component approaching the cube 22 on the path 130 is transmitted by the cube and emerges on the path 126, to be collected by the lens 138 and concentrated onto the detector cell 142.
Thus, a number of embodiments have been shown of a compact apparatus for use in measuring the absorption of a gas. Common to all of these embodiments is the use of a pockels cell and a polarizing beamsplitter to permit radiation from a source to be placed on a closed path which it travels repeatedly, and to be removed from the closed path after passing through the gas sample a great number of times.
The foregoing detailed description is illustrative of several embodiments of the invention, and it is to be understood that additional embodiments thereof will be obvious to those skilled in the art. The embodiments described herein together with those additional embodiments are considered to be within the scope of the invention. | The measurement of weak absorption lines is facilitated by the use of a long transmission path length, which is difficult to obtain in compact or portable instruments. In the present invention, light is made to travel through a limited volume of gas thousands of times. The light is placed on a closed optical path on which it circulates through the gas sample. After a desired number of passes through the gas sample, the light is removed from the closed optical path. Introduction of the light to the closed optical path and removal therefrom is accomplished through the use of a polarizing beamsplitter and a pockels cell located on the closed path. Light is put onto the closed path by the polarizing beamsplitter which imparts a specific polarization. During the first circuit the pockels cell alters the polarization by 90 degrees thereby preventing the light from escaping back out through the polarizing beamsplitter. After the desired number of circuits, the pockels cell again alters the polarization by 90 degrees thereby permitting the light to be redirected out of the closed path by the polarizing beamsplitter. | 6 |
RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. No. 62/192,380 titled Systems and Methods of Lighting and Control the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to systems and methods for optimizing power and control of a multicolored lighting system.
BACKGROUND
[0003] Standard connected lighting as depicted in FIG. 1 and found in the prior art, includes a plurality of bulbs 112 with two power supply lines connected thereto. A first power supply line, defined as an active line 103 provides a forward biasing electrical current in a direction toward the bulb 112 . A second power supply line, defined as a neutral line 104 accommodates little to no current directed away from the bulb 112 . Customary light emitting diode (LED) technology involves using individual bulbs 112 that act as housing for an antenna 114 , a radio 115 , a power supply 101 , and a board containing LEDs defined as an LED Board 102 . An LED consists of semiconducting material doped with impurities to create a p-n junction. The diode within the LED allows current to flow easily from the p-side, or anode, to the n-side, or cathode. However, current does not flow easily in the reverse direction. When forward biasing current reaches a threshold voltage, the LED emits light. In a connected lighting system, a series of LED bulbs are connected using the same active line 103 and neutral line 104 whereby the active line provides current with sufficient voltage to illuminate the LEDs on each respective bulb.
[0004] Operating connected lighting in this manner creates inefficiency. More specifically, since the power supply 101 regulates the current and electrical communication with the individual bulbs 112 , it accumulates much of the wear on the bulb. Indeed, it is known in the art that power supply failure is one of the most common modes of LED bulb failure. Therefore, when the power supply 101 on the bulb 112 is no longer operable, the entire bulb 112 must be replaced. This is true for the antennae 114 and radio 115 as well. When these components become damaged over time, the entire bulb 112 must be replaced.
[0005] Another inefficiency found in modern LED connected lighting technology is that delivered current only operates one LED string within each bulb 112 . This in turn only emits one color associated with that particular LED string. Therefore, should a user desire differently colored light, the entire bulb 112 must be replaced.
[0006] This background information is provided to reveal information believed by the applicant to be of possible relevance to the present invention. No admission is necessarily intended, nor should be construed, that any of the preceding information constitutes prior art against the present invention.
SUMMARY OF THE INVENTION
[0007] With the above in mind, embodiments of the present invention are related to a lighting system comprising a control unit and a lighting device. The lighting device may include an LED board within an optical chamber. The LED board may include a first string of LEDs and a second string of LEDs. The control unit and the LED board may be configured to electrically couple to first and second wires. The first string of LEDs and the second string of LEDs may be configured to emit light having different spectral power distributions within the visible spectrum. The first string of LEDs may be oriented in an electrically opposite direction than the second string of LEDs. The control unit comprises a switch configured to direct current between the first wire and second wire. The wire to which current is directed may be designated active. The designated active wire may activate one of the first string of LEDs and second string of LEDs.
[0008] The lighting system may include the first string of LEDs configured to emit light having a first color and the second string of LEDs configured to emit light having a second color. The first and second strings of LEDs may be alternately activated to emit light having a perceived third color defined as a perceived combined light. The alternate activation of the first and second strings of LEDs may be faster than can be detected by the human eye and may create a perceived third color different from the first color and the second color.
[0009] The control unit may include a timer configured to communicate a time of day. The first color, the second color, or third perceived color may be changed based on the time of day that is communicated by the timer. The control unit may further be operable to alternate the designated active wire between the first wire and second wire within a range from every 16 milliseconds to every 32 milliseconds, which, in turn, activates the respective LED string.
[0010] The lighting device within the lighting system may emit a first color as one of a red colored light, a blue colored light, or green colored light. The second color may be one of a red colored light, a blue colored light, or green colored light that is not emitted by the first string of LEDs.
[0011] The ratio of active time between the first string of LEDs and the second string of LEDs may be a ratio of 1:1 or may be a ratio of 2:1. Furthermore, the ratio of activation between the first string of LEDs and the second string of LEDs may be any combination capable of producing a perceivable color from the spectrum of combinatory colors ranging between the color emitted by the first string of LEDs and the color emitted by the second string of LEDs.
[0012] The lighting device may be configured to maintain a consistent emission of colored light designated by one of the color emitted by the first string of LEDs, the color emitted by the second string of LEDs, or a color from the spectrum of combinatory colors ranging between the color emitted by the first string of LEDs and the color emitted by the second string of LEDs.
[0013] The control unit may include a dimmer, a luminosity indicator, a color synthesizer, a color indicator, a driver circuit, and a power supply. The dimmer may be configured to control the amount of voltage delivered to a first wire and a second wire. The luminosity indicator may be configured to display the luminosity of a lighting device electrically coupled to the first wire and second wire. The color indicator may be configured to display one of an emitted color and a perceived emitted color of the lighting device. The color synthesizer may include a switch configured to alternate a frequency of forwardly biased current between the first wire and the second wire. Additionally, the wire that receives forwardly biased current may be designated active when the respective string of LEDs to emit light is operable.
[0014] The lighting device may include a plurality of lighting devices within a lighting system. The driver circuit and power supply may be configured to drive the plurality of lighting devices.
[0015] The control unit may be managed by at least one of a remote control and a computerized device. The control unit may also include an electrical outlet adapter configured to receive a plurality of electrical plugs from lighting devices and manage the emitted color and luminosity thereof. The color synthesizer may be configured to alternate a designated active wire between the first wire and second wire within the range from every 16 milliseconds to every 32 milliseconds.
[0016] Another embodiment of the present invention is directed to a luminaire. The luminaire may include a bulb defined by an optical chamber and an Edison base. It may also include an LED board within the optical chamber comprising a first string of LEDs and a second string of LEDs. The first string of LEDs and the second string of LEDs may be configured to emit a differently colored light. The first string of LEDs may be oriented in an electrically opposite direction than the second string of LEDs. The luminaire may be configured to maintain a consistent emission of colored light designated by one of the color emitted by the first string of LEDs, the color emitted by the second string of LEDs, or a perceived color from the spectrum of combinatory colors ranging between the color emitted by the first string of LEDs and the color emitted by the second string of LEDs.
[0017] The first string of LEDs may be configured to emit one of a red colored light, a blue colored light, and green colored light. Similarly, the second string of LEDs may be configured to emit one of a red colored light, a blue colored light, and green colored light that is not emitted by the first string of LEDs.
[0018] The first string of LEDs may be configured to emit light having a first color. The second string of LEDs may be configured to emit light having a second color. The first and second strings of LEDs may be alternately activated to emit light having a perceived third color. The perceived third color may be defined as a perceived combined light. The alternate activation of the first and second strings of LEDs is faster than can be detected by the human eye, and the perceived third color is different from the first color and the second color.
[0019] The luminaire may include a ratio of activation between the first string of LEDs and the second string of LEDs of 2:1. The luminaire may maintain a frequency of activation between the first string of LEDs and the second string of LEDs that includes a ratio capable of producing a perceivable color from the spectrum of combinatory colors ranging between the color emitted by the first string of LEDs and the color emitted by the second string of LEDs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 illustrates a connected lighting system as found in the prior art.
[0021] FIG. 2 illustrates a system for optimizing power and control found in standard connected lighting according to an embodiment of the present invention.
[0022] FIG. 3 is a cross-sectioned view of the interior of a bulb containing separate LED strings according to an embodiment of the present invention.
[0023] FIGS. 4 a - b show directional currents utilized in the system illustrated in FIG. 2 .
[0024] FIG. 5 is a demonstrative view according to the present invention of operation of the bulb illustrated in FIG. 3 .
[0025] FIG. 6 shows an embodiment of a control unit utilized in the system illustrated in FIG. 2 .
[0026] FIG. 7 shows alternative embodiments of the system illustrated in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0027] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. 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. Those of ordinary skill in the art realize that the following descriptions of the embodiments of the present invention are illustrative and are not intended to be limiting in any way. Other embodiments of the present invention will readily suggest themselves to such skilled persons having the benefit of this disclosure. Like numbers refer to like elements throughout.
[0028] Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
[0029] In this detailed description of the present invention, a person skilled in the art should note that directional terms, such as “above,” “below,” “upper,” “lower,” and other like terms are used for the convenience of the reader in reference to the drawings. Also, a person skilled in the art should notice this description may contain other terminology to convey position, orientation, and direction without departing from the principles of the present invention.
[0030] Furthermore, in this detailed description, a person skilled in the art should note that quantitative qualifying terms such as “generally,” “substantially,” “mostly,” and other terms are used, in general, to mean that the referred to object, characteristic, or quality constitutes a majority of the subject of the reference. The meaning of any of these terms is dependent upon the context within which it is used, and the meaning may be expressly modified.
[0031] Referring now to FIGS. 2, 3, 4 a and 4 b , the present invention will now be discussed. The present invention utilizes a control unit 105 to obviate the power supply 101 , antenna 114 , and radio 115 of the prior art illustrated in FIG. 1 . Therefore, each individual bulb 112 only contains an LED board 102 encased therein, and in some embodiments, minimal control circuitry to operate the LED board 102 managed by a control unit 105 . By consolidating the antenna 114 , radio 115 , and power supply 101 within a single control unit 105 , a user is only required to replace the individual component or control unit 105 upon its respective failure. This is opposed to replacing each individual bulb 112 each time an individual component within the bulb 112 fails as well as reduces the cost of each individual bulb 112 .
[0032] Additionally, the present invention utilizes an LED board 102 comprising at least two different LED strings. By way of non-limiting example, FIG. 3 depicts a bulb with two strings of LEDs. As shown in FIG. 3 , the LED board 102 comprises a first string 106 of LEDs operable to emit light having a first spectral power distribution, corresponding to a first color or correlated color temperature (CCT). Furthermore, the LED board 102 comprises a second string 107 of LEDs operable to emit light having a second spectral power distribution, corresponding to a second color or CCT. The first spectral power distribution may be different from the second spectral power distribution, and the first color or CCT may be different from the second color or CCT. The first string 106 may be oriented in an electrically opposite direction than the second string 107 , such that the forward direction for each of the strings is opposite to the other. Accordingly, whether the first or second string 106 , 107 emits light may be determined by the direction of current within the circuit.
[0033] Referring additionally to FIG. 4 , the control unit 105 determines which string is the active line 103 . Moreover, the control unit 105 may act as a switch to determine which wire receives enough voltage to activate the respective string of LEDs. Accordingly, the first string of LEDs 106 and the second string of LEDs 107 may be alternately activated to emit light having a perceived third color. The perceived third color 120 may be defined as a perceived combined light. The alternate activation of the first and second strings of LEDs 106 , 107 is faster than can be detected by the human eye. The perceived third color 120 is different than the first color and the second color.
[0034] In FIG. 4 a the control unit 105 delivers forward biasing current to a first wire 108 in order to operate the first string 106 of LEDs depicted in FIG. 3 . In this embodiment the first string 106 LED diodes are oriented so that the first wire 108 allows forward biasing current to flow into the p-side, or anode, and through to the n-side, or cathode, thereby making the first wire 108 the active wire and the second wire 109 the neutral wire. This causes the first string 106 of LEDs within each of the individual LED bulbs 112 to emit light with the first string 106 colored light.
[0035] Additionally, should a user desire a differently colored light than the first string 106 , the user may switch the control unit 105 to the mode of operation demonstrated by FIG. 4 b . This mode of operation enables a second wire 109 to receive forward biasing current and thereby activate the second string 107 LEDs. In this embodiment the second string 107 LED diodes are oriented so that the second wire 109 allows forward biasing current to flow into the p-side, or anode, and through to the n-side, or cathode, thereby making the second wire 109 the active wire and the first wire 108 the neutral wire. This causes the LEDs within the individual LED bulbs 112 to emit second string 107 colored light.
[0036] By switching the active line between the first wire 108 and the second wire 109 , a user is able to change or alternate the emitted light color within the same connected lighting system without replacing individual bulbs 112 to do so. It also obviates the need to purchase traditional color-changing bulbs that typically require use of a computerized device to communicate with the bulb or manipulation of an output selector on the bulb itself.
[0037] Referring now additionally to FIGS. 5 and 6 , another function of the present invention may include creating the perception of combined color 120 when the emitted colors of the first string 106 and the second string 107 are repeatedly alternated by the control unit 105 faster than the human eye can detect. This may optimally be achieved at rate within a range of 60 Hz to 480 Hz. Alternatively, the control unit 105 may be operable to alternate the designated active wire between the first wire 108 and the second wire 109 within a range from every 16 milliseconds to every 32 milliseconds. By way of non-limiting example, a first string color 106 may be red and a second string color 107 may be green within the same bulb. By alternating 16 milliseconds of green emitted light with 16 milliseconds of red emitted light, a human observer would perceive the light being emitted from a single bulb as yellow. Furthermore, by changing the ratio of how often the emitted colors are alternated, differently perceived colors may be achieved. Again, by way of non-limiting example, if the alternating ratio between red and green is changed from 1:1 to 2:1 respectively, the light emitted by the bulb may be perceived as orange. In this example, the red colored string would be emitted for 32 milliseconds while the green colored string would be emitted for 16 milliseconds. Conversely, if the ratio of red to green colored light emission was 1:2, meaning 16 milliseconds of red alternated with 32 milliseconds of green, the light emitted by the bulb may be perceived as blue.
[0038] The control unit 105 may include a dimmer 116 , a luminosity indicator 117 , a color synthesizer 118 , and a color indicator 119 . The control unit 105 may also include a driver circuit and a power supply 101 . The dimmer 116 may be adjusted by a user to control the amount of voltage delivered to the respective LED string within its threshold operating voltage range, i.e., the amount of voltage delivered to each of the first wire 108 and the second wire 109 . The luminosity indicator 117 may be a series of indicating lights located on the control unit 105 that indicate the brightness of either an individual LED string or all connected bulbs within a connected lighting system. More particularly, the luminosity indicator 117 may be configured to display luminosity of the lighting device electrically coupled to the first wire 108 and the second wire 109 .
[0039] The color indicator 119 may be configured to display one of animated color and the perceived emitted color of the lighting device. The color synthesizer 118 located on the control unit 105 may operate to combine the colors within the individual bulbs 112 . In one embodiment the color synthesizer 119 may represent the first string 106 at a first end and a second string 107 at a second end. The distance between the first and second end may represent the spectrum of colors between the first string 106 and second string 107 . In some embodiments, the ends may represent different points along the Planckian locus. By manipulating the color synthesizer between the first and second end, a user may manipulate the amount of emitted colored light of each LED string and therefore control the overall combined color of the emitted light. Likewise, the color indicator 118 may be a series of indicating lights representing the spectrum of colors between the first string 106 and the second string 107 at a respective first and second end. When the color synthesizer is positioned to emit a certain colored light at or between the first string 106 and second string 107 , the color indicator 118 may display the color indicating the user's selection. In one embodiment, the color synthesizer 118 may include a switch configured to alternate the frequency of forwardly biased current between the first wire 108 and the second wire 109 . The wire that receives forward bias current is designated active when a respective string of LEDs is operable.
[0040] In another embodiment, the lighting device may include a plurality of lighting devices within the lighting system. The driver circuit and the power supply 101 may be configured to drive the plurality of lighting devices 112 . Referring now to FIG. 7 , another embodiment of the present invention may include the control unit 105 being managed remotely via smart phone or other mobile device. The control unit 105 may be managed by at least one of a remote control or a computerized device. More specifically, the control unit by managed remotely by Bluetooth Low Energy controls 150 for easy and efficient management. In this embodiment a user may be able to manipulate the luminosity and color of the emitted bulbs 112 without physically touching the control unit 105 . Another embodiment includes adapting the control unit 105 to a standard outlet whereby a standard lamp may be managed similarly.
[0041] Yet another embodiment may include the control unit 105 including a timer. In this embodiment, the color synthesizer 119 may be managed by pre-set user instructions. Further, the timer may be configured to communicate a time of day to the color synthesizer 119 . The color synthesizer 119 may then activate a particular color within the lighting system based on the time of day. By way of non-limiting example, a user may desire a light emission with a higher color temperature during the morning hours of the day and a light emission with a lower color temperature during the evening hours. In this example a user would set the timer to communicate to the color synthesizer to activate the desired color in the morning then communicate to the color synthesizer to change the color in the evening. In another non-limiting example, a user may set the timer to a specific range of time whereby the emitted color would gradually shift from a starting color to an ending color based on a user input range of time and color.
[0042] Some of the illustrative aspects of the present invention may be advantageous in solving the problems herein described and other problems not discussed which are discoverable by a skilled artisan.
[0043] While the above description contains much specificity, these should not be construed as limitations on the scope of any embodiment, but as exemplifications of the presented embodiments thereof. Many other ramifications and variations are possible within the teachings of the various embodiments. While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best or only mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Also, in the drawings and the description, there have been disclosed exemplary embodiments of the invention and, although specific terms may have been employed, they are unless otherwise stated used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention therefore not being so limited. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.
[0044] Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not by the examples given. | Embodiments of the present invention are related to a lighting system comprising a control unit that manages a lighting device with an LED board within an optical chamber. The LED board includes a first string of LEDs and a second string of LEDs. The control unit and the LED board are configured to electrically couple to first and second wires. The first string of LEDs and the second string of LEDs are configured to emit light having different spectral power distributions within the visible spectrum. The first string of LEDs is oriented in an electrically opposite direction than the second string of LEDs. The control unit comprises a switch configured to direct current between the first wire and second wire. The wire to which current is directed is designated active. The designated active wire activates one of the first string of LEDs and second string of LEDs. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation application, and claims the benefit, of U.S. patent application Ser. No. 13/310,019, filed Dec. 2, 2011, which is a continuation of U.S. patent application Ser. No. 12/643,056, filed Dec. 21, 2009, now abandoned, which is a continuation of U.S. Ser. No. 12/180,057 filed Jul. 25, 2008, now U.S. Pat. No. 7,662,992, which is a continuation of U.S. Ser. No. 11/747,291 filed May 11, 2007, now abandoned, the entireties of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a process for the production of isosulfan blue, and in particular, to a process for the production of isosulfan blue in a substantially pure form.
BACKGROUND OF THE INVENTION
[0003] Isosulfan blue, having a chemical name, N-[4-[[4-(diethyl amino) phenyl](2,5-disulfophenyl) methylene]-2,5-cyclohexadien-1-ylidene]-N-ethylethanaminium, sodium salt and the formula
[0000]
[0000] is a triarylmethane dye used as a contrast agent for the delineation of lymphatic vessels and is particularly useful as a cancer diagnostic agent. Also known chemically as sulfan blue or patent blue, isosulfan blue is an active pharmaceutical ingredient used in the Lymphazurin™ blue dye pharmaceutical dosage form, available as 1% (10 mg/ml) 5 ml solution in phosphate buffer for injection. It is commonly used in a procedure called “mapping of the sentinel lymph nodes”. It is an adjunct to lymphography for visualization of the lymphatic system draining the region of injection. It has been used with increasing frequency in localizing sentinel lymph nodes in breast cancer patients. Isosulfan blue-guided surgical removal of cancerous tissue has been on the rise as it is cost effective and safer to use than technetium 99M radioisotope-labeled sulfur colloid. Isosulfan blue is a structural isomer of sulphan blue; both belong to the family of triarylmethane dyestuffs. Generally, preparation of triarylmethane dyes involves condensation of suitably substituted aryl aldehydes with 2 equivalents of alkyl-aryl amines giving rise to leuco-bases or leuco-acids followed by oxidation. Although the literature is replete with methods of preparing triarylmethane dyes, most of the methods involve strong acids for condensation resulting in leuco-bases or leuco-acids, hazardous oxidizing agents (lead oxide, chloranil, iron phthalocyanine/oxone) for converting to triarylmethane dyes, and crude methods (precipitation with sodium sulfate) of purification. See for example U.S. Pat. Nos. 4,330,476, 4,710,322, 1,531,507, 5,659,053, 1,805,925, 2,422,445, 1,878,530 and 2,726,252. Prior art methods of isolation of the crude leuco-acids or leuco-bases involve tedious neutralization/basification with strong bases and typically using the reaction mixtures in the oxidation step, giving rise to crude triarylmethane dyes. The triarylmethane dyestuffs thus prepared are used mainly for dyeing fabric, coloring paper, and printing inks The literature cites utilization of the same aforementioned synthetic and isolation methods for the preparation of diagnostically important dyes, such as isosulfan blue, sulphan blue and patent blue V. See, Rodd's Chemistry of Carbon Compounds by S. Coffey, 1974 2 nd Edition, Volume III Part F, 110-133.
[0004] Therefore there is a need in the art for an improved method in the process chemistry of isosulfan blue to be prepared in the purest form which is suitable for large scale cGMP production for its pharmaceutical formulation manufacturing.
SUMMARY OF THE INVENTION
[0005] It is therefore an object of the present invention is to provide a simple, safe, cost-effective, time saving and reliable process for the preparation of isosulfan blue in bulk scale and in substantially pure form. “Substantially pure” is defined herein as 99.0% or greater.
[0006] Another object of the invention is to provide a simple, cost-effective and reliable process for preparation of the intermediate, 2-chlorobenzaldehyde-5-sulfonic acid, sodium salt of formula (2), required in the preparation of isosulfan blue. This embodiment provides a process step that does not require tedious neutralization with very large quantities of sodium carbonate and effervescence, as is the case in prior art processes.
[0007] Another object of the invention is to provide a simplified procedure for the isolation of benzaldehyde-2,5-disulfonic acid, di-sodium salt of the formula (3) that does not include acidifying the reaction mixture with concentrated sulfuric acid and boiling until excess sulfurous acid is expelled, as is taught in the prior art.
[0008] Yet another object of the invention is to provide a procedure for obtaining the benzaldehyde-2,5-disulfonic acid, sodium salt of formula (3) free of inorganic salts, which essentially simplifies the isolation procedures to be implemented during isolation of isoleuco acid.
[0009] Yet another, object of the invention is to provide a process for the preparation of an isoleuco acid of formula (4), through the urea derivative as an in-situ intermediate. The isoleuco acid of formula (4) on further oxidation gives rise to the target compound, isosulfan blue (5). Still another object of the invention is to use very mild oxidation agent to avoid any over oxidized products and also to improve the stability of the isosulfan blue under reaction conditions.
[0010] According to this invention, there is provided a simple procedure for the isolation of benzaldehyde-2,5-disulfonic acid, isoleuco acid and isosulfan blue at acid stage and also at sodium salt formation stage by incorporating crystallization techniques, thereby avoiding distillation and other techniques using high temperatures which jeopardize the compound stability during the manufacturing process.
[0011] These and other aspects of the invention will be apparent to those skilled in the art.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] In the following description, for purposes of explanation, specific numbers, materials and configurations are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one having ordinary skill in the art that the invention may be practiced without these specific details. In some instances, well-known features may be omitted or simplified so as not to obscure the present invention. Furthermore, reference in the specification to phrases such as “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of phrases such as “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment. In accordance with one embodiment the present invention relates to a process for the preparation of isosulfan blue.
[0000]
Experimental Procedures
[0013] In accordance with one embodiment of the present invention a first step involves sulfonation of the commercially available starting material of the formula (1) to 2-chlorobenzaldehyde-5-sulfonic acid sodium salt of the formula (2).
[0000]
[0014] In one example, the sulfonation process involved reacting one equivalent of the 2-chlorobenzaldehyde of formula (1) with 2.0 equivalents of 20% fuming sulfuric acid at 15° C. to 70° C. for 16 hrs. The reaction mixture was poured into ice-water carefully followed by stirring with solid sodium chloride resulting in a cream colored precipitate, which upon filtration, washing with ether and drying afforded 2-chlorobenzaldehyde-5-sulfonic acid of the formula (2) in 86% yield.
[0015] In accordance with one embodiment of the present invention, a second step of the process involves nucleophilic displacement of the chloride in 2-chlorobenzaldehyde-5-sulfonic acid sodium salt of the formula (2) with an alkali metal sulfite/bisulfite such as sodium sulfite/sodium bisulfite at elevated temperatures under closed conditions.
[0016] In one example, this reaction was carried out in a Parr pressure vessel equipped with overhead magnetic stirring. 2-Chlorobenzaldehyde-5-sulfonic acid (2), sodium sulfite (2.29 equivalents), sodium bisulfite (10% of sodium sulfite), and water (3.45 mL/g) were charged into the Parr pressure vessel. The reaction mixture in the vessel was stirred and heated at 170-180° C. for 5-7 hours generating 140-150 psi pressure.
[0017] The reaction mixture, after cooling, was poured into methanol while stirring, so as to make 20% aqueous content of the whole volume. This process ensured total precipitation of the inorganic salts, which could be removed by filtration. The solvent from the filtrate was removed under reduced pressure to obtain a solid residue, which was triturated with methanol and filtered to afford light yellow colored compound, benzaldehyde-2,5-disulfonic acid, di sodium salt of the formula (3) in 93.9% yield.
[0018] In accordance with one embodiment a purification procedure for removing the inorganic salts essentially involves dissolving the crude solid in N,N dimethylformamide and stirring the contents for 1-2 hours at ambient temperature followed by filtration. The filtrate is precipitated by dichloromethane to afford the light yellow colored compound, benzaldehyde-2,5-disulfonic acid disodium salt of formula (3) with chromatographic purity NLT 99.0% and with HPLC assay greater than 90% w/w.
[0000]
[0019] In accordance with one embodiment of the present invention, a third step of the process involved condensing benzaldehyde-2,5-disulfonic acid, disodium salt of the formula (3) with N, N-diethylaniline to provide isoleuco acid of the formula (4).
[0000]
[0020] In one example, pure isoleuco-acid of the formula (4) with chromatographic purity greater than 98.0% was obtained in the solid form out of the reaction mixture. A mixture of benzaldehyde-2,5-disulfonic acid, disodium salt of the formula (3), N,N-diethylaniline (2.2 equivalents), and urea (0.75 equivalents) in glacial acetic acid was stirred and refluxed for 20-25 hrs. The reaction progressed through the intermediate formation in-situ which is a urea derivative of benzaldehyde-2,5-disulfonic acid disodium salt. To the above cooled reaction mixture after 20-25 hrs reflux, methanol was added to form a precipitate, which was collected by vacuum filtration and washed with diethyl ether to afford the isoleuco acid of the formula (4) in 56.8% yield.
[0021] The purification of isoleuco acid was carried out by dissolving the crude solid in 5 volumes of water and stirred for 1-2 hours at ambient temperature and filtering the solid. The above process was repeated twice before the final solid was washed with acetone to generate isoleuco acid of the formula (4) with chromatographic purity greater than 99.5%.
[0022] In accordance with one embodiment of the present invention a fourth step of the process involves conversion of the isoleuco acid (4) to isosulfan blue of the formula (5) under conditions that employ milder oxidizing agents with no strong acidic reagents and are less hazardous than the prior art.
[0000]
[0023] In an example of the present inventive process, a suspension of isoleuco acid of the formula (4) in methanol was stirred at room temperature for 12-14 hrs with silver oxide (2.5 equivalents). The blue colored reaction mixture was filtered through a pad of silica gel and Celite followed by filtration through an acidic zeolite bed and further through a 0.2 micron membrane filtration unit. The filtrate was then precipitated with isopropyl ether at room temperature to obtain crude isosulfan blue acid.
[0024] The isosulfan blue acid thus obtained was then purified by recrystallization from aqueous isopropyl alcohol/acetone to afford isosulfan blue acid of chromatographic purity NLT 99.5% performed by High Performance Liquid Chromatography.
[0025] The final product of isosulfan blue sodium (formula 5) was obtained when isosulfan blue acid was adjusted to a pH greater than 6.0 in aqueous acetone medium using sodium bicarbonate solution for pH adjustment. The reaction mass was filtered to give isosulfan blue sodium of formula (5) having purity greater than 99.5% by HPLC and also free of silver with silver content estimated by Atomic absorption spectrometer less than 20 ppm.
EXAMPLES
2-Chlorobenzaldehyde-5-sulfonic acid, sodium salt of the formula (2)
[0026] 113.82 g (based on SO 3 molecular weight, 569 mL) of 20% fuming sulfuric acid (FSA) was charged into a 1 L three-neck flask fitted with a dropping funnel, overhead stirrer, and thermometer. The reaction mass was cooled to 15 to 20° C. 100 g of 2-chlorobenzaldehyde of the formula (1) was added drop-wise to the stirred and cooled FSA over a period of 40 minutes, so that the temperature didn't rise above 20° C. The reaction mixture was stirred and heated at 70° C. for 16 hours to obtain a dark-brown colored reaction solution. The HPLC results indicated the absence of the starting material. The dark-brown colored reaction solution was carefully poured into a beaker containing 1200 g of crushed ice and stirred. 500 g of solid sodium chloride was added portion wise to the stirred colored acidic solution to precipitate a light-yellow colored solid. The light-yellow colored solid was collected by vacuum filtration and washed with diethyl ether to afford 150.0 g (86.92%) of 2-chlorobenzaldehyde-5-sulfonic acid, sodium salt of the formula (2).
Benzaldehyde-2,5-disulfonic acid, sodium salt of the formula (3)
[0027] 50 g (0.206 mol) of 2-chlorobenzaldehyde-5-sulfonic acid, sodium salt of the formula (2), 59.75 g (0.474 mol, 2.3 eq.) of Na 2 SO 3 and 5.97 g (10% of Na 2 SO 3 ) of NaHSO 3 were dissolved in 400 mL of water. The solution was charged into a 600 mL capacity Parr pressure cylinder equipped with stirring and heating. The reaction mixture was stirred (300-310 RPM) and heated at 180° C. (generates ˜150 psi pressure) for 5-7 hours. HPLC results indicate the absence of the starting material. After cooling and releasing the pressure, the reaction mixture was poured into 1600 mL of stirred methanol and stirred for 15-30 minutes to precipitate the unwanted inorganic salts. The inorganic salts were filtered off using a pad of Celite and the filtrate evaporated under reduced pressure to obtain a solid residue. The solid residue obtained was triturated with 200 mL methanol, collected by filtration and washed with ether to give 60 g (93.9%) of benzaldehyde-2,5-disulfonic acid, sodium salt of formula (3).
Purification of Benzaldehyde-2,5-disulfonic acid, sodium salt formula (3)
[0028] 60 g of crude benzaldehyde-2,5-disulfonic acid, disodium salt prepared as per the procedure above was dissolved in 500 mL of N,N-dimethylformamide and stirred for 2 hours at 20-25° C. The mixture was filtered through a buchner funnel and the filtrate was precipitated using 1500 mL of dichloromethane to afford 20 g of the light yellow colored compound, benzaldehyde-2,5-disulfonic acid disodium salt of formula (3) with chromatographic purity NLT 99.0% w/w.
Isoleuco Acid of the Formula (4).
[0029] 60 g of benzaldehyde-2,5-disulfonic acid sodium salt of formula (3), 8.76 g of urea (0.75 eq), and 1000 mL of glacial acetic acid were charged into a 3 L 3-neck flask fitted with a mechanical stirrer and reflux condenser. 65.61 mL (2.2 eq) of N,N-diethyl aniline was added to the stirred mixture and refluxed for 20-25 hrs. When the HPLC results indicated the content of starting material was less than 5%, the reaction mass was cooled to room temperature. After cooling to room temperature, 600 mL of methanol was added and the separated solid collected on a sintered funnel by vacuum filtration. The collected solid was washed with methanol to obtain 55-60 g (56.8%) of crude isoleuco acid of the formula (4).
Purification of Isoleuco Acid of Formula (4)
[0030] 50 g of crude isoleuco acid along with 250 ml of water was charged into a 1 L 3-neck round bottom flask fitted with a mechanical stirrer. The reaction mixture was stirred for 1 hour at 20-25° C. The solid was filtered through a buchner funnel.
[0031] The above process was repeated twice. The final product thus obtained was then washed with 25 ml of acetone and then dried to obtain 40-45 g of the desired isoleuco acid of formula (4).
Isosulfan Blue of the Formula (5)
[0032] 15 g (0.027 mol) of isoleuco acid of the formula (4) and 225 mL of Methanol were charged into a 1 L round bottomed flask and the suspension was stirred. To the stirred suspension, 15.91 g (0.068 mol, 2.5 eq.) of silver oxide was added in one portion at room temperature and stirred at room temperature for 12-14 hours. The reaction mixture turned blue in color as the oxidation to the desired product progressed. The HPLC results indicated the absence of starting material. The blue colored reaction mixture was filtered through a buchner funnel and the solid silver oxide collected was taken into the reaction flask and the filtrate was kept aside. 225 ml of methanol was added to the silver oxide taken in the reaction flask and stirred at 20-25° C. for 30 minutes and filtered through the buchner funnel. This silver oxide washing procedure with methanol was carried out twice more.
[0033] The combined filtrates along with the initial filtrate were then filtered through a bed of silica gel/celite (2 inch silica gel/1 inch of celite) and finally the bed was washed with 50 mL of methanol.
[0034] The filtrate was then subjected to a filtration through an acidic zeolite bed of 2 inch height (pH of the zeolite bed was adjusted to acidic pH by using 0.1N hydrochloric acid aqueous solution) followed by filtration through a 0.2 micron filtration unit.
[0035] Isopropyl ether was added three times the volume of the filtrate and the isosulfan blue acid was precipitated as a solid at about 10 gram (68.8%) yield.
[0036] In order to prepare the Isosulfan blue sodium salt of the formula (5), 10.0 g of the solid obtained above was dissolved in 30 mL deionized water. Saturated sodium bicarbonate solution was added drop wise to adjust the pH to 8.0. To this 300 mL of acetone was added and stirred at 20-25° C. for 30 minutes. The crystallized product was then filtered through a buchner funnel and the solid thus obtained was dried at 40° C. under vacuum to obtain the isosulfan blue sodium salt of formula (5).
[0037] While the preferred embodiments have been described and illustrated it will be understood that changes in details and obvious undisclosed variations might be made without departing from the spirit and principle of the invention and therefore the scope of the invention is not to be construed as limited to the preferred embodiment. | A process for the preparation of isosulfan blue (Active Pharmaceutical Ingredient) is provided. A process is also provided for preparation of the intermediate, 2-chlorobenzaldehyde-5-sulfonic acid, sodium salt of formula (2), used in the preparation thereof and a procedure for the isolation of benzaldehyde-2,5-disulfonic acid, di-sodium salt of the formula (3). Also provided is a process for the preparation of an isoleuco acid of formula (4), which upon mild oxidation gives rise to isosulfan blue of pharmaceutical grade which can be used for preparation of pharmaceutical formulations. The isolation and purification procedures provided in the process provide substantially pure isosulfan blue with HPLC purity 99.5% or greater. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 62/166,840 filed on May 27, 2015. The above identified patent application is herein incorporated by reference in its entirety to provide continuity of disclosure.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to building arrangements. More particularly, the present invention relates to residential building complexes designed to provide increased population density and eliminate the need for common entry areas to each of the individual housing units within the building.
[0003] Multi-family residential buildings typically require common areas to provide access to each unit within the building via stairs, elevators, hallways, or any combination thereof. However, common areas carry substantial construction and operational costs that can be prohibitive in meeting market needs. Therefore, there is a need in the prior art for building configurations that lack the prohibitively expensive common areas generally utilized for providing tenants access to their units, while at the same time not sacrificing the amount of livable space available in the residential area.
SUMMARY OF THE INVENTION
[0004] In view of the foregoing disadvantages inherent in the known types of multi-story buildings now present in the prior art, the present invention provides a multi-story building configured to maximize population density and eliminate the need for entryways common to all of the housing units within the building. The present multi-story building comprises two ground floor single story units that each have a front facing entry directly accessing each unit. The building further includes up to four second floor units that each have direct stair or elevator access from their ground floor entries. Each building has a front facing the street and a back with garages facing the alley. This configuration allows occupants direct access to their units without the need for common access ways, while simultaneously allowing for improved support for increased population density within an area. The present multi-story housing building eliminates the high initial and operating costs of common areas and provides an efficient and economical alternative to current building types.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself and manner in which it may be made and used may be better understood after a review of the following description, taken in connection with the accompanying drawings wherein like numeral annotations are provided throughout.
[0006] FIG. 1 shows a perspective view of the front of a diagram of an illustrative embodiment of the present multi-story building.
[0007] FIG. 2 shows a perspective view of the rear of a diagram of an illustrative embodiment of the present multi-story building.
[0008] FIG. 3 shows a plan view of the first floor of a diagram of an illustrative embodiment of the present multi-story building.
[0009] FIG. 4 shows a plan view of the second floor of a diagram of an illustrative embodiment of the present multi-story building.
[0010] FIG. 5 shows a perspective view of an illustrative embodiment of the present multi-story building.
[0011] FIG. 6 shows a plan view of the first floor of an illustrative embodiment of the present multi-story building.
[0012] FIG. 7 shows a plan view of the second floor of an illustrative embodiment of the present multi-story building.
[0013] FIG. 8 shows a plan view of the third floor of an illustrative embodiment of the present multi-story building.
[0014] FIG. 9 shows an elevational view of the front of an illustrative embodiment of the present multi-story building.
[0015] FIG. 10 shows an elevational view of the rear of an illustrative embodiment of the present multi-story building.
[0016] FIG. 11 shows an elevational view of the right side of an illustrative embodiment of the present multi-story building.
[0017] FIG. 12 shows an elevational view of the left side of an illustrative embodiment of the present multi-story building.
DETAILED DESCRIPTION OF THE INVENTION
[0018] Reference is made herein to the attached drawings. Like reference numerals are used throughout the drawings to depict like or similar elements of the XXX. The figures are intended for representative purposes only and should not be considered to be limiting in any respect.
[0019] Referring now to FIGS. 1 and 2 , there are shown perspective views of the front and the rear of a diagram of an illustrative embodiment of the present multi-story building. The present building 111 includes two one-story units, i.e. flats, disposed on the first level 131 thereof. The one-story units include a first one-story unit 112 A and a second one-story unit 112 B arranged adjacently to each other. The present building 111 further includes a garage unit 113 arranged adjacently to the first one-story unit 112 A and the second one-story unit 112 B. The first one-story unit 112 A, the second one-story unit 112 B, and the garage unit 113 together define the first level 131 of the building 111 . The first level 131 has the shape of a closed geometric shape, e.g., a rectangular cuboid.
[0020] As used herein, a “garage unit” is enclosed structure having one wall substantially occupied by one or more openable doors to permit access to the interior of the garage unit by a vehicle. The interior of the garage unit can contain one or more spaces in which a vehicle can park. As used herein, a “unit” in the context of a “one-story unit” or a “multi-story unit” is an enclosed structure utilizable as a dwelling by one or more individuals. As used herein, an “access way” is a structure or mechanism for obtaining entry to a unit, e.g., a stairway, an elevator, or a lift.
[0021] In one embodiment of the present building 111 , the garage unit 113 has a number of spaces equal to the number of dwelling units, i.e., the sum of the number of one-story units 112 A, B and the number of multi-story units 114 A, B, C, D in the building 111 . This arrangement ensures that each tenant has access to a parking space. For example, in the depicted embodiment of the building 111 , there are two one-story units 112 A, B and four multi-story units 114 A, B, C, D; therefore, there are six parking spaces within the garage unit 113 . In an illustrative embodiment of the present building 111 , the garage unit 113 is equal in height to the one-story units 112 A, B situated adjacently thereto, thereby creating a planar or level division between the first level 131 and the second level 132 lying thereover. Furthermore, in an illustrative embodiment of the present building 111 , the perimeter of the second level 132 is coextensive with the perimeter of the first level 131 such that the exterior walls of the first and second levels 131 , 132 are coplanar.
[0022] The present building 111 further includes up to four multi-story units, i.e. townhouses, disposed on the second level 132 thereof. In an illustrative embodiment of the present building 111 , the second level 132 includes a first multi-story unit 114 A, a second multi-story unit 114 B, a third multi-story unit 114 C, and a fourth multi-story unit 114 D arranged adjacently to each other. Whereas the first level 131 is a single story, the second level 132 has multiple stories as it is made up of multi-story units 114 A, B, C, D. Both the second level 132 individually and the combination of the first level 131 with the second level 132 have the shape of a closed geometric shape, e.g., a rectangular cuboid.
[0023] The present building 111 further includes a plurality of entries 115 A, B, C, D, E, F providing access to the various dwellings or units of which the building 111 is composed. The first entry 115 A is disposed on the front of the building 111 and provides access to the first one-story unit 112 A. The second entry 115 B is likewise disposed on the front of the building 111 , separated from the first entry 115 A, and provides access to the second one-story unit 112 B. A third entry 115 C and fourth entry 115 D are disposed on a first lateral side of the building 111 and provide access to the first multi-story unit 114 A and the second multi-story unit 114 B, respectively. A fifth entry 115 E and sixth entry 115 F are disposed on a second lateral side of the building 111 and provide access to the third multi-story unit 114 C and the fourth multi-story unit 114 D, respectively.
[0024] Within the context of a residential environment, an illustrative embodiment of the building 111 is positioned so that the front of the building 111 is facing a street 191 and the rear of the building 111 is facing an alley 192 extending behind the building 111 . The individuals living in the building 111 can access the garage unit 113 located on the rear of the building via the alley 192 . A plurality of the present buildings 111 can be arranged adjacently to each other along a common street or road, thereby forming a neighborhood or complex.
[0025] Referring now to FIGS. 3 and 4 , there are shown plan views of the first and second floors of a diagram of an illustrative embodiment of the present multi-story building. In an illustrative embodiment of the present building, the first level 301 includes the first one-story unit 302 A, the second one-story unit 302 B, and the garage unit 303 arranged in a rectangular floor plan. The first level 301 further includes a first entry 304 A positioned to provide access to the first one-story unit 302 A and a first entry 304 B positioned to provide access to the second one-story unit 302 B. The first entry 304 A and the second entry 304 B each provide individualized access to the first one-story unit 302 A and the second one-story unit 302 B.
[0026] The first level 301 further includes a third entry 304 C and a fourth entry 304 D positioned adjacently next to each other between the first one-story unit 302 A and the garage unit 303 . The third entry 304 C includes a first access way 305 A configured to provide individualized entry to the first multi-story unit 402 A. The fourth entry 304 D further includes a second access way 305 B configured to provide individualized entry to the second multi-story unit 402 B. The first level 301 further includes a fifth entry 304 E and a sixth entry 304 F positioned adjacently next to each other between the second one-story unit 302 B and the garage unit 303 . The fifth entry 304 E includes a third access way 305 C configured to provide individualized entry to the third multi-story unit 402 C. The sixth entry 304 F further includes a fourth access way 305 D configured to provide individualized entry to the fourth multi-story unit 402 D. In the depicted embodiment of the present building, the access ways 305 A, B, C, D are illustrated as stairways; however, the access ways 305 A, B, C, D in other embodiments of the present building include elevators, lifts, and other mechanisms for obtaining entry to a higher level unit or structure.
[0027] In the embodiment of the present building depicted in FIG. 1 , the multi-story units 402 A, B, C, D are two stories in height. However, no claim is made as to a specific maximum height restriction for the multi-story units 402 A, B, C, D. In alternative embodiments of the present building, the multi-story units 402 A, B, C, D can be three or more stories in height. Furthermore, in the depicted embodiment of the present building the multi-story units 402 A, B, C, D are depicted as symmetrical in shape in layout. However, no claim is made as to the multi-story units 402 A, B, C, D being symmetrical in shape, size, or layout.
[0028] The depicted configuration of the present building gives each unit within the building its own individual access way, while still supporting a degree of population density that does not needlessly sacrifice living space. By providing each unit its own access way, there is no need for common access ways that are prohibitively expensive to construct and operate for the building owner. Furthermore, the tight, compact design of the building is convenient to reproduce and situate in complexes or neighborhoods.
[0029] Referring now to FIGS. 5-12 , there are shown perspective, plan, and elevational views of an embodiment of the present building. As in the aforementioned diagrams depicted in FIGS. 1-4 , the present building 501 includes a garage unit 503 , a first entry 504 A that provides individualized access to a first single-story unit 502 A, a second entry 504 B that provides individualized access to a second single-story unit 502 B, a third entry 504 C that provides individualized access to a first multi-story unit 505 A, a fourth entry 504 D that provides individualized access to a second multi-story unit 505 B, a fifth entry 504 E that provides individualized access to a third multi-story unit 505 C, and a sixth entry 504 F that provides individualized access to a fourth multi-story unit 505 D. The third entry 504 C, the fourth entry 504 D, the fifth entry 504 E, and the sixth entry 504 F include a first access way 506 A, a second access way 506 B, a third access way 506 C, and a fourth access way 506 D, respectively.
[0030] The illustrative embodiment of the present building 501 further includes a patio 515 disposed along the front exterior of the building 501 for each of the single-story units 502 A, B and a balcony 514 disposed on the exterior of the building 501 for each of the multi-story units 505 A, B, C, D. Each of the single-story units 502 A, B and the multi-story units 505 A, B, C, D further includes bathrooms, living rooms, kitchens, and other such amenities common to living spaces. Furthermore, in the depicted illustrative embodiment of the present building 501 , each parking space of the garage unit 501 includes its own corresponding garage door.
[0031] It is therefore submitted that the instant invention has been shown and described in various embodiments. It is recognized, however, that departures may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
[0032] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A multi-story residential building complex. The building complex includes two ground floor single-story units that each have a front facing entry directly accessing each unit. The building complex further includes up to four second floor units that each have direct stair or elevator access from their ground floor entries. Each building has a front facing the street and a back with a garage unit having one or more parking spaces facing the alley. This configuration allows occupants direct access to their units without the need for common access ways, while simultaneously allowing for improved support for increased population density within a residential area. The present multi-story housing building eliminates the high initial and operating costs of common areas and provides an efficient and economical alternative to current building types. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a U.S. national stage of application No. PCT/JP2007/058254, filed on Apr. 16, 2007. Priority under 35 U.S.C. §119(a) and 35 U.S.C. §365(b) is claimed from Japanese Application No. JP-2006-126350, filed Apr. 28, 2006, the disclosure of which is also incorporated herein by reference.
FIELD OF THE INVENTION
[0002] At least an embodiment of the present invention relates to a medium processing system in which information data is sent and received between a medium processing apparatus and a host apparatus connected to the medium processing apparatus, as well as an intermediary medium processing apparatus.
BACKGROUND OF THE INVENTION
[0003] Being conventionally used as a bank card and/or a card for implementation of personal authentication in financial institutions and so on, there are a magnetic card made by forming a magnetic stripe on a plastic substrate surface, and a contact IC card in which an integrated circuit chip (IC chip) is embedded inside a plastic substrate and an IC terminal is placed on a surface of the plastic substrate. Then, writing and reading information data for such a magnetic card and a contact IC card is carried out by using a card reader equipped with a magnetic head and a IC contact.
[0004] Meanwhile, in recent years, there has appeared a non-contact card in which an IC chip and an antenna coil are embedded and writing and reading information data is carried out via the antenna coil by means of electromagnetic interaction. Such a non-contact IC card is provided with a memory capacity and a security level that are equivalent to what a contact IC card has. Furthermore, being compared to a magnetic card and the contact IC card with which data is sent and received while those cards are sliding (contacting), the non-contact IC card is excellent at operation performance (what a user has to do is only holding up the non-contact IC card) and maintainability (there exists no contacting part). Then, writing and reading information data for the non-contact IC card is carried out by a card reader that is equipped with an antenna for generating an electromagnetic wave.
[0005] Moreover, developed in recent years is an IC card reader provided with a hybrid function, with which all of the magnetic card, contact IC card, and non-contact IC card described above can be handled and processing for each card can be implemented (For example, refer to Patent Document 1). An IC card reader disclosed in Patent Document 1 includes; a magnetic head with which magnetic data is sent and received to/from a magnetic stripe of a magnetic card; an IC contact with which data is sent and received to/from an IC contact of a contact IC card; and a sending and receiving antenna with which data is sent and received to/from an antenna coil of a non-contact IC card.
[0006] On this occasion, in the view from a host apparatus such as an ATM; it is desirable in terms of control operation that there exists one and only device which handles various cards including a magnetic card, a contact IC card, a non-contact IC card, and so on. Furthermore, a device interface (for example, RS232C), which the host apparatus is equipped with, is limited in its number. Therefore, in the case of an IC card reader provided with a hybrid function, usually only a card reader for a magnetic card or a contact IC card is connected to the host apparatus, and then a control circuit for a non-contact IC card is additionally connected to the card reader.
[0007] FIG. 6 is a block diagram showing an electrical system structure of a conventional medium processing system.
[0008] As shown in FIG. 6 , only an existing card reader 201 for a magnetic card or a contact IC card in an IC card reader 200 is connected to a host apparatus 100 with an RS232C interface. Then, a non-contact IC card reader function 202 (such as an antenna coil, a control circuit, and so on) is mounted onto (additionally connected to) the existing card reader 201 .
[0009] Japanese Patent No. 3241254 (FIG. 1) relates to a conventional IC card reader.
[0010] Unfortunately, there exist problems described below in a conventional medium processing system.
[0011] A first point is that the non-contact IC card reader function 202 is able to carry out high-speed communication with a non-contact IC card (for example, a communication speed in the case is about 10 times faster than a communication speed of a case where the existing card reader 201 communicates with a contact IC card). Naturally it is desirable that a function of the high-speed communication is utilized. However, since the existing card reader 201 is connected to the host apparatus 100 via the RS232C interface (with a communication speed, for example, of 38,400 bps) in the conventional medium processing system, the non-contact IC card reader function 202 is able to access to the host apparatus 100 only through the existing card reader 201 (Refer to FIG. 6 ) so that an advantage of the high-speed communication cannot be utilized sufficiently.
[0012] Furthermore, when the non-contact IC card reader function 202 , being for example as a separate circuit board, is additionally connected to the existing card reader 201 , it is necessary to have some design specification change at a side of the existing card reader 201 . However, it is not only extremely complicated but also unpractical to additionally connect such a function for taking into account some possible refurbishment required in the market (non-contact IC card reader function) to the existing card reader 201 . Moreover, in a case of the existing card reader 201 that has already obtained for example an approval certification and so on, it becomes necessary to obtain a certification again due to the specification change and then such additional work is unpractical and furthermore it costs much.
[0013] At least an embodiment of the present invention is materialized in view of the problems described above, and at least an embodiment of the present invention provides a medium processing system that includes medium processing apparatuses, in which communication speeds for information recording media are different, and is able to take advantage of high-speed communication, and provides such a medium processing system and an intermediary medium processing apparatus that are practical and low-cost.
SUMMARY OF THE INVENTION
[0014] To solve the problems identified above, at least an embodiment of present invention may include:
[0015] (1) A medium processing system including: a first medium processing apparatus that carries out writing and reading information data to/from an information recording medium; a host apparatus having an interface with which the first medium processing apparatus is connectable; and a second medium processing apparatus that intermediates connection between the first medium processing apparatus and the host apparatus; wherein the second medium processing apparatus carries out writing and reading information data to/from an information recording medium at a higher speed than the first medium processing apparatus does.
[0016] According to at least an embodiment of the present invention, the medium processing system includes the first medium processing apparatus, and the second medium processing apparatus that intermediates connection to the host apparatus having an interface with which the first medium processing apparatus is connectable. Then, the second medium processing apparatus carries out writing and reading information data to/from an information recording medium at a higher speed than the first medium processing apparatus does. Therefore, at the second medium processing apparatus that carries out information data processing at a relatively higher speed in comparison with the first medium processing apparatus, information data processing can be carried out without taking care of the presence of the first medium processing apparatus that carries out information data processing at a relatively lower speed so that it becomes possible to take advantage of high-speed communication.
[0017] According to at least an embodiment of the present invention especially, the second medium processing apparatus can be added to the host apparatus, to which conventionally the first medium processing apparatus has been connected, without newly adding any interface. Thus, while the number of interfaces for devices, which the host apparatus has, being minimized (for example, one interface) and without adding any design specification change to the first medium processing apparatus, the second medium processing apparatus can be installed into the medium processing system. As a result, the setup described above is able to contribute to a cost reduction and improvement of practicality.
[0018] (2) The medium processing system according to item (1): wherein the first medium processing apparatus carries out writing and reading magnetic data to/from an information recording medium; and meanwhile the second medium processing apparatus carries out writing and reading information data to/from an information recording medium by means of electromagnetic induction in a non-contact manner.
[0019] According to at least an embodiment of the present invention, the first medium processing apparatus carries out writing and reading magnetic data to/from an information recording medium and meanwhile the second medium processing apparatus carries out writing and reading information data to/from an information recording medium by means of electromagnetic induction in a non-contact manner. Therefore, even though writing and reading magnetic data to/from a magnetic card is carried out at a low speed, sending and receiving data to a non-contact IC card can be carried out at a high speed.
[0020] For example, in a case especially where the first information data processing apparatus has already obtained an approval certification, etc., and adopted there is a conventional system structure (Refer to FIG. 6 ) in which the second information data processing apparatus (the non-contact IC card reader function 202 in FIG. 6 ) is additionally connected to the first information data processing apparatus (the existing card reader 201 in FIG. 6 ), it becomes necessary to obtain a certification again due to the specification change and then such additional work is unpractical and furthermore it costs much. However, according to at least an embodiment of the present invention, it is not necessary to add any design specification change to the first medium processing apparatus, and therefore obtaining a certification again as described above is not required so that a practical and low-cost medium processing system can be constructed.
[0021] (3) The medium processing system according to item (2): wherein the first medium processing apparatus includes an IC contact that contacts with an IC terminal placed on an information recording medium.
[0022] According to at least an embodiment of the present invention, the first medium processing apparatus includes an IC contact that contacts with an IC terminal placed on an information recording medium, and therefore it is possible to construct a hybrid medium processing system which includes both contact IC communication and non-contact IC communication (or magnetic data communication) and to take advantage of high-speed non-contact IC communication.
[0023] (4) The medium processing system according to any of item (1) through item (3): wherein the second medium processing apparatus includes a buffer that temporarily stores a command from the host apparatus.
[0024] According to at least an embodiment of the present invention, the second medium processing apparatus described above includes a buffer that temporarily stores a command from the host apparatus so that a processing speed difference between the first medium processing apparatus, which carries out magnetic data processing at a relatively low speed, and the second medium processing apparatus, which carries out non-contact information data processing at a relatively high speed can be canceled, and eventually both the medium processing apparatuses can carry out information data processing at an appropriate speed.
[0025] Additionally, in at least an embodiment of the present invention, the buffer can store a command to the first medium processing apparatus from the host apparatus and/or a command to the second medium processing apparatus from the host apparatus. Furthermore, the number of buffers may be one or two (one for the first medium processing apparatus and the other for the second medium processing apparatus).
[0026] (5) The medium processing system according to item (4): wherein the buffer temporarily stores a command from the host apparatus to the first medium processing apparatus.
[0027] According to at least an embodiment of the present invention, the buffer described above temporarily stores a command from the host apparatus to the first medium processing apparatus so that cancellation of a command due to an overflow and so on can be avoided even if the first medium processing apparatus has a low processing speed.
[0028] (6) The medium processing system according to item (5): wherein the buffer furthermore temporarily stores a command from the host apparatus to the second medium processing apparatus.
[0029] According to at least an embodiment of the present invention, the buffer described above temporarily stores a command from the host apparatus to the second medium processing apparatus so that information data processing of the second medium processing apparatus can get started at appropriate timing.
[0030] (7) The medium processing system according to item (5): wherein the second medium processing apparatus includes: a communication section that carries out writing and reading information data to/from an information recording medium; and a control section connected to the communication section and the buffer; and when having received a command from the host apparatus, the control section judges the command from the host apparatus to be for the first medium processing apparatus if so, and transfers the command to the buffer; and meanwhile the control section judges the command from the host apparatus to be for the second medium processing apparatus if so, and transfers the command to the communication section.
[0031] According to at least an embodiment of the present invention, the second medium processing apparatus includes not only a buffer but also a communication section that carries out writing and reading information data to/from an information recording medium, and a control section connected to the communication section and the buffer. Then, at the time of having received a command from the host apparatus, the control section transfers the command to the buffer if the command from the host apparatus is for the first medium processing apparatus; and meanwhile the control section transfers the command to the communication section if the command from the host apparatus is for the second medium processing apparatus. Therefore, the first medium processing apparatus, which carries out magnetic data processing at a relatively low speed, and the second medium processing apparatus, which carries out non-contact information data processing at a relatively high speed, can each carry out sending and receiving a command at an appropriate processing speed efficiently.
[0032] (8) The medium processing system according to item (6): wherein the control section judges a command from the host apparatus among commands stored in the buffer to be for the first medium processing apparatus if so, and transfers the command to the first medium processing apparatus; and meanwhile the control section judges a command from the host apparatus to be for the second medium processing apparatus if so, and transfers the command to the communication section.
[0033] According to at least an embodiment of the present invention, the control section described above transfers a command, which is received from the host apparatus for the first medium processing apparatus, to the first medium processing apparatus from the buffer; and meanwhile the control section transfers a command, which is received from the host apparatus for the second medium processing apparatus, to the communication section from the buffer. Therefore, both the medium processing apparatuses are able to efficiently carry out information data processing.
[0034] (9) The medium processing system according to any of item (1) through item (8): wherein the second medium processing apparatus includes a function for spontaneously controlling the first medium processing apparatus.
[0035] According to at least an embodiment of the present invention, the second medium processing apparatus described above includes a function for spontaneously controlling the first medium processing apparatus, and therefore it is possible without any command from the host apparatus to carry out information data processing between the first medium processing apparatus and the second medium processing apparatus. Accordingly, for example, a processing operation such as exclusive processing between the first medium processing apparatus and the second medium processing apparatus (one of the medium processing apparatuses is operating, the other is kept out of operation) can be carried out at a high speed, and furthermore it is possible to reduce a load of operation of the host apparatus.
[0036] (10) The medium processing system according to any of item (1) through item (9): wherein the second medium processing apparatus includes a function for automatically recognizing a sort of the first medium processing apparatus.
[0037] According to at least an embodiment of the present invention, the second medium processing apparatus described above includes a function for automatically recognizing a sort of the first medium processing apparatus, and therefore it is possible without receiving any command from the host apparatus to autonomously realize the function of item (9) compatible with the first medium processing apparatus.
[0038] (11) An intermediary medium processing apparatus including: an intermediary of connection between a medium processing apparatus for writing and reading information data to/from an information recording medium and a host apparatus having an interface with which the medium processing apparatus is connectable; wherein the intermediary medium processing apparatus carries out writing and reading information data to/from an information recording medium at a higher speed than the medium processing apparatus does.
[0039] According to at least an embodiment of the present invention, the intermediary medium processing apparatus corresponds to the second medium processing apparatus of the medium processing apparatuses described above, and therefore it is possible to take advantage of high-speed communication without taking care of the presence of a medium processing apparatus that carries out information data processing at a relatively lower speed (for example, a magnetic card reader).
[0040] According to a medium processing system and an intermediary medium processing apparatus relating to at least an embodiment of the present invention, as described above; even in a medium processing system including medium processing apparatuses in which communication speeds for information recording media are different, advantage of high-speed communication of a medium processing apparatus having a higher communication speed can be utilized and it is furthermore possible to construct a practical and low-cost system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Embodiments will now be described, by way of example only, with reference to the accompanying drawings which are meant to be exemplary, not limiting, and wherein like elements are numbered alike in several Figures, in which:
[0042] FIG. 1 is a block diagram showing an electrical system structure of a medium processing system relating to at least an embodiment of the present invention.
[0043] FIG. 2 is a block diagram showing an electrical system structure of a medium processing system relating to at least an embodiment of the present invention.
[0044] FIG. 3 is a flow chart showing system operation of a medium processing system relating to at least an embodiment of the present invention.
[0045] FIG. 4 is a block diagram showing an electrical system structure of a medium processing system relating to at least an embodiment of the present invention.
[0046] FIG. 5 is a block diagram showing an electrical system structure of another medium processing system relating to at least an embodiment of the present invention.
[0047] FIG. 6 is a block diagram showing an electrical system structure of a conventional medium processing system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] Preferred embodiments of the present invention is described below with reference to the accompanying drawings.
[0049] FIG. 1 is a block diagram showing an electrical system structure of a medium processing system relating to at least an embodiment of the present invention.
[0050] In FIG. 1 , a medium processing system relating to the present embodiment includes a host apparatus 11 , a non-contact IC card reader function (circuit) 12 , and an existing card reader 13 . Incidentally, in the present embodiment, the existing card reader 13 is adopted as a first medium processing apparatus while the non-contact IC card reader function 12 is adopted as a second medium processing apparatus. However, the present invention is not limited to the above arrangement. For example, it is also possible to adopt a printer or an image processing system as the second medium processing apparatus. In other words, it does not matter what device is adopted as the first information data processing apparatus and the second information data processing apparatus, as far as the second medium processing apparatus writes and reads to/from an information recording medium faster than the first medium processing apparatus does.
[0051] In FIG. 1 , the host apparatus 11 is an apparatus that sends a command relating to a motion instruction to the non-contact IC card reader function 12 and the existing card reader 13 . For example, a monetary transaction terminal device and an ID authentication terminal device may be listed as the host apparatus 11 . Furthermore, the host apparatus 11 includes a single interface (not illustrated) to which the non-contact IC card reader function 12 may be connected.
[0052] The non-contact IC card reader function 12 includes a CPU 121 and a non-contact communication antenna 126 (Refer to FIG. 2 to be described later). Then, according to a command from the host apparatus 11 , information data is written and read to/from a non-contact IC card via the non-contact communication antenna 126 by means of electromagnetic induction in a non-contact manner.
[0053] The existing card reader 13 includes a magnetic head (not illustrated) that contacts with and slides over a magnetic stripe of a magnetic card so as to carry out read/write processing (writing operation or reading operation) for the magnetic card, an IC contact (not illustrated) that makes contact with an IC terminal placed on a contact IC card so as to carry out communication processing for the contact IC card, and so on. Then, according to a command from the host apparatus 11 , information data is written and read to/from the magnetic card and the contact IC card via the magnetic head and the IC contact.
[0054] As shown in FIG. 1 on this occasion, the non-contact IC card reader function 12 (an intermediary medium processing apparatus) intermediates a connection between the existing card reader 13 and the host apparatus 11 , and then carries out information processing faster than the existing card reader 13 does. More concretely to describe, the existing card reader 13 is connected to the non-contact IC card reader function 12 through an RS232C interface (The communication speed is 38,400 bps), and meanwhile the non-contact IC card reader function 12 is connected to the host apparatus 11 through another RS232C interface (The communication speed is 115.2 Kbps). Therefore, at the non-contact IC card reader function 12 , information data processing can be carried out without taking care of the presence of the existing card reader 12 that carries out information data processing at a speed lower than the speed of the non-contact IC card reader function 12 so that it becomes possible to take advantage of high-speed communication of the non-contact IC card reader function 12 .
[0055] According to a medium processing system shown in FIG. 1 especially, the non-contact IC card reader function 12 can be added to the host apparatus 11 , to which conventionally the existing card reader 13 has been connected, without newly adding any interface. Furthermore, there is no need of adding any design specification change to the existing card reader 13 . Therefore, consequently it is possible to install the non-contact IC card reader function 12 into the medium processing system in a low-cost and practical manner.
[0056] Next, a detailed electrical structure of the non-contact IC card reader function 12 is described with reference to FIG. 2 . FIG. 2 is a block diagram showing an electrical system structure of a medium processing system relating to the present embodiment. FIG. 2 especially shows an electrical structure of the non-contact IC card reader function 12 in detail.
[0057] In FIG. 2 , the non-contact IC card reader function (circuit) 12 includes; the CPU 121 , a communication buffer 122 , a non-contact communication function (circuit) 123 , a host interface 124 , a slave interface 125 , and the non-contact communication antenna 126 . Incidentally, a non-contact IC card reader circuit (a section enclosed with a dotted line frame in the drawing) is constructed with various electrical elements including the CPU 121 , the communication buffer 122 , the non-contact communication function 123 , the host interface 124 , and the slave interface 125 . Furthermore, being connected with a cable, the non-contact communication antenna is detachable from the non-contact IC card reader circuit (the section enclosed with the dotted line frame in the drawing).
[0058] The CPU 121 controls not only communication with the host apparatus 11 as well as the existing card reader 13 by using a firmware program but also a communication function to/from the non-contact communication antenna 126 through the non-contact communication function 123 . Furthermore, when the CPU 121 receives a command for communication with a non-contact IC card from the host apparatus 11 , the non-contact communication function 123 is controlled by the CPU 121 so as to directly communicate with the non-contact IC card.
[0059] The host interface 124 receives a command from the host apparatus 11 for the non-contact IC card reader function 12 and the existing card reader 13 , and furthermore sends a response from the non-contact IC card reader function 12 and the existing card reader 13 . Additionally, for the purpose of materializing high speed processing of communication with a non-contact IC card that can be executed only by the host apparatus 11 and the non-contact IC card reader function 12 , it is desirable that a communication speed of the interface is preferably as fast as the host apparatus 11 allows.
[0060] Being connected to the existing card reader 13 , the slave interface 125 transfers a command from the host apparatus 11 to the existing card reader 13 , and furthermore receives a response from the existing card reader 13 that is a result of execution of the command. Incidentally, in a case where the slave interface 125 is equipped with control lines (for example, 4 control lines) in addition to a line for sending and receiving data, connecting the control lines to the CPU 121 makes it possible for the CPU 121 to control the control lines. Moreover, it is required that a communication speed of the interface is what the existing card reader 13 is able to cope with.
[0061] On this occasion, the non-contact IC card reader function 12 of the medium processing system relating to the present embodiment includes the communication buffer 122 , as described above. A command, which is sent from the host apparatus 11 to the non-contact IC card reader function 12 and the existing card reader 13 , is received from the host apparatus 11 at a communication speed of the host interface 125 . Then, the command is once stored in the communication buffer 122 by the CPU 121 . Then, according to a specific datum of the command stored in the communication buffer 122 , the CPU 121 discriminates either the command is for the non-contact IC card reader function 12 or it is for the existing card reader 13 . If the command is for the existing card reader 13 , the command stored in the communication buffer 122 is transferred to the existing card reader 13 by the CPU 121 . On the other hand, if the command is for the non-contact IC card reader function 12 , the command stored in the communication buffer 122 is transferred to the non-contact communication function 123 by the CPU 121 .
[0062] A response from the existing card reader 13 is received at a communication speed of the slave interface 125 . Then, the response is once stored in the communication buffer 122 by the CPU 121 . Afterwards, the response stored in the communication buffer 122 is transferred to the host apparatus 11 at a communication speed of the host interface 125 by the CPU 121 .
[0063] Additionally, as a thick line with arrows shows in FIG. 2 , the existing card reader 13 is supplied with electricity from the host apparatus 11 through the non-contact IC card reader function 12 . Furthermore, in the present embodiment, a device interface type of the host apparatus 11 is RS232C, and therefore the device interface type is compatible in general with a communication speed of 115.2 Kbps. By taking advantage of the communication speed performance; making the host interface 124 of the non-contact IC card reader function 12 , which is directly connected to the host apparatus 11 , compatible with a communication speed of 115.2 Kbps improves the communication speed about 3 times faster, being compared with a case where the non-contact IC card reader function 12 is connected at a lower position of the existing card reader 13 . Furthermore, in comparison to the interface of the non-contact IC card reader function 12 with the host apparatus 11 , the interface with the existing card reader 13 connected at a lower position is slower in the communication speed. In order to cope with the communication speed difference, a command from the host and a response from the slave are once stored in the communication buffer 122 by the non-contact IC card reader function 12 (Thus the communication speed difference can be canceled).
[0064] Next, system operation of the medium processing system shown in FIG. 2 is described with reference to FIG. 3 . FIG. 3 is a flow chart showing system operation of a medium processing system relating to at least an embodiment of the present invention. A flowchart of FIG. 3 especially focuses on a flow of information processing in the non-contact IC card reader function 12 .
[0065] In FIG. 3 , having started receiving command data from the host apparatus 11 , the non-contact IC card reader function 12 transfers the command data to the communication buffer 122 and stores the command data in the communication buffer 122 (Step S 1 ).
[0066] Next, it is judged whether all command data has already received or not (Step S 2 ). If all command data has not received yet, a procedure of Step S 1 is repeated. On the other hand, if it is judged that all command data has already received, an access is made to the communication buffer 122 , and then it is judged by referring to a specific datum whether the command data is for the non-contact IC card reader function 12 or for the existing card reader 13 (Step S 3 ).
[0067] In relation to a procedure of Step S 3 , it is preferable, for example, that a command sorting system is adopted for a command sent from the host apparatus 11 . That is to say; in order to simplify a conversion function at a relaying operation, it is preferable that the host interface 122 and the slave interface 123 of the non-contact IC card reader function 12 have the same specifications if possible. Furthermore, from the viewpoint of standardizing specifications, a sorting method that is independent of command specification details of the existing card reader 13 is preferred. For example; by a change in a data part, being common to all commands, of a command data string (for example, uppercase letters and lower letters are discriminatingly used), a command for the non-contact IC card reader function 12 and a command for the existing card reader 13 are discriminated from each other. Thus, a requirement described above is satisfied so that command sorting can be done efficiently.
[0068] Next, in the procedure of Step S 3 ; if the CPU 121 judges a command to be for a non-contact IC card (Step S 4 : “YES”), the command is executed as a command for a non-contact IC card. More concretely to describe, the non-contact communication function 123 gets operated and an access is made to the non-contact IC card via the non-contact communication antenna 126 . On the other hand, if the CPU 121 judges the command not to be a non-contact IC card (Step S 4 : “NO”), the command is transferred to the existing card reader 13 .
[0069] As described above with reference to FIG. 2 and FIG. 3 , provided in the medium processing system relating to the present embodiment is the communication buffer 122 in which a command from the host apparatus 11 to the existing card reader 13 is temporarily stored, and therefore both the non-contact IC card reader function 12 and the existing card reader 13 are able to carry out information data processing at each appropriate speed. Furthermore, a command from the host apparatus 11 to the non-contact IC card reader function 12 is also stored temporarily in the communication buffer 122 , and therefore information data processing of the non-contact IC card reader function 12 can get started at appropriate timing.
[0070] Moreover, the non-contact IC card reader function 12 includes the non-contact communication function 123 (a communication section) that carries out writing and reading information data to/from a non-contact IC card, and the CPU 121 (a control section) that is connected to the non-contact communication function 123 as well as the communication buffer 122 . Under a condition described above; while a command is received from the host apparatus 11 , it is possible to have a setup in which a command from the host apparatus 11 for the existing card reader 13 is judged by the CPU 121 to be so and then the command is transferred to the communication buffer 122 , and meanwhile a command from the host apparatus 11 for the non-contact IC card reader function 12 is judged by the CPU 121 to be so and then the command is transferred to the non-contact communication function 123 . According to the setup described above, both the existing card reader 13 , which carries out magnetic data processing at a relatively low speed, and the non-contact IC card reader function 12 , which carries out a non-contact information data processing at a relatively high speed, are each able to send and receive a command at an appropriate processing speed efficiently.
[0071] Furthermore, it is possible to have a setup in which, among the commands stored in the communication buffer 122 , a command from the host apparatus 11 for the existing card reader 13 is judged by the CPU 121 to be so and then the command is transferred to the existing card reader 13 , and meanwhile a command from the host apparatus 11 for the non-contact IC card reader function 12 is judged by the CPU 121 to be so and then the command is transferred to the non-contact communication function 123 . According to the setup described above, both the devices are able to carry out information data processing efficiently.
[0072] Additionally, a setup may be so made that the non-contact IC card reader function 12 spontaneously controls the existing card reader 13 . More concretely to describe, for example; in a case of a system in which exclusive processing between a non-contact IC card and any other card is executed, the non-contact IC card reader function 12 issues a command for a shutter to the existing card reader 13 when non-contact IC card is recognized. Moreover, it is also possible for the existing card reader 13 to be controlled spontaneously by a control line of the slave interface 125 . For example, in a case of an RS232C interface, the existing card reader 13 can be controlled through operation of a DSR signal and an RTS signal.
[0073] Furthermore, as described above; it is possible to add the non-contact IC card reader function 12 without any change on the existing card reader 13 . Moreover, in a case of the non-contact IC card reader function 12 provided with such a function described above, there exists a requirement of connection to multiple sorts of sets of the existing card reader 13 . On the other hand, a setup may be so made that the non-contact IC card reader function 12 is provided with a function for controlling the sets of the existing card reader 13 at a slave position spontaneously, and therefore different controls are required for the multiple sorts of sets of the existing card reader 13 . Then, the non-contact IC card reader function 12 automatically recognizes the sort of each set of the existing card reader 13 at a slave position, and switches a control for the slave device to enable satisfying the requirement. In the present embodiment, a command is sent from the non-contact IC card reader function 12 to the existing card reader 13 ; and then according to a response condition for the command, a sort of each connected set of the existing card reader 13 is recognized automatically.
[0074] Still further, in the present embodiment; the non-contact IC card reader function 12 is inserted and connected between the host apparatus 11 and the existing card reader 13 for a relaying operation. Taking it into consideration to carry out installation work at a job site in a market, a host interface connector of the non-contact IC card reader function 12 is prepared to be the same as an interface connector of the existing card reader 13 so that adding a function can be carried out more easily.
(Modification)
[0075] FIG. 4 is a block diagram showing an electrical system structure of a medium processing system relating to at least an embodiment of the present invention. FIG. 5 is a block diagram showing an electrical system structure of another medium processing system relating to at least an embodiment of the present invention. Incidentally, a structure of the system shown in FIG. 4 is the same as a structure of the system shown in FIG. 2
[0076] As shown in FIG. 4 , in the system structure shown in FIG. 2 ; an electrical power supply line for the existing card reader 13 is so connected as to be also relayed through the non-contact IC card reader function 12 and to supply electricity to the existing card reader 13 , and therefore it becomes possible for both the non-contact IC card reader function 12 and the existing card reader 13 to be supplied with electricity through one and only electrical power supply line. As a result, it becomes possible to add the non-contact IC card reader function 12 without adding an electrical power supply line from the host apparatus 11 .
[0077] Furthermore, as shown in FIG. 5 , mostly an interface at a device side is less advanced in USB compatibility than a side at the host apparatus 11 . If the side at the host apparatus 11 is compatible with USB, it becomes possible to have high-speed communication with the host apparatus 11 by making only the host interface 124 of the non-contact IC card reader function 12 compatible with USB even though the existing card reader 13 is not compatible with USB.
[0078] The medium processing system and the intermediary medium processing apparatus, which relate to at least an embodiment of the present invention, are able to take advantage of high-speed communication, and furthermore useful as being low-cost and practical.
[0079] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention.
[0080] The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims, rather than the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A medium processing system for use with an information recording medium is disclosed. The system may include a first medium processing apparatus, a host apparatus, and a second medium processing apparatus. The first medium processing apparatus may be structured to carry out writing and reading information to and from the information recording medium. The host apparatus may have an interface with which the first medium process apparatus is connectable. The second medium processing apparatus may be structured to intermediate a connection between the first medium processing apparatus and the host apparatus. The second medium processing apparatus may also be structured to carry out writing and reading information to and from the information recording medium at a higher speed than the first medium processing apparatus does. | 6 |
[0001] This application claims priority from U.S. provisional application Ser. No. 60/381,315, filed May 17, 2002, entitled FIRE PROTECTION SYSTEM, by Eldon D. Jackson, the entire disclosure of which is incorporated herein by reference in its entirety.
[0002] TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0003] The present invention relates to a control system for a sprinkler system and, more particularly, to a control system for a preaction sprinkler system.
[0004] There are several types of preaction systems, but all preaction systems typically employ closed sprinklers in the sprinkler system piping. The detection system may be hydraulic, pneumatic, or electric and may be actuated manually or by detecting a temperature rise or by other means. Typically, the detection system operates before the sprinkler fuses and sounds an alarm. Preaction systems are used in areas where it is desirable to keep water intrusion to a minimum, such as areas that are subject to high potential water damage or freezing of the system piping.
[0005] Current technology requires continuous power to the various components that control the opening and closing of the flow control valve. For example, in the trim piping for some preaction systems, a normally open solenoid valve is used to control the pressure in the priming chamber of the system control valve. The solenoid valve must be powered closed during normal system operation. When a fire occurs, the solenoid valve is de-energized and opens to release the main sprinkler system control valve. However, this requires back-up power and a continuous power condition for the solenoid valve, which may result in a high-heat condition and possible failure due to sticking and/or failure of the electrical coil of the solenoid valve. In order to make these systems fail-safe, the system relies on a loss of power condition to release the main valve to allow the system to operate.
[0006] Consequently, there is a need for a preaction system that can fail-safe but which can operate in a no-power condition.
SUMMARY
[0007] Accordingly, the control system of the present invention provides a supervised fail-safe electric release control system for a preaction system that can operate in a low power or loss of power condition.
[0008] In one form of the invention, a fire suppression system includes system piping, with at least one sprinkler for dispersing fire suppressant when sensing temperatures associated with a fire condition and a deluge valve. The deluge valve is in selective fluid communication with the system piping and has a normally closed condition whereby the system piping is normally dry. The fire suppression system further includes at least one normally open fire detector, which is adapted to detect temperatures associated with a fire and has an open no-fire condition state and a closed fire condition state and generates a fire condition signal when in the closed fire condition state. A control system is provided that monitors the pressure in the system piping and is in communication with the fire detector, a source of power, the deluge valve, and the system piping. The control system is adapted to actuate the deluge valve to open in response to a fire condition signal and a low pressure condition in the system piping. The control system includes a pneumatic actuator that is adapted to detect a drop in pressure in the system piping and to actuate the deluge valve between the closed condition and an open condition when the pneumatic actuator detects a drop in pressure in the system piping and when the control system experiences a loss of power from the source of power. The control system also includes a shut-off valve in communication with the deluge valve that is adapted to latch the deluge valve open once the deluge valve opens until manually shut-off.
[0009] In one aspect, the deluge valve includes an inlet chamber, an outlet chamber, a priming chamber, and a clapper assembly. The inlet chamber and the outlet chamber are separated from the priming chamber by the clapper assembly. The deluge valve further includes a priming line in fluid communication with the inlet and the priming chamber, which pressurizes the priming chamber. The clapper assembly opens the deluge valve in response to pressure in the priming chamber, with the control system controlling the flow from the priming line to the priming chamber to open the deluge valve.
[0010] In other a further aspect, the priming line includes at least one solenoid valve, which is actuated by the control system to open the deluge valve. Preferably, the priming line includes a second solenoid valve, with one of the first solenoid valve and the second solenoid valve comprising a normally closed solenoid valve and another of the first solenoid valve and the second solenoid valve comprising a normally open solenoid valve to control the flow of fire suppressant through the priming line. The control system actuates the normally open solenoid valve to close and the normally closed solenoid valve to open in response to the fire condition signal.
[0011] In another form of the invention, a fire suppression system includes a fire suppressant supply line, system piping, a pressure supervisory system, which monitors pressure in the system piping, and at least one sprinkler for dispersing fire suppressant when sensing temperatures associated with a fire condition. The fire suppression system also includes a control valve, which is in fluid communication with the system piping and the supply line. The control valve has a normally closed condition but is opened when a low pressure condition in the system piping and a fire condition occur. The fire suppression system further includes at least one fire detector, which is adapted to detect temperatures associated with a fire, and a control system, which is in communication with a power source, the fire detector, the pressure supervisory system, and the priming line. The control system is adapted to control the flow of suppressant in the priming line to open the control valve when detecting a fire condition signal and a low pressure condition in the system piping and, further, is adapted to open the valve when the power source is in a power loss state in response to a low pressure condition in the system piping. Preferably, the control system is also adapted to latch the valve open when the valve opens requiring manual closing of the valve.
[0012] In one aspect, the control system includes a shut-off valve to latch the control valve open when the control valve opens.
[0013] According to yet another form of the invention, the flow of fire suppressant from a fire suppression supply to sprinkler system piping is controlled by providing a deluge valve, which has a normally closed condition. The pressure in the system piping is monitored to detecting a low pressure condition in the system piping. The deluge valve is actuated when a low pressure condition and a fire condition is detected. Furthermore, when opened, the deluge valve is latched open so that the deluge valve must be manually shut down.
[0014] Accordingly, the fire protection system of the present invention can operate in both a powered state or condition and a loss of power state or condition while still providing a normally dry system. In a powered state, the control system opens the sprinkler system piping control valve only in a fire condition (i.e. when a sprinkler opens and a fire detector is actuated). In a loss of power state, the control system only opens the control valve when there is a loss of pressure in the sprinkler system piping (i.e. when a sprinkler opens). Furthermore, the control system latches the control valve open, requiring manual closing of the control valve. These and other objects, advantages, purposes, and features of the invention will become more apparent from the study of the following description taken in conjunction with the drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
[0015] [0015]FIG. 1 is a schematic diagram of the control system of a fail-safe preaction system of the present invention;
[0016] [0016]FIG. 2 is a schematic diagram of a control panel of the control system of FIG. 1;
[0017] [0017]FIG. 3 is a release panel function table of the control panel of FIG. 2;
[0018] [0018]FIG. 4 is a schematic diagram of another embodiment of a control system of the present invention;
[0019] [0019]FIG. 5 is a schematic diagram of a control panel of the control system of FIG. 4; and
[0020] [0020]FIG. 6 is a release panel function table of the control panel of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIG. 1, the numeral 10 generally designates a control system of the present invention. As will be more fully described below, control system 10 is pneumatically pressurized to monitor the integrity of the sprinkler piping, fittings and sprinklers and acts as a fail-safe emergency backup to an electrical detection system. Control system 10 controls a preaction fire suppressant system in which the sprinkler piping system is normally dry and, therefore, may be installed in locations sensitive to water damage, such as an area subject to freezing. Control system 10 minimizes accidental water damage and, therefore, can be used in areas where detectors and/or sprinklers are easily damaged or broken. Furthermore, as will be more fully described, control system 10 may be used to control in a preaction system 11 to provide a fire protection environment with or without electrical power.
[0022] Referring again to FIG. 1, control system 10 controls the pressure in the priming chamber ( 14 ) of valve 12 to open and close valve 12 . When open, valve 12 delivers fire suppressant, such as water, to sprinkler system piping 16 and sprinklers (not shown) of preaction system 11 . Valve 12 includes an inlet 20 and an outlet 22 , which is in communication with system piping 16 . Hereinafter, reference will be made to water, though it should be understood that other fire suppressant fluids may be used. Water is delivered to inlet 20 from water supply 23 through a water supply control valve 24 . Outlet 22 is connected to system piping 16 through a check valve 26 , which restricts the flow of pressurized air from system piping 16 to valve 12 as will be more fully described below.
[0023] Valve 12 comprises a deluge valve and includes a body, which forms a passage between inlet 20 and outlet 22 , and a movable clapper which moves between a first position in which the passage is blocked to thereby close the valve and a second position in which the passage is open to permit flow of water from inlet 20 to outlet 22 . Positioned above the clapper assembly is priming chamber 14 . When priming chamber 14 is sufficiently pressured, the clapper assembly is moved to its first or closed position to thereby close the valve. When pressure is released in the priming chamber, the clapper moves to its second position in which the passage is open to permit valve 12 to open. Further details of valve 12 are omitted, as valve 12 is conventional and available in a number of different configurations. Suitable deluge valves are available from The Viking Corporation of Hastings, Mich.
[0024] As best seen in FIG. 1, control system 10 includes a priming line 30 with a normally open priming valve 32 , a strainer 34 , a restricted orifice 36 , and a check valve 38 . Priming line 30 supplies the system water supply pressure to the priming chamber 14 of valve 12 via priming outlet line 40 through a pressurized shut-off valve 42 . Priming outlet line 40 is also connected through a normally emergency release 44 (such as a manually operated valve) to a drain 45 . The flow of water through priming outlet line 40 is further controlled by a normally open solenoid valve 46 and a normally closed solenoid valve 48 and a pneumatic actuator 50 . As will more fully described below, solenoid valves 46 and 48 are actuated by a control panel 52 (FIG. 1). In a set condition, water supply pressure is trapped in the priming chamber 14 of valve 12 by check valve 38 , normally closed emergency release 44 , normally closed solenoid valve 48 , and pneumatic actuator 50 . The water supply pressure in the priming chamber holds the clapper assembly of valve 12 on the valve seat until the pressure is released.
[0025] In order to detect when a sprinkler is opened, system piping 16 is supervised by an air supply 51 and one or more supervisory pressure switches 58 and 60 , which are in communication with control panel 52 . As noted above, valve 26 prevents the flow of pressurized air from system piping 16 to valve 12 . Control panel 52 is also in communication with one or more normally open detectors 56 , such as heat detectors, and optionally sounds an alarm 62 and further closes normally open solenoid valve 46 when detector 56 detects a fire condition as well a low pressure condition. In addition as noted, control panel 52 is in communication with pressure switches 58 and 60 , which detect the supervisory pressure in system piping 16 .
[0026] Pneumatic actuator 50 is also in communication with the supervisory air system that pressurizes sprinkler system piping and opens in response to a pressure drop in system piping 16 . When the sprinklers operate in response to a fire, the system supervisory air is lost and pressure switches 58 and 60 are actuated. Normally after receiving both signals from the pressure switches 58 and 60 and from detector 56 , control panel 52 energizes normally closed release solenoid valve 48 open so that pressure is released from priming chamber faster than it is supplied through restricted orifice 36 . Water entering piping system 16 increases the pressure on pressurized shut-off valve 42 , which shuts off the priming fluid to priming chamber 30 of valve 12 to thereby latch valve 12 open.
[0027] If system piping 16 and/or sprinklers are damaged and none of the AC power or the stand-by battery power is available, supervisory switch 58 will cause control panel 52 to activate alarm 62 . In addition, normally open solenoid valve 46 will close to prevent valve 12 from opening and to prevent water flow from any of the open sprinklers. In the even of a fire, which will cause detector 56 to operate, control panel 52 will open normally closed release solenoid 48 so that the priming pressure will be released from priming chamber 14 and valve 12 will open and water will flow through the sprinkler system and through the sprinklers.
[0028] If there is a loss of power while the system is flowing water, normally open release solenoid valve 46 will open and normally closed release solenoid valve 48 will close. Since the pressurized shut-off valve 42 is already pressurized closed to prevent pressure in the chamber from building up, the water from the main water supply 23 will continue entering the fire protection system and through any open sprinkler.
[0029] If there is a loss of power prior to operation, control system 10 will continue to operate on stand-by batteries 96 and 98 (FIG. 2). Should the AC power and the stand-by batteries drop power to a point less than required to operate solenoid valves 46 and 48 , solenoid valves 46 and 48 will fail respectively open and close. However, as long as air pressure remains in the system piping, pneumatic actuator 50 will keep valve 12 from opening. If the system air pressure is lost, valve 12 will open allowing water to flow into the sprinkler piping and be discharged from any open sprinklers.
[0030] As noted above, system 10 includes an emergency release 44 . Emergency release 44 includes a handle, which when pulled permits the pressure from priming chamber 14 to be discharged through discharge line 47 to drain 45 so that valve 12 will open and water will flow in system piping 16 , which will actuate any connected alarms, but will not be discharged from any closed sprinklers attached to the system until a sprinkler is operated such as by a fire.
[0031] In this manner, control system 10 provides an electric pneumatic control system which converts to a pneumatic system once power is lost.
[0032] After a system has been subjected to a fire, the entire system must be inspected for damage or possible repair or replacement as necessary. Typically, if all system components are operational, the system is drained by an auxiliary drain 72 and by a system drain valve 74 . The inlet chamber of the valve 12 is drained by valve 76 .
[0033] In order to test the system on a regular basis, system 10 includes a water supply pressure gage and valve 80 and a normally closed alarm test valve 82 . The outlet of alarm test valve 82 is connected to a drain check valve 84 ′ which is connected to the output of pressure operated shut-off valve 44 . Test valve 82 is also connected in parallel to an alarm shut-off valve 86 , whose outlet is connected to a water monitor alarm 88 through a strainer 90 . Preferably, the piping connecting alarm shut-off valve 86 to water monitor alarm 88 includes an alarm pressure switch 92 .
[0034] As noted above, solenoid valves are actuated by control panel 52 . As best seen in FIG. 2, control panel 52 is communication with first and second solenoid valves 46 and 48 as well as with one or more fire detectors 56 , supervisory switches 58 and 60 , and an optional water flow pressure switch 57 (FIG. 1). Fire detectors 56 may include, for example, conventional heat or smoke detectors, which preferably comprise open contact detectors that close to signal an alarm. Preferably, detectors 56 are chosen to have detection temperatures lower than the lowest temperature rated sprinkler being used. The sprinklers are preferably conventional heat triggered sprinklers and include a sprinkler body, which has an outlet, that is coupled and in fluid communication with the system piping 16 . The sprinklers further include frames and temperature sensitive triggers, which are positioned between the outlets and the frames, which break or release to open the outlets upon detecting temperatures associated with a fire.
[0035] Control panel 52 is a microprocessor controlled releasing panel and includes a microprocessor 52 a and at least one zone relay 52 b . Zone relay module 52 b preferably comprises a commercially available zone relay module 4XCM part from The Viking Corporation of Hastings, Mich. Zone relay module 52 b includes six relay contacts 53 , namely a detection contact 53 a , a supervisory contact 53 b , a release one contact 53 c , a release two contact 53 d , an alarm contact 53 e , and a trouble contact 53 f Relay contacts 53 are actuated as follows. Detection relay contact 53 a is actuated detection circuits 56 a or 58 a or by water flow alarm switch circuit 57 a . Detection circuit 56 a includes one or more detectors 56 . Supervisory relay contact 53 b of zone relay module 52 b is actuated by detection circuit 60 a . Release one contact 53 c is actuated by detection circuit 56 a . The switch positions are shown in tabular form in FIG. 3A. Release two contact 53 d is actuated by detection circuit 58 a . Alarm relay contact 53 e is actuated by detection circuits 56 a or 58 a or by optionally water flow switch circuit 57 a . Trouble contact 53 f is actuated by a panel malfunction or fault in the field wiring.
[0036] Control panel 52 includes outputs for first and second solenoid valves 46 and 68 and for an alarm bell 62 and, optionally, a remote trouble signal 63 . In addition, control panel 52 preferably includes stand-by batteries 96 and 98 so that the control panel 52 will remain operational in the event of a power failure. Microprocessor 52 a , zone relay module 52 b , and the various supporting circuitry are preferably mounted on common circuit board, for example, a 110-volt mother board part commercially available from The Viking Corporation of Hastings, Mich.
System Operation
[0037] Preaction system 11 preferably operates as a dry pipe system. As previously noted, solenoid valves 46 and 48 as well as pneumatic actuator 50 control the opening of control valve 12 , with solenoid valves 46 and 48 controlled by control panel 52 and actuator 50 controlled by the drop in pressure in the system piping. Control panel 52 is activated to close normally open solenoid 46 and open normally closed solenoid valve 48 in response to detectors 56 closing and by supervisory pressure switches 58 and 60 indicating a low pressure condition in system piping 16 .
[0038] In a normal operating condition, the water supply enters flow control valve 12 through inlet 20 of flow control valve 12 and the system water also enters priming chamber 14 of control valve 12 through the priming line 30 . Solenoid valve 46 is normally open, and solenoid valve 48 is normally closed. Pneumatic actuator 50 , however, is normally closed so that the priming fluid is trapped in priming chamber 14 by actuator 50 , solenoid 48 , and valve 38 in priming line 30 . If a fire is detected by detector 56 (which should close before the sprinklers are actuated), control panel 52 will sound an alarm. When one or more sprinklers then operate, the supervisory pressure switches 58 and 60 will actuate control panel 52 to close solenoid valve 46 and open solenoid valve 48 so that valve 12 will open. Only when control panel 52 detects or receives both fire condition and low pressure signals will control panel 52 actuate solenoid valves 46 and 48 .
[0039] If the AC power supply to control panel 52 fails, solenoid valves return to their non-energized normal states and valve 12 will open only when actuator 50 detects a loss of system pressure.
[0040] Once valve 12 opens, pressurized shut-off valve 42 closes to latch valve 12 in its open state until manually closed.
[0041] Referring to FIG. 4, the numeral 110 generally designates another embodiment of a control system for a fire protection system. The fire protection system includes a control valve 112 , preferably a deluge valve, which controls the flow of water from a water supply 123 to sprinkler system piping 116 , in a similar manner described in reference to the previous embodiment. In addition, similar to the previous embodiment, system piping 116 is pneumatically pressurized to monitor the integrity of the piping, fittings, and sprinkler and acts as a fail-safe emergency backup to the electrical detection system.
[0042] In the illustrated embodiment, control system 110 comprises a double interlocked fail-safe preaction control system which is also particularly suitable for use in an area where the environment is sensitive to water and, more particularly, in an environment where water can not flow into the sprinkler piping unless both the detector and the one or more sprinklers are operated, such as in the event of a fire.
[0043] Similar to the previous embodiment, supply water enters priming chamber 114 of valve 112 through a priming line 130 . Priming line 130 includes a priming valve 132 , a strainer 134 , a restricted orifice 136 , and a check valve 138 whose outlet directs the flow of water through a priming outlet line 140 through a pressure operated shut-off valve 142 . Priming outlet line 140 is also connected to a normally closed emergency release valve 144 and a normally open solenoid valve 146 and a normally closed solenoid valve 148 . The pressure in priming outlet line 140 is maintained by check valve 138 , emergency release valve 144 , normally closed solenoid valve 148 and pneumatic actuator 150 , similar to the previous embodiment. Solenoid valves 146 and 148 are in communication with control panel 152 , which actuates solenoid valves 146 and 148 when control panel receives low-pressure signals from pressure switches 158 and 160 and a fire-condition signal from detector 156 .
[0044] In a fire condition, control panel 152 activates an alarm 158 , such as a pezio sounder, and initiates detection alarms. At this time, no water enters the sprinkler system piping. When a sprinkler operates, such as when detecting a temperature associated with a fire, switches 158 and 160 are actuated. Only when control panel 152 receives signals from switches 158 and 160 and, further, from detector 156 , control panel 152 opens normally closed solenoid valve 148 and closes normally open solenoid valve 146 . When solenoid valve 148 is open, pressure is released through pneumatic actuator 142 , which opens and discharges the priming fluid through discharge line 147 to drain 145 in response to a low pressure condition in system piping 116 .
[0045] If the system piping and/or sprinklers are damaged and either the AC power or the stand-by battery power is available, switches 158 and 160 will activate a trouble alarm when switches 158 and 160 detect a low-pressure in the supervisory air system. When the supervisory air drops below a pressure just above operation of pneumatic actuator 150 , control panel 152 will activate a trouble alarm. The second pole of supervisory switch 160 activates normally open release solenoid valve 146 to close to prevent water flow through any open sprinkler. In the event of fire that causes the detector 156 to operate when air pressure drops below the trouble air setting, air supervisory switch 158 , which is linked to normally closed solenoid valve 148 , will actuate valve 148 to open. When the normally closed release solenoid valve 148 opens, water will flow through any open sprinkler.
[0046] If the detection system is damaged or malfunctions, control panel 152 will go into an alarm mode. In the event of fire, valve 112 will not open and emergency release 144 must be pulled in order to provide water through the opened sprinklers.
[0047] If the AC power fails, system 110 will continue to operate on the stand-by batteries. Should the stand-by batteries fail prior to operation system, all alarms will be lost. However, when the DC power drops to a point less than required to operate normally closed solenoid valve, both solenoid valves return to their normal states allowing normally open solenoid valve 146 to open and solenoid valve 148 to close. As long as air pressure remains in piping system 116 , pneumatic actuator 150 will keep valve 112 from opening. If system air pressure is lost, valve 112 will open, allowing water to flow into system piping 116 and be discharged from any open sprinkler.
[0048] If all power fails while system 110 is flowing with water, normally open release solenoid valve 146 will open and normally closed release solenoid valve 148 will close. Since the pressurized shut-off valve 142 is already pressurized closed to prevent pressure in the chamber from building up, water from main supply line will continue entering system 116 through valve 112 , thus requiring manual shut-down of the fire protection system.
[0049] Anytime emergency release valve 144 is actuated, pressure is released from priming chamber 114 of valve 112 faster than it can be replaced through priming line 130 ; therefore, valve 112 opens. While water enters system piping 116 , the water will not be discharged until a sprinkler has operated, such as in the case of a fire.
[0050] It should be understood that since both fire protections systems of the present invention are normally dry, they may be installed in locations subject to freezing or in locations with equipment that is sensitive to water. In addition, systems 10 and 110 also provide excellent fire protection equipment with or without electrical power. Although the systems are equipped with backup batteries, which provide many hours of emergency power, the system will fail-safe and continue flowing until power is restored or the system is manually shut off. System 110 is particularly suitable where the environment is sensitive to water—where it is preferably that water can not flow into the system piping unless both a detector and sprinkler operates, such as in the case of a fire.
[0051] Referring to FIGS. 5 and 6, control panel 152 is similar to control panel 52 but includes in the detection circuit 158 b for solenoid 148 a connection to air supervisory switch 158 . Reference is therefore made to control panel 52 for the remaining details of control panel 152 .
[0052] While several forms of the invention have been shown and described, other changes and modifications will now be apparent to those skilled in the art. Therefore, it will be understood that the embodiments shown in the drawings and described above are merely for illustrative purposes, and are not intended to limit the scope of the invention which is defined by the claims which follow as interpreted under the principles of patent law including the doctrine of equivalents. | A fire suppression system includes system piping and at least one sprinkler with the system piping for delivering fire suppressant to the sprinkler. The sprinkler has an outlet and a temperature sensitive trigger with temperature sensitive trigger opening the outlet for dispersing fire suppressant when sensing temperatures associated with a fire condition. The system also includes a deluge valve that is in selective fluid communication with the system piping and has a normally closed condition whereby the system piping is normally dry. The deluge valve controls the flow of suppressant to the system piping and the sprinkler. A control system, which is in communication with at least one source of power, opens the deluge valve in a fire condition when the power source is in a powered condition and opens the deluge valve in a loss of pressure condition when the power source is in a loss of power condition. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2009-056924, filed Mar. 10, 2009, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to, for example, an information storage medium called a smartcard (IC card) having incorporated in it an integrated circuit (IC) chip having such a control device as a CPU, ROM, RAM, or EEPROM. The present invention relates to, for example, an authentication data generation method applied to the information storage medium. The present invention relates to, for example, an authentication system comprising the information storage medium and a medium authentication device which authenticates the information storage medium.
[0004] 2. Description of the Related Art
[0005] In recent years, smartcards provided with various functions have appeared. For example, Jpn. Pat. Appln. KOKAI Publication No. 2005-216234 discloses a smartcard provided with a contact interface comprising metal terminals or the like, and a non-contact interface comprising an antenna for performing transmission and reception of a radio signal, and the like.
[0006] Further, smartcards which can accept a plurality of communication protocols also appear. For example, Jpn. Pat. Appln. KOKAI Publication No. 2004-151864 discloses a smartcard which can accept both communication protocols of TCP/IP and ISO7816.
[0007] According to appearing of these smartcards, application of the smartcards spreads, so that, for example, smartcards are used in various fields as not only a credit card, a commuter pass, a passport, a license, and means for business transactions but also such an ID card as an employee ID card, a membership card, or an insurance card.
[0008] Since the smartcard is used in an environment required for high security in this manner, security countermeasures of the smartcard are important.
[0009] According to enhancement of security applied to a smartcard, processing speed within the smartcard decreases and more memory within the smartcard is used as a general trend.
[0010] Smartcard providers try to apply higher security to smartcards, but they must consider adverse effects of the application, as described above. Therefore, although there are higher security countermeasures, a case arises that the higher security countermeasures cannot be applied to a smartcard.
BRIEF SUMMARY OF THE INVENTION
[0011] An object of the present invention is to provide an information storage medium where higher security countermeasures can be performed according to a situation. Another object of the present invention is also to provide an authentication data generation method which can generate authentication data based upon higher security countermeasures according to a situation. Still another object of the present invention is to provide a medium authentication system which can generate authentication data based upon higher security countermeasures according to a situation to authenticate a medium based upon the authentication data.
[0012] According to one embodiment of the present invention, there is provided an information storage medium comprising: a storage unit configured to store a plurality of encryption keys therein; a signal receiving unit configured to receive an authentication command from an authentication device; a generation unit configured to determine a communication protocol with the authentication device, change encryption key reference information included in the authentication command based upon a determination result of the communication protocol with the authentication device, select a target encryption key corresponding to the changed encryption key reference information from the plurality of encryption keys, and generate authentication data based upon the target encryption key and inclusion data included in the authentication command; and a signal transmission unit configured to transmit the authentication data to the authentication device.
[0013] According to another embodiment of the present invention, there is provided an authentication data generation method comprising: receiving an authentication command from an authentication device; determining a communication protocol with the authentication device; changing encryption key reference information contained in the authentication command based upon the determination result of the communication protocol with the authentication device; selecting a target encryption key corresponding to the changed encryption key reference information from a plurality of encryption keys stored in advance; generating authentication data based upon the target encryption key and inclusion data included in the authentication command; and transmitting the authentication data to the authentication device.
[0014] According to still another embodiment, there is provided a medium authentication system comprising an information storage medium and an authentication device authenticating the information storage medium, wherein the information storage medium: comprising a encryption key storage unit configured to store a plurality of encryption keys therein; a command receiving unit configured to receive an authentication command from an authentication device; an authentication data generation unit configured to determine a communication protocol with the authentication device, change encryption key reference information included in the authentication command based upon the determination result of the communication protocol with the authentication device, select a target encryption key corresponding to the changed encryption key reference information from the plurality of encryption keys, and generate authentication data based upon the target encryption key and inclusion data included in the authentication command; and an authentication data transmission unit configured to transmit the authentication data to the authentication device, and the authentication device comprising: a decryption key storage unit configured to store a plurality of decryption keys corresponding to the plurality of encryption keys; a command transmission unit configured to transmit the authentication command to the information storage medium; an authentication data receiving unit configured to receive the authentication data from the information storage medium; and an authentication unit configured to change encryption key reference information included in the authentication command based upon the determination result of a communication protocol with the information storage medium, select a target decryption key corresponding to the changed encryption key reference information from the plurality of decryption keys, decrypt the inclusion data from the authentication data based upon the target decryption key, and authenticate the information storage medium based upon the decrypted inclusion data.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0015] 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.
[0016] FIG. 1 is a block diagram showing a schematic configuration of a smartcard system (medium authentication system) according to one embodiment of the present invention;
[0017] FIG. 2 is a block diagram showing a schematic configuration of a card reader/writer of the smartcard system shown in FIG. 1 ;
[0018] FIG. 3 is a diagram showing one example of data stored in a data memory in the card reader/writer shown in FIG. 2 ;
[0019] FIG. 4 is a block diagram showing a schematic configuration of a smartcard of the smartcard system shown in FIG. 1 ;
[0020] FIG. 5 is a diagram showing one example of data stored in a data memory in the smartcard shown in FIG. 4 ;
[0021] FIG. 6 is a flowchart for explaining an outline of communication between the card reader/writer and the smartcard; and
[0022] FIG. 7 is flowchart showing one example of change processing of encryption processing based upon a communication protocol.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Embodiments of the present invention will be explained below with reference to the drawings.
[0024] FIG. 1 is a block diagram showing a schematic configuration of a smartcard system (medium authentication system) according to one embodiment of the present invention. As shown in FIG. 1 , the smartcard system comprises a terminal 1 and a smartcard 2 (information storage medium). The terminal 1 is provided with a main body (an upper device) 11 , a display 12 , a keyboard 13 , and a card reader/writer 14 . The terminal 1 is configured to be capable of performing communication with the smartcard 2 , and the terminal 1 performs transmission of data to the smartcard 2 and reception of data from the smartcard 2 .
[0025] The main body 11 executes applications and handles input and output of data. The display 12 displays a communication result with the smartcard 2 , an authentication result, and the like. The keyboard 13 inputs characters, numerals, and the like into the main body 11 . The card reader/writer 14 communicates with the smartcard 2 .
[0026] Incidentally, in the embodiment, a case including a combination type where the smartcard 2 supports both contact-type communication and non-contact-type communication and similarly a combination type where the card reader/writer 14 supports both contact-type communication and non-contact-type communication will be explained.
[0027] FIG. 2 is a block diagram showing a schematic configuration of the card reader/writer 14 according to one embodiment of the present invention. As shown in FIG. 2 , the card reader/writer 14 is provided with a contact terminal 141 , a communication interface 142 , a CPU 143 , a data memory 144 , a RAM 145 , a ROM 146 , an antenna 147 , and a communication interface 148 .
[0028] FIG. 4 is a block diagram showing a schematic configuration of a smartcard according to an embodiment of the present invention. As shown in FIG. 4 , the smartcard 2 is a plastic card, for example, and it is provided with an IC chip 20 (IC module). The IC chip 20 is provided with a contact terminal 201 , a communication interface 202 , a CPU 203 , a data memory 204 , a RAM 205 , and a ROM 206 . Further, the smartcard 2 is provided with an antenna 21 and a communication interface 22 .
[0029] The contact terminal 141 of the card reader/writer 14 comes into contact with the contact terminal 201 of the smartcard 2 so that data is transmitted and received between the card reader/writer 14 and the smartcard 2 . The communication interface 142 controls input and output of data transmitted to the smartcard 2 and data received from the smartcard 2 .
[0030] The antenna 147 of the card reader/writer 14 communicates with the antenna 21 of the smartcard 2 in a non-contact state, where data is transmitted and received between the card reader/writer 14 and the smartcard 2 . The communication interface 148 controls input and output of data transmitted to the smartcard 2 and data received from the smartcard 2 .
[0031] The CPU 143 generates various commands (authentication commands) based upon instructions from the main body (upper device) 11 . Further, the CPU 143 is provided with a random number generation unit 143 a , and the random number generation unit 143 a generates a random number based upon an instruction from the main body (upper device) 11 . The data memory 144 is a nonvolatile memory such as EEPROM or FRAM. The RAM 145 is work memory temporarily storing data transmitted from the smartcard 2 therein, for example. The ROM 146 is a memory storing a control program and the like therein.
[0032] As shown in FIG. 3 , the data memory 144 stores decryption key information, encryption key information, encryption algorithm information, and fixed data therein. The decryption key information includes a plurality of decryption keys A, B, C, . . . , and the respective decryption keys A, B, C, . . . are managed by decryption key reference numbers 0, 1, 2, . . . . The encryption key information includes a plurality of encryption keys A, B, C, . . . , and the respective encryption keys A, B, C, . . . are managed by encryption key reference numbers 0, 1, 2, . . . . The abovementioned respective decryption keys A, B, C, . . . and the respective encryption keys A, B, C, . . . are keys corresponding to one another. The encryption algorithm information includes a plurality of encryption algorithms A, B, C, . . . and the respective encryption algorithms A, B, C, . . . are managed by encryption algorithm reference numbers 0, 1, 2, . . . . The authentication processing utilizing the decryption key information, the encryption key information, the encryption algorithm information, and the fixed data will be explained in detail later.
[0033] On the other hand, the contact terminal 201 of the smartcard 2 comes into contact with the contact terminal 141 of the card reader/writer 14 , so that data is transmitted and received between the smartcard 2 and the card reader/writer 14 . The communication interface 202 controls input and output of data transmitted to the card reader/writer 14 and data received from the card reader/writer 14 .
[0034] The antenna 21 of the smartcard 2 communicates with the antenna 147 of the card reader/writer 14 in a non-contact state, so that data is transmitted and received between the smartcard 2 and the card reader/writer 14 . The communication interface 22 controls input and output of data transmitted to the card reader/writer 14 and data received from the card reader/writer 14 .
[0035] The CPU 203 performs various kinds of processing based upon various commands (authentication commands) from the card reader/writer 14 . The data memory 204 is such a nonvolatile memory as EEPROM or FRAM. The RAM 205 is a work memory temporarily storing therein data transmitted from the card reader/writer 14 , for example. The ROM 146 is a memory storing a control program and the like therein.
[0036] As shown in FIG. 5 , the data memory 204 stores the encryption key information and the encryption algorithm information therein. The encryption key information and the encryption algorithm information are as already described above.
[0037] Next, outline of communication between the card reader/writer 14 and the smartcard 2 will be explained with reference to the flowchart shown in FIG. 6 .
[0038] First of all, the card reader/writer 14 transmits a SELECT command for selecting an object application via the contact terminal 141 or the antenna 147 . The smartcard 2 receives the SELECT command via the contact terminal 201 or the antenna 21 to return a normal status.
[0039] The card reader/writer 14 receives the normal status via the contact terminal 141 or the antenna 147 and transmits an interpreter command designating a parameter reading internal record information within the smartcard 2 via the contact terminal 141 or the antenna 147 . The smartcard 2 receives the interpreter command via the contact terminal 201 or the antenna 21 to return record information corresponding to the parameter.
[0040] The card reader/writer 14 receives the record information via the contact terminal 141 or the antenna 147 to transmit a GET PROCESSING OPTION command to the smartcard 2 . On the other hand, the smartcard 2 receives the GET PROCESSING OPTION command via the contact terminal 201 or the antenna 21 to return the card reader/writer 14 to normal status.
[0041] Transmission and reception of necessary data are performed between the card reader/writer 14 and the smartcard 2 in this manner, so that, for example, the card reader/writer 14 generates an INTERNAL AUTHENITICATE command (authentication command) for authenticating the smartcard 2 to transmit the INTERNAL AUTHENITICATE command via the contact terminal 141 and the antenna 147 . The smartcard 2 receives the INTERNAL AUTHENITICATE command via the contact terminal 201 and the antenna 21 to return encrypted authentication data and normal status.
[0042] Here, the authentication command generated by the card reader/writer 14 will be briefly explained. In the embodiment, a first authentication command corresponding to a first communication protocol for non-contact-type communication (T=CL [Connectionless]) and a second authentication command corresponding to a second communication protocol for contact-type communication (T=1) will be explained.
[0043] A first authentication command format corresponding to the first communication protocol for non-contact-type communication (T=CL) is defined, for example, in the following manner.
[0044] First authentication command format:
CLA/INS/P 1 /P 2 /Lc/Data/Le
[0045] CLA: class byte
[0046] INS: instruction code
[0047] P 1 : parameter 1
[0048] P 2 : parameter 2
[0049] A second authentication command format corresponding to the second communication protocol for contact-type communication (T=1) is defined, for example, in the following manner.
[0050] Second authentication command format:
NAD/PCB/Len/CLA/INS/P 1 /P 2 /Lc/Data/Le/EDC
[0051] NAD: node address
[0052] PCB: protocol control byte
[0053] Len: length
[0054] EDC: error defection code
[0055] For example, P 1 contained in the first and second authentication command formats shows a encryption algorithm reference number j (j: integer, 0≦j), and P 2 contained in the first and second authentication command formats shows a encryption key reference number n (n: integer, On). Data contained in the first and second authentication command formats includes a random number and fixed data. Incidentally, the random number is generated by the random number generation unit 143 a , as described above.
[0056] Incidentally, in the embodiment, the communication between the smartcard 2 and the card reader/writer 14 according to the first or second communication protocol will be explained, as described above, but the present invention is not limited to this communication. For example, the present invention can be applied to communication between the smartcard 2 and the card reader/writer 14 according to a third communication protocol (T=0).
[0057] Subsequently, authentication processing based upon the authentication command will be explained. The smartcard 2 which has received the authentication command determines a communication protocol with the card reader/writer 14 and changes or does not change an encryption system based upon the determination result of the communication protocol. Thereby, the encryption level can be changed according to the communication protocol. That is, a security level can be changed according to the communication protocol (status).
[0058] For example, the smartcard 2 changes or does not change the encryption key based upon the determination result of the communication protocol. That is, it is possible that the smartcard 2 changes the encryption key based upon the non-contact communication protocol and does not change the encryption key based upon the contact communication protocol. Further, it is possible that the smartcard 2 changes or does not change the encryption algorithm based upon the determination result of the communication protocol. That is, it is possible that the smartcard 2 changes the encryption algorithm based upon the non-contact communication protocol and does not change the encryption algorithm based upon the contact communication protocol.
[0059] One example of change of the encryption processing based upon the communication protocol will be explained below with reference to a flowchart shown in FIG. 7 .
[0060] First of all, the card reader/writer 14 generates a first or second authentication command. As described above, the first and second authentication commands include a encryption key reference number n, a encryption algorithm reference number j, a random number, and fixed data, and the card reader/writer 14 stores the encryption key reference number n, the encryption algorithm reference number j, the random number, and the fixed data therein.
[0061] The card reader/writer 14 transmits the first or second authentication command to the smartcard 2 , while the smartcard 2 receives the first or second authentication command (ST 10 ). The CPU 203 of the smartcard 2 analyzes the received first or second authentication command to determine a communication protocol. The CPU 203 can determine the communication protocol from the format of the received first or second authentication command, or it can determine the communication protocol according to whether the authentication command is received by the contact-type communication (the contact terminal 201 ) or the non-contact-type communication (the antenna 21 ).
[0062] For example, when the CPU 203 determines that the communication accords to the first communication protocol (ST 20 , YES), it performs change processing of the encryption key reference number. The CPU 203 adds m 1 (m 1 : integer) to encryption key reference number n contained in the received first authentication command to change encryption key reference number n and selects a target encryption key corresponding to changed encryption key reference number (n+m 1 ) from a plurality of encryption keys A, B, C, . . . stored in the data memory 204 . For example, the CPU 203 adds 2 to a encryption key reference number 0 (ST 31 , YES) (ST 32 ) and sets a encryption key C corresponding to encryption key reference number 2. Alternatively, the CPU 203 adds 2 to encryption key reference number 1 (ST 31 , NO) (ST 33 ) and sets a encryption key D corresponding to encryption key reference number 3.
[0063] Further, the CPU 203 selects a target encryption algorithm corresponding to a encryption algorithm reference number j contained in the received first authentication command from the plurality of encryption algorithms A, B, C, . . . stored in the data memory 204 . For example, the CPU 203 sets a encryption algorithm A corresponding to encryption algorithm reference number 0 (ST 34 , YES) (ST 35 ). Alternatively, the CPU 203 sets a encryption algorithm B corresponding to encryption algorithm reference number 1 (ST 34 , NO) (ST 36 ).
[0064] Further, the CPU 203 generates authentication data based upon set encryption algorithm A and encryption key C, and the fixed data (ST 37 ). Alternatively, the CPU 203 generates authentication data based upon set encryption algorithm B and encryption key D, and the fixed data (ST 37 ). The smartcard 2 transmits the authentication data to the card reader/writer 14 (ST 50 ).
[0065] The card reader/writer 14 receives the authentication data from the smartcard 2 and the CPU 143 of the card reader/writer 14 analyzes the authentication data and authenticates the smartcard based upon the analysis result. The CPU 143 discriminates the communication protocol with the smartcard 2 . For example, when the CPU 143 determines that the communication accords to the first communication protocol, it adds m 1 (m 1 : integer) to encryption key reference information n contained in the first authentication command transmitted to the smartcard 2 to change encryption key reference number n and selects a target decryption key corresponding to changed encryption key reference number (n+m 1 ) from the plurality of decryption keys A, B, C, . . . stored in the data memory 144 . For example, the CPU 143 adds 2 to encryption key reference number 0 and selects decryption key C corresponding to encryption key reference number 2. Alternatively, the CPU 143 adds 2 to encryption key reference number 1 and selects decryption key D corresponding to encryption key reference number 3. Further, the CPU 143 selects a decoding algorithm corresponding to encryption algorithm reference information j contained in the first authentication command. For example, the CPU 143 selects a decoding algorithm 0 corresponding to encryption algorithm reference information 0. Alternatively, the CPU 143 selects a decoding algorithm 1 corresponding to encryption algorithm reference information 1.
[0066] The CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key C and the decoding algorithm 0. Alternatively, the CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key D and the decoding algorithm 1. The CPU 143 compares the decoded fixed data and the fixed data contained in the first authentication command with each other, and it authenticates the smartcard 2 if both the data coincide with each other, but it does not authenticate the smartcard 2 if both the data do not coincide with each other.
[0067] In the above explanation, the case that the encryption algorithm is not changed has been explained, but the encryption algorithm can be changed like the encryption key. For example, when the CPU 203 determines that the communication accords to the first communication protocol, the CPU 203 adds k 1 (k 1 : integer) to encryption algorithm reference number j contained in the received first authentication command to change encryption algorithm reference number j and selects a target encryption algorithm corresponding to changed encryption key reference number (j+k 1 ) from a plurality of encryption algorithms A, B, C, . . . stored in the data memory 204 . For example, the CPU 203 adds 1 to encryption algorithm reference number 0 and sets a encryption algorithm B corresponding to encryption algorithm reference number 1. Alternatively, the CPU 203 adds 1 to encryption algorithm reference number 1 and sets encryption key C corresponding to encryption algorithm reference number 2.
[0068] In this case, the CPU 203 generates authentication data based upon set encryption algorithm B and encryption key C, and the fixed data. Alternatively, the CPU 203 generates authentication data based upon set encryption algorithm C and encryption key D, and the fixed data. The smartcard 2 transmits the authentication data to the card reader/writer 14 .
[0069] The card reader/writer 14 receives the authentication data from the smartcard 2 and the CPU 143 of the card reader/writer 14 analyzes the authentication data and authenticates the smartcard 2 based upon the analysis result. For example, when the CPU 143 determines that the communication accords to the first communication protocol, it adds m 1 (m 1 : integer) to encryption key reference number n contained in the first authentication command transmitted to the smartcard 2 to change encryption key reference number n and selects a target decryption key corresponding to changed encryption key reference number (n+m 1 ) from the plurality of decryption keys A, B, C, . . . stored in the data memory 144 . For example, the CPU 143 adds 2 to encryption key reference number 0 and selects decryption key C corresponding to encryption key reference number 2. Alternatively, the CPU 143 adds 2 to encryption key reference number 1 and selects decryption key D corresponding to encryption key reference number 3.
[0070] Further, the CPU 143 adds k 1 to encryption algorithm reference information j contained in the first authentication command transmitted to the smartcard 2 to change encryption algorithm reference number j and select a decoding algorithm (j+k 1 ) corresponding to changed encryption algorithm reference number (j+k 1 ). For example, the CPU 143 adds 1 to encryption algorithm reference information 0 and selects a decoding algorithm 1 corresponding to encryption algorithm reference number 1. Alternatively, the CPU 143 adds 1 to encryption algorithm reference information 1 and selects decoding algorithm 2 corresponding to encryption algorithm reference number 2.
[0071] The CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key C and decoding algorithm 1. Alternatively, the CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key D and decoding algorithm 2. The CPU 143 compares the decoded fixed data and the fixed data contained in the first authentication command with each other, and if both the data coincide with each other, the CPU 143 authenticates the smartcard 2 , but if both the data do not coincide with each other, the CPU 143 does not authenticate the smartcard 2 .
[0072] In the above explanation, the case that the encryption key is changed or the encryption algorithm is changed at the communication time according to the first communication protocol has been explained. Next, processing at a communication time according to the second communication protocol will be explained.
[0073] For example, when the CPU 203 determined that the communication accords to the second communication protocol (ST 20 , YES), it performs change processing of the encryption key reference number. The CPU 203 adds m 2 (m 2 : integer) to encryption key reference number n contained in the received second authentication command to change encryption key reference number n and selects a target encryption key corresponding to changed encryption key reference number (n+m 2 ) from the plurality of encryption keys A, B, C, . . . stored in the data memory 204 . Incidentally, in the embodiment, for example, m 2 =0 is set. Thereby, the encryption key reference number is not changed at the communication time according to the second communication protocol. For example, the CPU 203 adds 0 to encryption key reference number 0 (ST 41 , YES) (ST 42 ) and sets encryption key A corresponding to encryption key reference number 0. Alternatively, the CPU 203 adds 0 to encryption key reference number 1 (ST 41 , NO) (ST 43 ) and sets encryption key B corresponding to encryption key reference number 1.
[0074] Further, the CPU 203 selects a target encryption algorithm corresponding to encryption algorithm reference number j contained in the received second authentication command from the plurality of encryption algorithms A, B, C, . . . stored in the data memory 204 . For example, the CPU 203 sets encryption algorithm A corresponding to encryption algorithm reference number 0 (ST 44 , YES) (ST 45 ). Alternatively, the CPU 203 sets encryption algorithm B corresponding to encryption algorithm reference number 1 (ST 44 , NO) (ST 46 ).
[0075] Further, the CPU 203 generates authentication data based upon set encryption algorithm A and encryption key A, and the fixed data (ST 47 ). Alternatively, the CPU 203 generates authentication data based upon set encryption algorithm B and encryption key B and the fixed data (ST 47 ). The smartcard 2 transmits the authentication data to the card reader/writer 14 (ST 50 ).
[0076] The card reader/writer 14 receives the authentication data from the smartcard 2 , and the CPU 143 of the card reader/writer 14 analyzes the authentication data and authenticates the smartcard 2 based upon the analysis result. The CPU 143 determines the communication protocol with the smartcard 2 . For example, when the CPU 143 determines that the communication accords to the second communication protocol, it adds m 2 (m 2 : integer) to encryption key reference information n contained in the second authentication command transmitted to the smartcard 2 to change encryption key reference number n and selects a target decryption key corresponding to changed encryption key reference number (n+m 2 ) from the plurality of decryption keys A, B, C, . . . stored in the data memory 144 . For example, the CPU 143 adds 0 to encryption key reference number 0 and selects decryption key A corresponding to encryption key reference number 0. Alternatively, the CPU 143 adds 0 to encryption key reference number 1 and selects decryption key B corresponding to encryption key reference number 1. Further, the CPU 143 selects a decoding algorithm corresponding to encryption algorithm reference information j contained in the second authentication command. For example, the CPU 143 selects a decoding algorithm 0 corresponding to decoding algorithm reference information 0. Alternatively, the CPU 143 selects decoding algorithm 1 corresponding to encryption algorithm reference information 1.
[0077] The CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key A and the decoding algorithm 0. Alternatively, the CPU 143 decodes the random number and the fixed data from the authentication data based upon decryption key B and the decoding algorithm 1. The CPU 143 compares the decoded fixed data and the fixed data contained in the second authentication command with each other, and if both the data coincide with each other, the CPU 143 authenticates the smartcard 2 but the CPU 143 does not authenticate the smartcard 2 if both the data do not coincide with each other.
[0078] Further, it is assumed that the data lengths of encryption keys C and D are greater than the data lengths of encryption keys A and B. For example, it is assumed that encryption key A is 768 bits long, encryption key B is 968 bits long, encryption key C is 1024 bits long, and encryption key D is 2048 bits long. Thereby, the data length of authentication data generated by encryption key C or D becomes greater than the data length of authentication data generated by encryption key A or B. That is, authentication data having a greater data length is transmitted at a communication time according to the first communication protocol, while authentication data having a smaller data length is transmitted at a communication time according to the second communication protocol. Thereby, security can be made high at the communication time according to the first communication protocol, while processing time can be reduced at the communication time according to the second communication protocol.
[0079] Thus, in execution of a predetermined application of the smartcard 2 , the case that the card reader/writer 14 has transmitted the first authentication command (including encryption key reference number n) corresponding to the first communication protocol to the smartcard 2 and the case that the card reader/writer 14 has transmitted the second authentication command (similarly including encryption key reference number n) corresponding to the second communication protocol to the smartcard 2 are different from each other regarding a encryption key actually used, where, for example, the security level can be made high at a non-contact communication time and processing time can be shortened at a contact communication time.
[0080] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | An authentication data generation method includes receiving an authentication command from an authentication device, determining a communication protocol with the authentication device, changing encryption key reference information contained in the authentication command based upon the determination result of the communication protocol with the authentication device, selecting a target encryption key corresponding to the changed encryption key reference information from a plurality of encryption keys stored in advance, generating authentication data based upon the target encryption key and inclusion data included in the authentication command, and transmitting the authentication data to the authentication device. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority of German patent application No. 10 2008 030 446.8 filed on Jun. 26, 2008.
FIELD OF THE INVENTION
The invention relates to a sail membrane made of a woven fabric of synthetic fibers, a method for manufacturing such a sail membrane and sails manufactured from said sail membrane.
BACKGROUND OF THE INVENTION
When manufacturing sails, also for competition purposes, it is an essential requirement to combine quite a number of special characteristics such as low weight, good handling qualities, low permeability to wind, high tearing resistance, elasticity, low water absorptiveness, UV resistance and similar properties. Therefore, the ultimate goal sailmakers have in mind is to create an optimized woven fabric for sail manufacturing which purposefully features all these characteristics.
In sail manufacturing processes it has not yet been attempted hitherto to integrate in a well-aimed manner structures into the surface that improve the aerodynamic properties of the material. If sail membranes are made from sheets they essentially have a smooth surface. If these membranes consist of woven fabrics which is frequently the case with high-grade and large-size sails the surface of the sails is characterized by structures that reflect the inherent woven material structures, as the case may be concealed by sheets, modified by coatings or changed by bonding or fusion means. While these fabric structures have an influence on the aerodynamic properties of the sails and, if applicable, their permeability to wind and water absorptiveness, they are unsuited, however, to purposefully change the resistance to air which is also due to their quite coarse structuring.
Resistance-causing air flow or stream separation and micro-eddying will arise on both smooth as well as structured surfaces that are facing the wind. By purposefully creating microroughness on said surfaces the resistance can be reduced. Roughness in this context is particularly microroughness that brings down the degree of turbulence in the turbulence layer in relation to the surface of the sail. Such microroughness has been developed for aircraft construction purposes where as a rule it is provided in the form of parallel grooves or flutes arranged longitudinally to the direction of the approaching air flow.
In the manufacture of sails a distinction is made between sails used for sailing close to the wind the propulsion of which is produced by the differential pressure occurring between the windward and leeward side and those sails used for sailing downwind (wind astern) the propulsion of which is for the main part brought about by the pressure exerted by the wind. Sails used for wind astern operation shall be tight to air, have a high tearing resistance and strength to withstand tear propagation and, especially in the case of spinnakers, be made of a light-weight material, feature good haptic characteristics and are easily set.
It is thus the objective of the invention to propose a sail membrane having a surface structure especially suited for sailing with wind astern, which can thus be used for the making of spinnakers and gennakers.
SUMMARY OF THE INVENTION
This objective is achieved with a sail membrane of woven synthetic fiber fabric which is provided with microroughness in the form of intersecting groove families or sets arranged so as to achieve a density of 5 to 25 grooves/mm and deposited on or integrated into said fabric structure.
According to the invention the term “sail membrane” shall be understood to relate to any woven fabric made of synthetic fibers suited for and/or employed in sailmaking. Such sail membranes are, in particular, intended for the making of sails used (also) when sailing with astern wind. The fabrics may be manufactured from fibers of a single type such as, for example, polyamide fibers, polyolefin fibers and polyester fibers but may as well comprise mixed systems. Said fabrics may be coated in a manner known per se with a view to reducing or eliminating their permeability to air and, as a rule, are hydrophobized. To bring down their permeability to air the fabrics may also be rolled and/or treated thermally, for example by fusing a fiber with a low melting point of a mixed fabric consisting of various synthetic fibers.
Especially preferred materials are polyamide (Nylon-6.6), polyester as well as polyethylene (Dyneema® and/or Spectra®).
As proposed by the invention the groove density within a groove family ranges between 5 and 25 grooves/mm corresponding to a groove crest spacing of 200 μm to 40 μm, preferably 8 to 20 grooves/mm corresponding to a crest spacing ranging between 125 μm and 50 μm.
The amplitude of the grooves, i.e. the height of the valleys between two crests up to the crest top preferably amounts to 25 to 75% of the crest spacing of a groove family and in particular 40 to 60%.
Essentially, the all the grooves of each family extend parallelly to each other and, to all intents and purposes, may be arranged on the fabric in any conceivable orientation and direction. However, preferred is a diagonal arrangement at an angle of 45° in relation to the warp or weft filaments, +/−15°. Especially preferred is an essentially diagonal arrangement at 45° because such an extension is best suited to cover up the irregularities of the fabric.
Microroughness in the form of at least two parallelly extending groove families may be integrated into the fabric structure in any desired manner, for example by printing, weaving in, applying rows of nanoparticles or by rolling-in methods. Especially preferred is the calendering method using a structuring or groove roller, with said roller being heated as a rule to a temperature which is lower than the softening temperature of the synthetic fiber or the synthetic fiber having the lowest softening point, preferably approx. 10° C. below. In the interest of improving the embossing effect it may prove expedient to treat the fabric with hot steam before it is calendered, for example at a temperature of 110° C.
Calendering takes place at elevated temperature at a pressure of at least 50 N/mm 2 , preferably at a pressure between approx. 100 and 600 N/mm 2 , and especially at approx. 200 to 400 N/mm 2 .
Preferably, both sides of the sail membrane are calendered by means of such a structuring or groove roller.
Especially preferred for the inventive sail membrane is a diamond pattern consisting of grooves crossing each other, i.e. of two groove families crossing one another particularly at an angle of between 80° and 120°. In this way, a rectangular or diamond pattern is formed which is skewed by 45°+/−15° in relation to the normal fabric pattern consisting of warp and weft filaments crossing one another. However, three groove families crossing one another may also be provided, with said families intersecting at an angle of, for instance, 60° and encompassing hexagonal depressions.
The sail membrane in accordance with the invention may be hydrophobized in a manner known per se, with such a hydrophobization especially being brought about using a perfluoropolyalkylene, for example by means of Teflon®. Preferably, the hydrophobization takes place prior to the calendering process. If the fabric is dyed/colored and finished in a special manner such dyeing and finishing processes shall also take place prior to the calendering operation.
A hydrophobization may in particular be brought about, also additionally, by applying hydrophobic particles, for example by the application of nanoparticles causing a hydrophobic wetting regime according to Cassie-Baxter. Such nanoparticle coatings may be of irregular nature and particularly in terms of dimensioning should significantly fall short of the dimensioning of the groove pattern imprinted. The height of said particles should not exceed a value of 5 μm, in particular 2 μm. Such a nanoparticle coating ensures that drops of water accumulating in those locations do not wet and penetrate into the sail membrane itself but roll off the surface and thus reduce the water absorption of the membrane.
Moreover, the invention relates in particular to a process for manufacturing a sail membrane in accordance with one of the claims described hereinbefore, with the fabric in the form of gray cloth or semi-finished product being dyed and/or finished as the case may be after production and then calendered on at least one side at a pressure of at least 50 N/mm 2 using a structuring roll for the embossing of intersecting groove families having a density ranging between 5 and 25 grooves/mm.
In the process according to the invention the calendering operation as a rule is to be the final manufacturing step yielding the finished sail membrane product. All dyeing and finishing steps are to be carried out beforehand which also applies to hydrophobization coatings that may be applied. Calendering takes place at elevated temperature with the roll being heated up to a temperature adjusted so as to be below the softening or melting point of that synthetic fiber that has the lowest melting point. Preferably, this temperature is approx. 10° C. below the melting or softening point. With a view to improving the embossing effect the fabric may be subjected to an initial water vapor treatment, e.g. using hot steam of 110° C. A hydrophobization step as described above is also performed before the calendering operation. Further refining measures, for example the application of nanoparticle coatings aimed at improving hydrophobic characteristics, take place after calendering.
Taking the inventive sail membrane sails can be manufactured in a customary manner. Normally, the sail is assembled from individual webs or fabric segments, with the main load lines and the tearing resistance in various directions being duly taken into account in a manner known per se.
Accordingly, the invention also relates to a sail manufactured from an inventive sail membrane, especially spinnakers and gennakers.
It has been found that thanks to the intersecting groove structure provided sail membranes manufactured on the basis of the present invention have special aerodynamic properties, in particular when sailing with astern wind. Due to the calendering process the fabric's permeability to air is significantly reduced. The air permeability low as it is already may still be reduced further and even brought down to zero by taking customary coating measures for which considerably less coating material will be needed. It is advisable to carry out such a coating measure after the calendering operation.
Spinnaker and gennaker woven fabrics made in this manner as provided by the invention can be manufactured so as to be of considerably less weight. For example, if a given minimum weight is desirable or required, this saving in weight may be used to integrate reinforcing yarns so that with the overall weight being of comparable magnitude a higher tearing resistance and tear propagation strength can be achieved.
The inventive sail membranes are especially suited for the manufacture of spinnakers and gennakers. The embossed pattern of groove families crossing one another results in improved haptic characteristics which makes sail setting easier. Although for downwind sailing purposes stream separation and micro-eddying do not have a decisive influence on air resistance, the microroughness and structuring of the sail surface and the vortex separation associated with them lead to the aerodynamic properties being improved, higher sailing stability and, in particular, facilitate the setting of the spinnaker.
If the inventive sail membrane is additionally provided with a nanoparticle layer aimed at improving the membrane's water repellency its water absorptiveness can be significantly reduced in this way. In this case a continuous coating with a water-repellent agent—as well as a coating intended to reduce the permeability to wind—can be dispensed with entirely or to a large extent so that altogether a considerable reduction in weight of both a dry sail and of a sail in use at a given time is achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail by way of the enclosed figures where
FIG. 1 shows a sailcloth fabric after calendering, 60× magnified, and
FIG. 2 shows another sailcloth fabric after calendering, 300× magnified, and
FIG. 3 shows a third sailcloth fabric after calendering, 60× magnified,
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 a sailcloth is illustrated that consists of a woven polyamide fabric with its clearly visible warp and weft yarns extending perpendicularly to each other and being of plain weave design. By means of a calendering roll with X-corrugations an X-pattern of intersecting grooves is embossed into this fabric, said grooves running diagonally to the direction of the fabric. The individual grooves are spaced at approximately 125 μm corresponding to 8 grooves/mm. The sets of grooves running diagonally from top left to bottom right and from bottom left to top right intersect at an angle of approximately 90°. The embossing pressure was 300 N/mm 2 , the roll temperature was adjusted to a value of 200° C.
FIG. 2 illustrates a sailcloth made of a polyamide fabric of plain weave design with 20 grooves/mm, magnified 300×. Clearly visible are the crests of the intersecting grooves extending diagonally to the direction of the fibers and the enclosed diamond-shaped depressions made in the fiber surface, with said chain-like depressions continuing in fiber direction. The sailcloth was treated by means of a cross-corrugation calender at 200° C. and 300 N/mm 2 .
In FIG. 3 a sailcloth is illustrated that consists of a woven polyester fabric with its clearly visible warp and weft yarns extending perpendicularly to each other and being of plain weave design. By means of a calendering roll cross-corrugations were embossed into this fabric, said corrugations running diagonally to the fiber direction. The individual grooves are spaced at 50 μm from groove to groove corresponding to a groove density of 20 grooves/mm. The families or sets of grooves running diagonally from top left to bottom right and from bottom left to top right intersect at an angle of approximately 95°. The embossing pressure was 400 N/mm 2 at a roll temperature of 200° C.
Examinations carried out on a raw polyamide woven fabric processed by means of a corrugated roll with 8 lines/mm at a temperature of 200° C. have shown that after calendering the permeability to air at 20 mm WC of 600 to 800 l/dm 2 /min was significantly reduced to 30 to 40 l/dm 2 /min for the gray cloth. Further reduction is to be expected for the dyed cloth. In case of the coated sailcloth the permeability to air goes down to zero, with the coating amount being considerably lower for the calendered cloth. A lower amount of coating enables the weight of the finished sail to be reduced and such a saving in weight can be utilized to apply reinforcing measures (reinforcing yarns).
With a view to achieving optimum results the treatment by means of the corrugated roll must always be performed on both sides.
Examination series carried out on a polyamide gray cloth processed by means of a cross-corrugation roll with 20 lines/mm at a temperature of 200° C. have shown a significant interdependency between air permeability and pressure, with an optimum at 200 to 400 N/mm 2 :
Pressure N/mm 2
Permeability to air, l/dm 2 /min
100
100
150
70
200
40
300
30
400
30
The gray cloth had been calendered on both sides. With dyed cloth the permeability (at 300 to 400 N/mm 2 ) was found to be 10 to 20 l/dm 2 .
For the purpose of determining the resistance to air sail membrane samples were tested in a wind tunnel using an MAV scales test piece (6-component strain gauge MAV scales) at a windspeed of 18 m/s. The MAV scales test piece was a trapezoidal wing of small extension having a symmetrical profile. The leading edge sweep was 36°, the rear edge was straight. The wing area was covered with the cloth patterns in such a manner that the covering embraced the top side of the wing completely while just abt. a quarter of the bottom side was covered.
For a non-corrugated sail membrane the measuring results showed a coefficient of drag value C Wa of 7.08×10 −3 on average, for a membrane with intersecting corrugations comprising 10 grooves/mm a value of 6.54×10 −3 and with 20 grooves/mm a value of 6.4×10 −3 . These are mean values determined from 500 measurements on eight measuring points.
The sail membrane samples were made of a polyester/polyethylene mixed woven fabric. | Sail membrane made of a woven fabric of synthetic fibers, with said fabric having a microroughness in the form of groove families crossing one another arranged so as to achieve a density of 5 to 25 grooves/mm deposited on or integrated into said fabric structure. | 3 |
BACKGROUND OF THE INVENTION
The present invention is related to the field of pulp production, more particularly the invention relates to the field of refining wood chips into pulp for paper manufacturing.
Two broad categories of pulp manufacturing techniques are known in the art. The first technique is known as the digestion process, wherein lignocellulose fiber containing material (wood chips) are treated with chemicals and heat in order to break down the structure of the wood chips and produce pulp suitable for use in the paper making process. A second technique for producing pulp, known as the mechanical pulping process, involves passing lignocellulose fiber containing material, such as wood chips, through an attrition device where the fibers of the wood chips are mechanically separated. Variations of the mechanical pulping process are also known and include the thermo-mechanical pulping process (“TMP”). In the TMP process, wood chips are fed into a pressurized pre-heater, treated with steam and are subsequently ground into pulp. U.S. patent application Ser. No. 08/736,366, filed Oct. 23, 1996, “Low-Resident, High-Temperature, High Speed Chip Refining”, (now U.S. Pat. No. 5,776,305) discloses a further variation on the ground wood pulp process, whereby the wood chips are held at a temperature greater than the glass transition temperature (T g ) of the lignin in the wood chips for a period of time preferably less than 30 seconds, then immediately refined in a high speed disc refiner. According to the application, the wood chips are preferably subjected to a preheat environment of saturated steam at an elevated pressure in the range of 75-95 psi. (All values of pressure expressed as psi throughout this Specification including claims, refer to pounds per square inch gage pressure, i.e., psig). The assignee of the 08/736,368 application identifies the system and associated process as the “RTS”.
In both the chemical digestion and mechanical pulping techniques of making pulp, pulp wood logs are fed to chipper machinery where the logs are cut and sheared into pieces appropriately sized for subsequent processing. Once in chip form, the material is fed to a digestion reactor vessel, mechanical refining apparatus, or the pre-heating stage of the mechanical refining apparatus.
SUMMARY OF THE INVENTION
The inventor of the present invention has found that pretreating the lignocellulose fiber containing chip material with heat, pressure and physical compression or, preferably, with moist heat, moisture, pressure and physical compression confers several beneficial effects which are realized in subsequent processing steps and in the quality of pulp obtained thereby. One benefit of pretreating the wood chips is that refiner intensity in the mechanical pulping process may be increased, fostering process energy savings. Also, improvements in the pulp strength properties and shive content of pulps obtained by pretreating the wood chips as described in this application may be noted.
The present invention comprises a method and apparatus for pretreating or conditioning lignocellulose materials and destructuring said materials, thereby fostering improved quality pulp and more economical pulp processing conditions. The invention is accomplished by subjecting lignocellulose materials, principally pulp wood chips, to conditions of elevated temperature, pressure and optionally, moisture, and preferably while the materials are under the influence of these conditions, physically compressing the materials at elevated compression levels in an amount sufficient to cause high levels of axial compression and thus destructuring of the wood chips.
Destructuring is defined as a significant separation of at least a portion of the fibers of the wood chips. This includes, but is not limited to, a separation of some or all of the wood fibers from one another along the longitudinal axis of the fibers. A characteristic of destructuring using the method and apparatus of this invention is that the destructuring causes significantly less damage to the wood fibers than if the chips were simply subjected to mechanical compression alone without pretreatment of heat, pressure and, optionally, moisture. For example, when wood chips are compressed without benefit of the conditioning step of this invention, a large proportion of the wood fibers tend to break across the grain of the fiber rather than separate from each other along the grain of the fiber. Breaking across the grain generates wood “fines” or minute particles of broken wood, and results in shorter pulp fibers. Both fines and short wood fibers generated by shattering or breaking are undesirable in the pulp processing industry.
The method of the invention comprises subjecting the wood chips to pretreatment conditions including a temperature in the range of 90-150° C., pressure in the range of 10-100 psi and optionally a moist atmosphere for a period of time prior to physical compression, wherein said pretreatment conditions are sufficient to promote destructuring of the wood chips when the chips are compressed at a ratio of from 4:1 or greater. The inventor envisions that a 3 to 180 second exposure time to pretreatment conditions of elevated temperature, pressure and moisture would be sufficient for pulping needs. However, a 3 to 60 second exposure to pretreatment conditions is preferred.
Practitioners in the art of pulp manufacturing will recognize the temperature and pressure ranges for the pretreatment conditions may need to be varied according to the pulping method being practiced. In TMP pulping, the pretreatment temperature may preferably be in the range of 90-120° C. and the pressure in the range of 15-25 psi. At temperatures above 120° C. some undesirable discoloration (darkening) of the wood chips or components thereof might occur. As the TMP process is practiced to obtain a suitably bright pulp for paper manufacture, anything which causes discoloration of the wood and pulp derived therefrom is to be minimized. This is primarily because most of the lignin, which contains the dark color bearing structures (i.e., chromophores), remains in the pulp following processing. On the other hand, in the kraft paper process, most of the lignin is removed from the pulp during pulping. Consequently, for the kraft process, heating in the pretreatment step to higher temperatures in the range of 120-150° C. and higher retention times is acceptable, i.e., a higher pretreatment temperature may be used in the chemical digestion pulping process as washing and bleaching of the pulp removes lignin, leaving the pulp white. In the kraft pulping and chemical digestion processes, higher pretreatment pressures in the range of 25-100 psi may be used.
The amount of compression to which the wood chips are subjected is expressed as a volummetric compression ratio, that is, the volume of the wood chips in an uncompressed state:the volume of the wood chips in a compressed state. According to the present invention, a compression ratio of 4:1 or greater provides the proper destructuring of the wood fibers. Generally, the destructuring can be accomplished in a compression ratio range of 4:1-8:1, with a preferred ratio in the range of 4.5:1-5.5:1.
Moisture is typically introduced to the pretreating process of the invention as a consequence of using steam as the heating medium. At the pressures and temperatures at which the process is practiced the steam is likely to be in a saturated state. It is possible, however, that a moist atmosphere could be obtained by simply introducing water into the heated and pressurized area, wherein the water would quickly turn to steam in that environment. Steam is the preferred way to add moisture, pressure and heat to the process, however it is foreseeable that means of heating, other than steam, could be practiced.
The compressive forces necessary to destructure the pretreated wood chips may be applied in various ways. One method of applying physical compression includes placing the wood chips between two plates or surfaces of a press and forcing the plates together to achieve the desired compression ratio. Where atmospherically presteamed wood chips are carefully aligned between the plates of a press so that compression force can be applied in a direction parallel to the longitudinal axis of the wood grain of the chips, they exhibit structural buckling, thereby indicating achievement of the desired result of a high level of separation between fibers at the S 1 -S 2 interface. However, when atmospherically pre-steamed wood chips are compressed in this manner, a significant level of fiber shattering across the grain boundary of the fiber also occurs, thereby generating large numbers of fines. In the present invention, a high level of axially compressed wood chips is also desired, however, the conditioning of the wood chips by heating to elevated temperature levels in a pressurized environment and optionally, in the presence of moisture prior to compression reduces shattering and fines. It is believed that alignment of the wood chips as in these experiments, although feasible on a small scale, such as in a laboratory setting, would be not feasible for high volume operating requirements of commercial pulp and paper mills. Operation in a pressurized environment would also render axial alignment impractical. A viable alternative, and one which would be commercially acceptable, includes passing conditioned wood chips through a screw driven compression device. Such a device is exemplified by screw compression equipment sold under the registered trademark PRESSAFINER and commercially available from Andritz, Inc., Muncy, Pa. Other means of physically compressing and destructuring pretreated wood chips at elevated compression levels may be used. The compaction device should preferably produce a blend of destructured material with a high level of axially compressed wood chips present.
The apparatus of the present invention in its most basic embodiment comprises a conditioning chamber in communication with a compression device. The conditioning chamber is a vessel adapted for treatment of lignocellulose-containing feed materials under conditions of elevated pressure, elevated temperature, and optionally, moisture. Wood chips in the conditioning chamber are subjected to these conditions for a period of time in order to improve their processability in the compression device. The conditioning chamber may include means of transporting the wood chips through the chamber from a feed inlet to an outlet in communication with the compression device. Also, the conditioning chamber may include a rotary valve, plug screw feeder or other means to decouple the conditions within the chamber from ambient conditions, thereby allowing for effective conditioning treatment of the wood chips. The compression device is designed to receive conditioned feed materials from the conditioning chamber and compress them by mechanical means, thereby causing the fiber of the wood chips to separate and the chips to become destructured. The compression device of the present invention comprises a screw shaft rotatably mounted within a housing. The screw shaft is in spaced-apart relation with the housing, thereby defining a space around the shaft for movement and compression of the wood chips. Screw flights are disposed about the shaft in a generally helical fashion and are adapted for engaging the wood chips and impelling them from the inlet end of the compression device to the outlet end of the device. Compression of the wood chips is performed by moving the wood chips from an area of low compression in the compression device (in the region of the inlet) where the volume of space around the shaft is relatively large, to an area of high compression (toward the outlet) where the volume of space around the shaft is smaller. Compression occurs by impelling the wood chips into a decreasing volume space. In the present invention, the compression of the wood chips is practiced in the range of 4:1-8:1, wherein the ratio represents the relationship of the uncompressed volume to the compressed volume of a sample of wood chips.
In another embodiment of the invention an additional means of applying compression forces to the wood chips is envisioned. In this embodiment compression bolts are arranged to extend into the space around the screw compression shaft, thereby further decreasing the volume space and increasing compression. These bolts may be made adjustable so the distance they extend into the volume space around the shaft, and hence the additional compression they produce, can be altered to suit processing needs. It is also believed that the compression bolts, because they extend into the space around the shaft, make physical contact with at least a portion of the wood chips and “work” the chips, causing additional opening of the fiber structure. In those embodiments of the invention incorporating compression bolts, the bolts may be situated at the end of the screw shaft, or at one or more points along the shaft, preferably in the area of high compression along the shaft. In the event the compression bolts are located along the shaft the screw flights of the shaft are preferably made discontinuous, thereby providing a gap allowing the flighted shaft to rotate with clearance for the bolts.
The compression device of the present invention has features which are substantially as disclosed in published International Patent Application WO 92/13710, entitled “Adjustable Compression Screw Device and Components” and incorporated by reference herein.
Output from the compression device may be sent directly to pulp refiner equipment or held in a storage bin. The refiner equipment for use in connection with the invention includes, for example, TMP and RTS refiners, or it may be sent to a storage bin for a refiner on either a long or short term storage. In chemical pulping applications, the output of the compression device would feed the chemical digesters directly or via an intermediary storage bin. Various means may be employed for moving the chips from the compression device to the refiner or storage bin and include, for example, plug screw feeders and transfer conveyors. Further details of the apparatus of the invention will be apparent in the discussion of the drawings presented below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of the wood chip conditioning equipment of the invention combined in an atmospherically decoupled arrangement with RTS rotating disc pulp refiner equipment.
FIG. 2 is a schematic diagram of a second embodiment of the wood chip conditioning equipment of the invention combined in an atmospherically decoupled arrangement with RTS rotating disc pulp refiner equipment.
FIG. 3 is a schematic diagram of a third embodiment of the wood chip conditioning equipment of the invention combined in an atmospherically coupled arrangement with RTS rotating disk pulp refiner equipment.
FIG. 4 depicts a longitudinal sectional view of one embodiment of a compression unit for implementing the invention.
FIGS. 5-11 are graphs showing various performance aspects of pulp made according to the invention compared to other pulps.
FIG. 12 is an electron photomicrograph (100×magnification) of a wood chip which has not been conditioned, compressed, or otherwise pretreated.
FIG. 13 is an electron photomicrograph (100×magnification) of a wood chip which has undergone steam heating and pressurization at 22 psi, and high compression at a 5:1 compression ratio according to the present invention.
FIG. 14 is an electron photomicrograph (100×magnification) of a wood chip which has received atmospheric steaming treatment, followed by 4:1 compression.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic diagram of conditioning equipment in an atmospherically decoupled arrangement with an RTS pulp refiner. In a first embodiment of the wood chip conditioning equipment 1 of the invention, wood chips are introduced to the conditioning equipment via rotary valve 2 . The rotary valve allows chips to be transferred from a storage bin or other bulk feeding means which is open to the atmosphere and is otherwise at ambient conditions of pressure and temperature to the steam tube 3 where conditions of elevated pressure, temperature and optionally moisture are maintained. Other means of decoupling the conditioning equipment from the ambient conditions in which the chips are stored or transported may be used. The wood chips are resident in the steam tube for a period of time sufficient to condition the chips for subsequent compression. Typically, exposure to conditions of elevated temperature, pressure and optionally moisture for a period of 3-180 seconds is sufficient for pulping needs. However, it is envisioned that a 3-60 second exposure to pretreatment conditions is preferred.
The conditions within the steam tube include a temperature in the range of 90-150° C. and a pressure in the range of 10-100 psi. Optionally, the steam tube has a moist atmosphere. Heating of the steam tube may be accomplished by introducing steam directly to the tube via line 4 . Those practitioners of ordinary skill in the art will recognize that other means may be employed to heat the steam tube and its contents to the operating temperatures of the invention. These means include electric heating coils disposed about the steam tube, or a jacket disposed about the steam tube for heating with steam. Those of ordinary skill in the art will recognize the advantages of introducing steam directly into the steam tube for purposes of heating as the steam may also be used to not only pressurize the steam tube to operating pressures but provide a moist atmosphere within the steam tube. If means other than introducing steam directly into the steam tube are used for heating the steam tube, additional means must be provided for raising the pressure within the steam tube to operating condition. This may be accomplished by such means as a pump or compressor which raises the pressure within the steam tube to operating condition. It will also be appreciated that if heating of the steam tube is accomplished with means other than introducing steam into the steam tube, if required for a particular embodiment of the process of the invention, moisture or water may be introduced to the steam tube along with the wood chips or through an inlet or other conduit means directly into the steam tube itself.
The conditioned wood chips pass to the inlet end of the screw compression unit 6 . The screw compression unit features a screw shaft 7 driven by a variable speed motor 8 . Disposed along and about the shaft in a generally helical fashion are compression screw flights 9 . The screw flights impel the wood chips toward the outlet end of the screw compression device as the shaft is rotated. In FIG. 1 , the rotatable screw shaft is outwardly tapered from its narrow, low compression, wood chip inlet end to its wider, high compression, outlet end of the compression unit. Compression of the wood chips in this embodiment is accomplished by the screw flights impelling the wood chips into an ever-decreasing volume space about the shaft. Also, the level of compression in the compression unit may be enhanced through the use of a restrictor bolt section 11 . The restrictor bolt section includes bolts or other projections which extend into the space around the shaft further reducing the volume space in that region and make contact with the wood chips passing through the unit in a manner which “works” the wood chips, destructuring them even further. Those practitioners of ordinary skill in the art will recognize that the desired compression ratio of from 4:1-8:1 of the invention can be attained through various means, including adjusting the volume space about the shaft by altering the taper of the shaft or profile of the housing in which the shaft rotates, changing the pitch of the flights, and adjusting the degree of restriction imposed by the restrictor bolt section. These examples are not intended to limit in any way the means by which the compression aspect of the present invention is accomplished.
As the compressed wood chips leave the outlet end of the compression device they are carried by transfer conveyor 13 to storage bin 14 . In the embodiment shown in FIG. 1 , the transfer conveyor and storage bin are both under ambient conditions, although it is within the scope of this invention to maintain the compressed wood chips at elevated pressure and temperature until being further processed. For example, when the compressed wood chips have an undesirably low moisture content, water and/or chemicals may be added to the chips by way of water impregnation or chemical impregnation. As a further example, bleaching chemicals may be added by way of chemical impregnation. It is preferred that such water or chemical impregnation be carried out as the wood chips are discharged from the compression device. From the storage bin, the wood chips are conveyed by plug screw feeder 15 to chamber 20 of, preferably, an RTS refiner system 10 . The plug screw feeder features a rotatable screw shaft 16 which is rotated by variable speed motor 17 . Disposed in a helical fashion about the rotatable screw shaft of the plug screw feeder are screw flights 18 . When the screw shaft is rotated, the plug screw flights impel the conditioned wood chips toward the outlet ends of the plug screw feeder. The plug screw feeder is designed to cause a degree of crowding of the transported material thereby making a plug of material which effectively atmospherically decouples the downstream outlet end of the plug screw feeder from the inlet end in communication with the storage bin. Formation of a plug and the atmospheric decoupling of these portions of the apparatus are necessary as the chamber 20 is maintained at a high level of pressure and temperature. In order to prevent the blow back of the plug toward the inlet end of the screw feeder, an air cylinder 19 provides pressure relief, thereby preventing the refiner pressure from blowing through the plug.
Once in the chamber 20 of the RTS refiner system, the chips are maintained under conditions of elevated temperature, pressure and moisture as required by the RTS preheating process. The conditioned chips are conveyed along variable speed screw 22 to the steam separation chamber 24 . Steam from the separator 24 is routed to chamber 20 for heating and treatment of the wood chips. Water or other treatment chemicals may be added to the mixture through line 28 . In this portion of the apparatus, the chips experience a saturated steam preheat at a temperature at least 10° C. above T g , for a total residence time through vessel 20 , screw 22 and separator 24 of between 5-10 seconds.
The preheated wood chips are then driven by a high speed ribbon feeder 30 into the primary refiner 32 which is powered by motor 33 . In a single disc refiner (as shown as 32 ), the rotating disc operates at a speed greater than 1800 rpm, preferably above 2200 rpm. In a double counter rotating disk refiner, the disks each rotate at a speed greater than 1500 rpm, preferably above 2,000 rpm. Bleaching agents and other chemicals can be introduced into the pulp at primary refiner 32 through lines 34 and 36 by metering system 38 from bleaching agent reservoir 40 . The primary pulp is fed through line 42 to the secondary refiner 44 which is driven by motor 46 . The refined pulp of the secondary refiner is transferred by line 48 to a storage facility or other apparatus for further processing into a final product.
In the embodiment of FIG. 1 , the steam tube can be considered a passive inlet portion of the compression unit 6 . It should be appreciated that the pre-treatment process 1 according to the invention, may be implemented in hardware in which steam tube or chamber 3 is distinct from compression unit 6 , for example as shown in FIGS. 2 and 3 . In the embodiment of FIG. 1 , a plug is formed immediately upstream of 11 , before expansion at atmospheric pressure at 12 . The plug in effect decouples the pre-treatment at elevated temperature and moisture in process 1 , from the atmospheric pressure in storage bin 14 . Alternatively, the conveyor 13 , bin 14 and plug screw feeder 15 can be omitted, and a specially adapted Pressafiner screw device, such as described with respect to FIG. 3 below, can be employed to introduce pre-treated material directly into the refiner pre-heating chamber 20 . Similarly, the RTS refining system 10 can have a variety of configurations. For example, in some installations, the chamber 20 may be eliminated, because even when present, the level of wood chips therein is very low, whereby the retention time of the material at the temperatures of T g , can be controlled substantially entirely by controlling the speed of the variable speed conveyor 22 .
Further details regarding the preferred refiner system 10 are set forth in pending U.S. patent application Ser. No. 08/736,366, the disclosure of which is hereby incorporated by reference.
In FIG. 2 , a schematic diagram of conditioning equipment in an atmospherically decoupled arrangement with an RTS pulp refiner is shown. Wood chips are fed to the apparatus through rotary valve 51 . The rotary valve is in communication with the inlet end of a variable speed pressurized conveyor 52 which is pressurized and heated by steam line 54 . The screw flights of rotating screw shaft 53 impel the wood chips from the inlet ends of the pressurized conveyor to the outlet end of the pressurized conveyor. The outlet end of the pressurized conveyor is in communication with the wood chip compression unit 6 . Those of ordinary skill in the art will recognize that the compression units, transfer conveyor 13 , atmospheric bin 14 , plug screw feeder 15 and RTS refiner 10 are identical to that previously described in regard to FIG. 1 . An additional embodiment of the apparatus shown in FIG. 2 includes the apparatus as described, but with the substitution of the rotary valve 57 by a side-entry plug screw feeder.
FIG. 3 shows yet another embodiment of the apparatus and method of the invention. Wood chips are introduced through rotary valve 70 to the variable speed pressurized conveyor 74 . As is shown in the drawing of FIG. 3 , a steam line 76 is used to introduce steam to the interior of the pressurized conveyor. The steam heats and pressurizes the wood chips being transported through the conveyor and also subjects them to moisture. It is within the scope of this invention that other means be used to subject the wood chips to conditioning levels of heat, pressure and, optionally, moisture. These other means include dry heating of the wood chips through electrically resistive wires disposed around the pressurized conveyor, or indirect heating of the pressurized conveyor through steam jackets or other alternative heating media. In the event one of the dry heating methods is used to heat the wood chips, moisture may still be introduced in the process through water injectors or other ways of introducing water or water vapor into the process equipment. Also, when one of the dry heating methods is used, a pump or compressor device must be used to condition the wood chips under pressure, this being necessary to emulate conditions when steam is used to heat and pressurize the conditioning equipment directly. The pressurized conveyor moves the wood chips from the inlet end to the outlet end thereof and the outlet of the pressurized conveyor is then in communication with a wood chip compression unit 80 featuring a rotatable compression screw shaft 81 driven by a variable speed motor 82 . The screw shaft features a first flight section 83 , a second flight section 85 and a flightless zone 87 , a portion of screw shaft without flights, by which the first flight zone and second flight zone are spaced apart. As in other embodiments, the compressive forces imposed upon the wood chips are caused by impelling the wood chips into a decreasing volume space about the shaft and additionally, by forcing the wood chips through a region of the unit where constrictor bolts 90 create additional compression which acts on the wood chips. In this embodiment of the invention, the constrictor bolts are located a distance set back from the outlet end of the compression device. The constrictor bolts in this embodiment are disposed in a generally radial pattern around the screw shaft in the interrupted flight zone (flightless zone) of the compression device. As in previous embodiments, the constrictor bolts exert additional pressure on the wood chips being impelled through the compression device and also act to “work” the wood chips and aid in destructuring and opening the fibers of the chip. The outlet end of the compression unit is in communication with the inlet portions of the RTS refining equipment 10 . An air cylinder 88 is used at or near the outlet end of the compression unit to prevent the higher atmospheric pressure found in the RTS refiner portion of the apparatus from blowing through the plug of wood chips formed in the compression unit. Other features of the RTS refiner portion of this apparatus shown in FIG. 3 are as previously described in FIGS. 1 and 2 .
FIG. 4 depicts a longitudinal sectional view of one embodiment of the wood chip compression unit of the present invention. This embodiment is an improvement to the conventional MSD PRESSAFINER available commercially from Andritz, Inc. In this embodiment, the wood chip compression unit 100 comprises a housing 101 having an inlet end 103 and an outlet end 105 . In operation, the inlet housing (not shown in FIG. 4 ) is in communication with the conditioning chamber and is preferably configured to permit pressurization of the inlet to process condition pressures. Within the housing is a rotatably mounted screw shaft 110 having one or more screw flights 113 disposed about the shaft in a helical arrangement for impelling the wood chips out of the inlet, causing compression of the wood chips, and impelling the wood chips out of the compression unit at the outlet. The screw shaft is preferably driven by a variable speed motor 112 . It will be noted that this embodiment of the compression unit features a screw shaft with a tapered portion 111 for imparting compressive forces to the wood chips. It will be noted that the tapered portion of the screw shaft is widest at the end nearest the outlet of the compression unit and narrowed at the inlet portion of the compression unit. This taper to the shaft allows the compression volume space 115 to gradually decrease toward the outlet end of the unit. Wood chips introduced at the inlet are impelled by the screw flights toward the tapered portion of the shaft and the region of decreasing volume space, i.e., the compression zone of the unit.
This embodiment of the invention shown in FIG. 4 features restrictor bolts 120 near the outlet end of the compression unit. The restrictor bolts serve to increase the compressive forces imposed upon the wood chips by further decreasing the flow cross-section about the shaft through which the chips are forced to pass. The restrictor bolts are adjustable so that the length of the bolt protruding into the space about the shaft can be adjusted by the operator. This adjustability of the restrictor bolts permits the operator to adjust the compression of the unit as demanded by the process. The restrictor bolts also serve to “work” the wood chips which pass through the restrictor bolt region of the unit, further opening, or otherwise destructuring, the fibers of the wood chips. In the embodiment shown in FIG. 4 , a short helical impeller screw flight is located downstream of the restrictor bolts at the outlet of the compression unit. The impeller screw 130 serves to move the already compressed wood chips from the unit to the next phase of the pulp process. It will be noted that in the embodiment shown the housing of the unit flares outward at the outlet, thereby increasing the volume space in that area. It is not believed that the impeller screw imposes any additional compression on the wood chips. Rather, the impeller screw merely serves to move the opened wood chips to the next phase of the pulp refining process.
The inventor performed a number of experiments to evaluate the effect of the wood chip pretreatment process of the invention on RTS and conventional TMP pulp with a view toward determining whether any savings in specific energy requirements accrued when the pretreatment method was employed. The inventor discovered that wood chips which were pretreated with the process of the invention and refined at RTS conditions demonstrated a reduction in the specific energy required for refining compared to conventional TMP. This reduction was in the range of 448-511 kWh/ODMT, as further shown in FIG. 5 . By comparison, wood chips which were not treated according to the process of the invention, but were refined at RTS conditions demonstrated only a 315 kWh/ODMT reduction in specific energy compared to conventional TMP. The experimental results also indicate that pretreatment of the wood chips according to the invention could permit a further increase in primary refiner intensity which would result in additional energy saving. Increasing the disc speed of the primary refiner from 2600 rpm to 2700 rpm yielded additional savings in energy while maintaining improved pulp quality compared to conventional TMP pulps.
In addition to energy savings, the inventor discovered that pulps which were refined from wood chips pretreated according to the present invention had the highest strength properties and lowest shive content at a given freeness or specific energy compared to other processes evaluated, as shown in FIGS. 6-11 . The experiments also revealed that in order to obtain the most benefits from the pretreatment process of the invention, it is most preferable to feed the pretreated wood chips directly to the refiner system without cooling, loss of moisture, or pressure. In this way, further increases in TEA index and reduction in shive content are possible.
FIG. 12 is an electron photomicrograph (100×magnification) of a wood chip which has not been conditioned, compressed, or otherwise pretreated. The micrograph shows the intact rigid fiber structure of the wood and lack of separation of the individual softwood fibers along their longitudinal axis.
FIG. 13 is an electron photomicrograph (100×magnification) of a wood chip conditioned and compressed according to the present invention, wherein the chip was exposed to steam heating and pressurization at 22 psi, followed by high compression at a 5:1 compression ratio. The micrograph shows a high level of axial separation along the longitudinal axis of the individual softwood fibers. Some surface delamination is also in evidence, which may explain the improved bonding strength results as shown in connection with FIGS. 6 and 7 .
FIG. 14 is an electron photomicrograph (100×magnification) of a wood chip which has been atmospherically pre-steamed, then compressed at a 4:1 compression ratio. A high level of axial separation of fibers is noted in this micrograph, but this is tempered by the large number of fractured fibers. The presence of fibers sheared in the compression step is also noted. Some sheared fibers appear in the lower central region of the micrograph. They are identified by the somewhat flattened “O” shape of the sheared end of the fiber.
Wood samples for these experiments were obtained from Stora SFI of Hawkesbury, Nova Scotia, Canada and blended according to the following distribution:
48% balsam fir
27% black/red spruce
18% white spruce
7% pine/hemlock/larch
In Table A an experimental comparison of the pulp quality obtained by the process of the invention is shown. All wood chips processed in the experiment set forth in Table A were drawn from the wood chip mix described herein above.
In Example 1 wood chips were pretreated according to the invention, wherein they were subjected to a saturated steam atmosphere at 22 psi and 128° C. for a period of six seconds. The wood chips of Example 1 were then subjected to compression in a PRESSAFINER screw compression device where a compression ratio of 5:1 was achieved. The wood chips were fed to a pressurized single disc refiner (Andritz Model 36-ICP 91 cm (36 inch) diameter) operating at the speed and pressure shown in Table A (i.e., RTS operating conditions).
In Comparative Example 1 a sample of wood chips was exposed to steam under ambient atmospheric conditions for a period of 25 minutes. The steamed chips were then compressed in a PRESSAFINER compression device under conditions suitable to achieve a compression ratio of 4:1.
In Comparative Example 2, the sample of wood chips did not undergo either pretreatment with heat, temperature and pressure or mechanical compression. Rather, the wood chips of Comparative Example 2 were placed directly in the RTS refiner system without receiving pretreatment as in the present invention.
After refining under conditions of a refiner pressure of 85 psi and refiner speed of 2600 rpm the pulps obtained from the Examples were examined for various properties and qualities. The results from these examinations are presented below in Table A.
TABLE A
COMPARATIVE
COMPARATIVE
EXAMPLE 1
EXAMPLE 1
EXAMPLE 2
Pretreatment
Heat, Pressure,
Atmospheric
None
Moisture
Pressure 25
128° C., 22 psi,
minutes,
6 seconds; 5:1
Steam; 4.1
Compression
Compression
Inlet Pressure
22
Ambient
Ambient
(psi)
Refiner Process
RTS
RTS
RTS
Process
85
85
85
Pressure (psi)
Refiner Speed
2600
2600
2600
(rpm)
Freeness (ml)
103
104
104*
Spec. Energy
1782
1954
1987
(kWh/ODMT)
Bulk
2.54
2.52
2.51
Burst Index
2.5
2.3
2.2
Tear Index
9.6
8.6
9.1
Tensile Index
45.4
42.9
43.5
Opacity
96.7
96.1
96.5
Brightness
50.9
50.9
51.4
(% ISO)
% Shive
0.20
0.26
0.46
Content
Sample I.D.
A18
A9
* Interpolated at 104 ml
The performance of Example 1 demonstrates improved strength properties including burst index, tear index and tensile index. In addition, the specific energy required for producing the pulp in Example 1 was found to be 172 kWh/ODMT lower than required for the pulp produced in Comparative Example 1. In terms of appearance, opacity and brightness, Example 1 and Comparative Examples 1 and 2 were similar. However, Example 1 was determined to have a slightly lower percent shive content compared to Comparative Example 1, and a significantly lower percent shive content compared to Comparative Example 2.
Experiments were conducted to determine the effect of allowing wood chips which had been conditioned and compressed according to the invention to cool to room temperature prior to refining. In these experiments a sample of wood chips was pretreated and compressed according to the invention and one half of the sample was fed immediately to the RTS pulp refiner while still at their conditioned temperature. These wood chips, constituting Example 2, were at a temperature of approximately 90° C. when fed to the refiner. The other half of the sample was allowed to cool to room temperature (23° C.) before being fed to the same RTS refiner. These latter wood chips are identified as Comparative Example 3.
The results of the experiments conducted on these two groups of wood chips is presented below in Table B.
TABLE B
COMPARATIVE
EXAMPLE 2
EXAMPLE 3
Pretreatment
Per Invention
Per Invention
Chip Temp (° C.)
90
23
Primary Refiner Speed
2700
2700
(rpm)
Primary Refiner
85
85
Pressure (psi)
Retention time (sec)
11
11
Sample I.D.
A14
A18
Freeness (ml)
106
103
Specific Energy
1822
1789
(kWh/ODMT)
Bulk
2.69
2.52
Burst Index
2.3
2.4
Tear Index
10.0
9.2
Tensile Index
41.7
40.9
% Stretch
2.11
2.08
T.E.A.
37.34
35.60
% Opacity
95.8
96.1
Brightness
50.9
50.6
% Shives
0.40
0.64
+28 Mesh
31.4
30.3
The pulp produced in Example 2 showed slightly higher tear index and a lower shive content compared to the pulp produced from the wood chips treated as in Comparative Example 3. This is to be expected from the higher level of thermal softening achieved in the wood chips of Example 2 prior to the primary refining step. The remaining properties of the two examples, including the energy requirements, were quite similar. The results indicate that the RTS system refining conditions of 85 psi and 11 second retention are such that the cooled chips must be heat shocked quite rapidly in order to withstand the high speed (2700 rpm) refining conditions.
A series of analytical tests were conducted to determine the comparative differences of long fiber strength properties in pulps processed according to the TMP process, RTS system process and the process of the present invention (designated in the table as RTPR). The test samples of wood pulp obtained from these various processes were fractionated using the well-known Bauer McNett technique to remove the +14 and +28 mesh size fractions for analysis. The fractionated fibers were then analyzed for hand sheet strength and bulk, and were also subjected to fiber size distribution analysis performed on FIBERSCAN analytical equipment, commercially available from Andritz, Inc. Muncy, Pa. The results of the analysis are presented below in Table C.
TABLE C
Comparative
Comparative
Example 4
Example 5
Example 3
Example 4
Example 5
Example 6
Example 7
Sample ID
A5
A10
A18
A23
A12
A14
A18
Process
TMP
RTS
RTPR
RTPR
RTPR
RTPR
RTPR
and Refiner
(2600)
(2600)
(2600)
(2700)
(2700)
Speed
(rpm)
Ref.
40
85
85
85
75
85
85
Pressure
(PSI)
Freeness
115
129
103
104
100
106
103
(ml)
Tensile
12.8
14.4
15.1
14.8
14.5
17.2
18.0
(Nm/g)
% Stretch
0.76
0.72
0.77
0.72
0.81
0.80
0.83
T.E.A.
3.48
4.35
4.39
4.00
4.61
4.95
5.35
BULK
4.27
3.65
4.42
4.44
4.19
3.88
4.08
(cm 3 /g)
LW AVE.
2.15
2.10
2.15
2.15
2.12
2.21
2.10
(mm)
Width
14.86
14.56
14.70
14.11
14.93
14.96
14.24
Index
Report
1611
1611-4
1611
1611
1611-3
1611-2
1611-2
The +14 and +28 fraction of the RTS and RTPR pulps were found to have higher tensile and T.E.A. strength properties compared to the conventional TMP long fiber fraction.
The use of the process and apparatus of the present invention in connection with chemical pulping offers some obvious benefits over conventional chemical pulp digestion techniques. Destructuring of the wood chips according to the present invention would improve the penetration and diffusion of the digestion chemicals, reduce the amount of digestion chemicals needed to produce a pulp of a given quality, and reduce pulp rejects caused by cooking oversized wood chips.
Tests were conducted comparing the performance of pulps obtained from mixed samples of wood chips from Stora SFI (described above). The results of the tests are presented in Tables D and E, below. In Table D, the wood chips of Comparative Example 6 were subjected to a conditioning treatment consisting of atmospheric steaming and 4:1 compression, but the wood chips of Comparative Example F received no pretreatment or compression. Both examples were processed to pulp using the kraft pulping process. The digestion conditions include a rise to temperature of 1.5 hours and a cooking temperature of 170° C. Table D below compares the pulp performance results.
TABLE D
Comparative
Comparative
Example 6
Example F
Pretreatment
4:1 Compression
None
Atmospheric
Yes
No
Presteaming
Yield %
48.3
48.1
Tensile Index (Nm/g)
63.7
69.4
Tear Index (mN.m2/g)
17.8
22.1
% + 28 Mesh
68.8
80.1
% − 200 Mesh
10.2
4.1
It was noted that compression of the atmospherically steamed wood chips exhibited shortened fiber length and a high level of fines due to fiber breakage upon compression.
In Table E, additional tests were conducted wherein the wood chips of Example 8 were subjected to conditioning treatment according to the invention followed by 5:1 compression and a the wood chips of Comparative Example 8 which received no pretreatment or compressing, both of which were processed to pulp using a kraft pulping process. The digestion conditions include a rise to temperature of 1.5 hours and a cooking temperature of 170° C. Table E below compares the pulp performance results.
TABLE E
Example 8
Comparative Ex. 8
Pretreatment
5:1 Compression
None
Inlet Pressure (psi)
22
—
Active Alkali (%)
23
23
Sulphidity (%)
18
18
L:W Ratio
6
6
Freeness (ml)
684
682
BULK (cm 3 /g)
1.89
1.90
Tensile Index (Nm/g)
78.8
77.8
% Stretch
2.76
2.47
T.E.A. (J/m 2 )
80.96
79.5
Tear Index (mN.m 2 /g)
16.7
17.5
Shive content (%)
0.65
3.80
(0.15 mm)
% + 28 Mesh
66.0
69.2
% − 200 Mesh
10.8
7.7
The results indicate similar pulp strength properties in both the conditioned and compressed pulp example and the unpretreated sample. This similarity suggests that no damage to the wood fibers occurred in the compression step due presumably to the prior conditioning step of heat and pressure. It is expected that an increase in the conditioning temperature and retention time under pressure would further improve chemical pulp quality for a given application of digestion chemicals, or alternately reduce the chemical requirements for obtaining a given pulp quality. | A method and apparatus for pretreating or conditioning lignocellulose fiber containing feed material in preparation for conversion to pulp. Wood chips are pretreated under conditions of elevated temperature, pressure and humidity and subsequently compressed to cause destructuring of the fibers of the feed material. The pretreated wood chips are then converted to pulp using such methods as the ground wood pulping process or chemical digestion process. | 3 |
[0001] The present invention is directed to the field of nucleic acid diagnostics and the identification of base variation in target nucleic acid sequences. The invention provides novel mutations or mutational profiles of HIV-1 protease gene correlated with a phenotype causing alterations in sensitivity to anti-HIV drugs. The present invention also relates to the use of genotypic characterization of a target population of HIV and the subsequent association, i.e. correlation, of this information to phenotypic interpretation in order to correlate virus mutational profiles with drug resistance. The invention further relates to methods of utilizing the mutational profiles of the invention in databases, drug development, i.e., drug design, and drug modification, therapy and treatment design and clinical management.
[0002] The development and standardization of plasma HIV-1 RNA quantification assays has led to the use of viral load measurements as a key therapy response monitoring tool. The goal of antiretroviral therapy is to reduce plasma viremia to below the limit of detection on a long-term basis. However, in a significant number of patients, maximal suppression of virus replication is not achieved and for those in whom this goal is reached, a significant number experience viral load rebound. Viral load data provide no information on the cause of the failure.
[0003] Therapy failure may be due to a number of factors, including insufficient antiviral activity of the regimen, individual variations in drug metabolism and pharmacodynamics, difficulties in adhering to dosing regimen, requirements for treatment interruption due to toxicity, and viral drug resistance. Moreover, drug resistance may develop in a patient treated with sub-optimal antiretroviral therapy or a patient may be infected with drug-resistant HIV-1. Although drug resistance may not be the primary reason for therapy failure, in many cases any situation which permits viral replication in the presence of an inhibitor sets the stage for selection of resistant variants.
[0004] Viral drug resistance can be defined as any change in the virus that improves replication in the presence of an inhibitor HIV-1 drug resistance was first described in 1989 and involved patients that had been treated with zidovudine monotherapy (Larder, B. A., et al., Science 243, 1731-1734 (1989)). Emergence of resistance is almost always being observed during the course of treatment of patients with single antiretroviral drugs. Similarly, in vitro passage of viral cultures through several rounds of replication in the presence of antiretroviral compounds leads to the selection of viruses whose replication cycle is no longer susceptible to the antiretroviral compounds used. Resistance development has also been observed with the introduction of dual nucleoside reverse transcriptase inhibitors (NRTI) combination therapy as well as during the administering of the more potent non-nucleoside reverse transcriptase inhibitors (NNRTIs), protease inhibitors (PIs) and combinations thereof. Individual antiretroviral agents differ in the rate at which resistance develops: selection for resistant variants may occur within weeks of treatment or resistance may emerge after a longer treatment period.
[0005] Extensive genetic analysis of resistant viral isolates generated through in vivo or in vitro selection has revealed that resistance is generally caused by mutations at some specific site(s) of the viral genome. The mutational patterns that have been observed and reported for HIV-1 and that are correlated with drug resistance are very diverse: some antiretroviral agents require only one single genetic change, while others require multiple mutations for resistance to appear. A summary of mutations in the HIV genome correlated with drug resistance has been compiled (See e.g. Schinazi, Int. Antiviral News. 6, 65 (2000)). Electronic listings with mutations are available at different web locations such as hiv-web.lanl.gov/content/index, www.hivb.stanford.edu, and www.hivresistanceweb.com.
[0006] A genetic mutation is normally written in reference to the wild type virus, i.e., K101N refers to replacement of a Lysine at codon 101 with a Asparagine (The Molecular Biology of the Cell, 1994, Garland Publishing, NY). However, the mutations of the invention do not depend on the wild-type example listed in order to be within the practice of the invention. For example, the mutation 101N, refers to an Asparagine at the 101 codon regardless of the whether there was a Lysine at 101 prior to mutation. Alternatively, it may be said that a particular amino acid occurs at a given position, wherein “position” is equivalent to “codon”. Mutations can also be identified in nucleic acids such as RNA, DNA, mRNA.
[0007] The degree of susceptibility of a genetic variant to an antiretroviral compound is expressed herein relative to the wild-type virus (HIV IIB/LAI reference sequence) as found, for example, in GenBank, the sequence of which is hereby incorporated by reference (K03455, gi 327742, M38432). An alteration in viral drug sensitivity is defined as a change in resistance or a change in susceptibility of a viral strain to said drug. Susceptibilities are generally expressed as ratios of EC 50 or EC90 values (the EC 50 or EC 90 value being the drug concentration at which 50% or 90% respectively of the viral population is inhibited from replicating) of a viral strain under investigation compared to the wild type strain. Hence, the susceptibility of a viral strain can be expressed as a fold change in susceptibility, wherein the fold change is derived from the ratio of for instance the EC 50 values of a mutant viral strain compared to the wild type. In particular, the susceptibility of a viral strain or population may also be expressed as resistance of a viral strain, wherein the result is indicated as a fold increase in EC 50 as compared to wild type EC 50 .
[0008] As antiretroviral drugs are administered for longer periods, mostly in combination with each other, and as new antiretrovirals are being developed and added to the present drugs, new resistance-correlated genetic variants are being identified. Of particular importance is that the combination of antiretroviral agents can influence resistance characteristics.
[0009] Once viral resistance has developed, salvage therapy options may be severely restricted due to cross-resistance within each drug class. This is as important for initial treatment as for when a therapy change is called for in order to minimize the emergence of resistance and improve the long-term prognosis of the patient. The choice of therapy regimen will be supported by knowledge of the resistance profile of the circulating virus population. Additionally, therapy combinations will have a greater chance of being effective if they include agents that have a demonstrated potential of suppressing a particular virus population.
[0010] A number of applications describe the occurrence of mutations in HIV and their correlation to the development of drug resistance (WO 00/73511; WO 02/33402; WO 02/22076; WO 00/78996). The instant invention adds to the art mutations in the protease gene and their correlation i.e. association to viral drug resistance.
DETAILED DESCRIPTION OF THE INVENTION
[0011] The knowledge that mutations at position 41 and 70 correlate with a fold change in resistance can be applied in certain useful methods. The present invention relates to methods for evaluating the effectiveness of a protease inhibitor, based on the presence of at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E, in HIV protease. In particular, the present invention relates to methods for evaluating the effectiveness of a protease inhibitor, based on the presence of at least one mutation selected from 41T, 41I, 41K, 41G and 70E, in HIV protease. The presence of at least one of said mutations correlates to a fold change in susceptibility or resistance of an HIV viral strain towards at least one protease drug. The effectiveness of a protease inhibitor in the presence of at least one of said mutations may be determined using e.g. enzymatic, phenotypic and genotypic methods. The correlation between the mutational profiles in HIV protease and drug usage may be useful for clinical toxicological and forensic applications. A combined approach involving genotypic and phenotypic resistance testing to correlate mutations with resistance phenotypes may be used. More in particular, the present invention provides a correlation between at least one strain of HIV having at least one mutation in HIV protease selected from 41T and 70E and a fold change in resistance. In one aspect of the invention, the HIV protease mutations, 41T and 70E, are both present in a viral strain.
[0012] The effectiveness of a protease inhibitor as an antiviral therapy for a patient infected with at least one HIV strain comprising mutant protease may be determined using a method comprising: (i) collecting a sample from an HIV-infected patient; (ii) determining whether the sample comprises a HIV protease having at least one mutation selected from 41S, 41T, 41I, 41K, 41G, and 70E; and (iii) correlating the presence of said at least one mutation of step (ii) to a change in effectiveness of said protease inhibitor. In particular, the effectiveness of a protease inhibitor as an antiviral therapy for a patient infected with at least one HIV strain comprising mutant protease-may be determined using a method comprising: (i) collecting a sample from an HIV-infected patient; (ii) determining whether the sample comprises a HIV protease having at least one mutation selected from 41T, 41I, 41K, 41 G, and 70E; and (iii) correlating the presence of said at least one mutation of step (ii) to a change in effectiveness of said protease inhibitor.
[0013] In general a change in effectiveness can be expressed as a fold change in resistance. The fold change may be determined using a cellular assay including a cytopathogenic assay or the Antivirogram® (WO 97/27480). Alternatively, the fold change in susceptibility may be derived from database analysis such as the VirtualPhenotype™ (WO 01/79540). A decrease in susceptibility vis-á-vis the wild type virus correlates to an increased viral drug resistance, and hence reduced effectiveness of said drug. To determine the viral drug susceptibility the activity of the mutant enzyme may be compared to the activity of a wild type enzyme. In phenotyping assays pseudotyped viruses may be used. The mutations present in HIV protease may be determined at the nucleic acid or amino acid level using sequencing or hybridization techniques. A report may be generated that shows the region of the patient virus that has been sequenced, including at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E, in particular, including at least one mutation selected from 41T, 41I, 41K, 41G and 70E. The report may include antiretroviral drugs, drug(s) for which a known resistance-associated mutation has been identified and/or to what extent the observed mutations selected from at least 41S, 41T, 41I, 41K, 41G and 70E are indicative of resistance to said drugs. In particular, the report may include drug(s) for which a known resistance-associated mutation has been identified and J or to what extent the observed mutations selected from at least 41T, 41I, 41K, 41G and 70E are indicative of resistance to said drugs. HIV may be present in combinations of several strains This may result in the presence of multiple mutations at a particular amino acid, including partial mutations. Partial mutations include the combination of the wild amino acid and a mutant amino acid at a particular position. Examples thereof include partial mutations at position 41 in HIV protease, including 41RS, 41S/R, 41R/K, 41G/R, in particular 41R/K, 41G/R. The sample to be evaluated can be a bodily fluid including blood, serum, plasma, saliva, urine, or a tissue including gut tissues.
[0014] The fact that particular data correlate, indicates that a causal relationship exits between the data. Hence, a particular result renders a particular conclusion more likely than other conclusions.
[0015] A drug effective against mutant HIV protease may be identified by a method, comprising: (i) providing a nucleic acid comprising HIV protease comprising at least one mutation chosen from 41S, 41T, 41I, 41K, 41G and 70E; (ii) determining a phenotypic response to said drug for said HIV recombinant virus; and (iii) identifying a drug effective against mutant HIV based on the phenotypic response of step (ii). In particular, a drug effective against mutant HIV protease may be identified by a method, comprising: (i) providing a nucleic acid comprising HIV protease comprising at least one mutation chosen from 41T, 41I, 41K, 41G and 70E; (ii) determining a phenotypic response to said drug for said HIV recombinant virus; and (iii) identifying a drug effective against mutant HIV based on the phenotypic response of step (ii). The nucleic acid comprising HIV of step (i) may be recombined into a proviral nucleic acid deleted for said sequence to generate a recombinant HIV virus.
[0016] Identifying a drug is defined as making a selection of drugs clinically available based on the effectiveness of said drug. In addition to the selection of clinically available drugs, identifying also relates to the selection of clinical drug candidates. The phenotypic response may be determined using cellular assays such as the Antivirogram®. An effective drug against mutant HIV comprising at least one mutation in protease selected from 41T and 70E, is defined as a drug having a phenotypic response expressed, as e.g. a fold change in susceptibility lower than a defined cut-off that may be determined for a drug.
[0017] An other useful method for identifying a drug effective against mutant HIV protease comprising, (i) providing a HIV protease comprising at least one mutation chosen from 41S, 41T, 41I, 41K, 41G and 70E;
(ii) determining the activity of said drug on said HIV protease; (iii) determining the activity of said drug on wild type HIV protease; (iv) determining the ratio of the activity determined in step (iii) over the activity determined in step (ii); (v) identifying an effective drug against mutant HIV based on the ratio of step (iv).
[0022] In particular, a usefull method for identifying a drug effective against mutant HIV protease comprising: (i) providing a HIV protease comprising at least one mutation chosen from 41T, 41I, 41K, 41G and 70E;
(ii) determining the activity of said drug on said HIV protease; (iii) determining the activity of said drug on wild type HIV protease; (iv) determining the ratio of the activity determined in step (iii) over the activity determined in step (ii); (v) identifying an effective drug against mutant HIV based on the ratio of step (iv).
[0027] A ratio lower than a defined cut-off value that can be specific for said drug is indicative that the drug is effective against mutant HIV (WO 02/33402).
[0028] The activity of said drug on said HIV protease, having at least one mutation selected from 41S, 41T, 41I, 41K, 416G and 70E, in particular 41T, 41I, 41K, 41G and 70E, can be determined in an enzymatic assay, wherein the mutant protease, is compared to the wild type enzyme by its enzymatic characteristics (e.g. Maximal velocity (V max ), Michaelis-Menten constant (K m ), catalytic constant (k cat )). A activity means any output generated by the assay including fluorescence, fluorescence polarization, luminiscence, absorbance, radioactivity, resonance energy transfer mechanisms, magnetism. The use of fluorescent substrates to measure the HIV protease activity was described by e.g. Matayoshi et al. [Science 1990, 247, 954], Tyagi et al. [Anal. Biochem. 1992, 200(1), 143], Toth et al. [Int. J. Pept. Protein Res. 1990, 36(6), 544] and Wang et al. [Tetrahedron 1990, 31(45), 6493] and in several patent applications [see e.g. WO99/67417; EP428000, EP518557]. A suitable substrate for the enzymatic determination is R-E(EDANS)—S-Q-N—Y—P—I—V-Q-K(DABCYL)-R—OH (Science, 1989, 247, 954-958). Alternatively HPLC based methods may be used to determine the activity.
[0029] The response of a mutant HIV protease having at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E, in particular 41T, 41I, 41K, 41G and 70E, may be expressed as viral fitness (WO 00/78994). This viral fitness can be defined as hee ability of a viral strain to replicate in the presence or absence of a component, such as a protease inhibitor. This viral fitness is dependent on a combination of factors including viral factors which include mutations occurring in viral proteins, such as the mutations described herein, host factors which include immune responses, differential expression of membrane proteins and selective pressures which include the presence of antiviral agents such as protease inhibitors.
[0030] Interestingly, protease inhibitors that can be used in the present methods include Nelfinavir, Saquinavir, Indinavir, Amprenavir, Tipranavir, Lopinavir, Ritonavir, Palinavir, Atazanavir, Mozenavir, Fosamprenavir, compound 1 Carbamic acid, [(1S,2R)-3-[[(4-aminophenyl)sulfonyl](2-methylpropyl)arino]-2-hydroxy-1-(phenylmethyl)propyl]-, (3R,3aS,6aR)-hexahydrofuro[2,3-b]furan-3-yl ester, compound 1), and compound 2, which has been described as a HIV protease inhibitor in WO02/083657 and which can be prepared according to the procedures described therein. Compound 2 has the following chemical structure:
In an embodiment, the protease inhibitor is selected from Indinavir, Saquinavir, Lopinavir, Nelfinavir, compound 1, and compound 2. In particular, the protease inhibitor is selected from Indinavir, Saquinavir, Lopinavir and compound 1.
[0031] Conveniently, the methods of the present invention are performed using samples of an HIV-infected patient that has been treated with at least a protease inhibitor. More in particular, the patient contains mutant viruses bearing at least one additional mutation at position in the HIV protease selected from 10, 30, 33, 46, 47, 50, 54, 63, 71, 74, 77, 82, 84, 88 or 90. Even more in particular, the mutant viruses are resistant towards the therapy the patient is taken.
[0032] A vector comprising an HIV sequence having at least one mutation in the HIV protease gene chosen from 41S, 41T, 41I, 41K, 41G and 70E may be useful for the phenotypic analysis. In particular, a vector comprising an HIV sequence having at least one mutation in the HIV protease gene chosen from 41T, 41I, 4K, 41G and 70E may be useful for the phenotypic analysis. The present knowledge about the correlation between a fold change in susceptibility and the presence of at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E in HIV protease can be used to prepare an isolated and purified HIV protease sequence having at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E. In particular, the knowledge about the correlation between a fold change in susceptibility and the presence of at least one mutation selected from 41T, 41I, 41K, 41G and 70E in HIV protease can be used to prepare an isolated and purified HIV protease sequence having at least one mutation selected from 41T, 41I, 41K, 41G and 70E.
[0033] The knowledge of the mutations of the present invention offers the possibility to develop probes and primers directed to said mutations. An isolated and purified oligonucleotide comprising a HIV protease sequence of 5 to 100 bases comprising at least one mutation chosen from 41S, 41T, 41I, 41K, 41G and 70E, may be useful for in vitro diagnosis of viral drug resistance. In particular, an isolated and purified oligonucleotide comprising a HIV protease sequence of 5 to 100 bases comprising at least one mutation chosen from 41T, 41I, 41K, 41G and 70E, may be useful for in vitro diagnosis of viral drug resistance. Suitable oligonucleotides for nucleic acid amplifying technologies contain 5 to 35 nucleic acid bases. Suitably such oligonucleotides contain 15 to 30 nucleic acid bases. An oligonucleotide may contain the mutant base at the 3′ end so as to enable the detection of the mutant using PCR. Oligonucleotides may also be used as probes including molecular beacons (Tyagi, Nature Biotechnol 1998, 16(1) 49-53), and TaqMan probes.
[0034] A computer system comprising at least one database correlating the presence of at least one mutation in a human immunodeficiency virus protease and fold change in susceptibility of at least one strain of HIV to a protease inhibitor, comprising at least one record corresponding to a correlation between at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E, in particular 41T, 41I, 41K, 41G and 70E, and treatment with at least a protease inhibitor can be used for evaluating resistance towards therapy.
[0035] A neural network that predicts the development of therapeutic agent resistance or sensitivity against at least one viral strain comprising at least one mutation selected from 41S, 41T, 41I, 41K, 41G and 70E can be used (WO 01/95230). In particular, a neural network that predicts the development of therapeutic agent resistance or sensitivity against at least one viral strain comprising at least one mutation selected from 41T, 41I, 41K, 41G and 70E can be used (WO01/95230).
[0036] Genotyping methodologies
[0037] Resistance of HIV to antiretroviral drugs may be determined at the genotypic level by identifying mutations in the HIV-1 genome and by inferring the resistance of HIV-1 to antiretroviral drugs through searching for mutational patterns known to correlate with resistance. Assays for detection of mutations in HIV-1 may be based on polymerase chain reaction (PCR) amplification of viral genomic sequences. These amplified sequences are then analyzed using either hybridization or sequencing techniques. Hybridization-based assays include primer-specific PCR, which makes use of synthetic oligonucleotides designed to allow selective priming of DNA synthesis. See Larder, B. A., et al., AIDS 5, 137-144 (1991); Richnan, D. D., et al., J. Infect. Dis. 164, 1075-1081 (1991); Gingeras, T. R., et al., J. Infect Dis. 164, 1066-1074(1991). Only when primer sequences match the target sequence (wild-type or mutant) at the 3′ end, is amplification of target sequences possible and DNA fragments are produced. Knowledge of the primer sequences allows one to infer the sequence of the viral isolate under investigation, but only for the region covered by the primer sequences. Other hybridization-based assays include differential hybridization (Eastman, P. S., et al., J. Acq. Imm. Def. Syndr. Human Retrovirol. 9, 264-273 (1995); Holodniy, M., et al., J. Virol. 69, 3510-3516 (1995); Eastman, P. S., et al., J. Clin, Micro. 33, 2777-2780 (1995).); Line Probe Assay (LipA® HIV-11 RT, Innogenetics) (Stuyver, L., et al., Antimicrob. Agents Chemotherap. 41, 284-291 (1997)); and biochip technology such as GENECHIP® technology (Affymetrix) (D'Aquila, R. T. Clin. Diagnost. Virol. 3, 299-316 (1995); Fodor, S. P. A. et al., Nature 364, 555-556 (1993); Fodor, S. P. A. Nature 227, 393-395 (1997). The sequence may also be determined using mass spectroscopic technologies. DNA sequencing assays provide information on all nucleotides of the sequenced region Sequencing results may be reported as amino acid changes at positions in the protease gene and the reverse transcriptase gene compared to the wild-type reference sequence. The changes included in the genotyping report may be limited to mutations at positions known to manifest drug resistance-associated polymorphisms. Polymorphisms at positions not associated with drug resistance may be omitted.
[0038] Phenotyping methodologies
[0039] Phenotyping assays measure the ability of a replicating virus to grow in the presence of compounds compared to a wild-type reference virus such as e.g. HIV-1LAI, HIV- l /NL4.3, HIV-1/HXB2 or e.g. HIV-2/ROD. Alternatively, phenotyping assays are performed with pseudotyped viruses not able to replicate (WO 02/38792). Consequently, these assays directly measure the degree of viral susceptibility to specific inhibitors. In this case, one measures the effect of all mutational interactions, the effects of genetic changes as yet unknown or not previously identified, the effect of the background genotype, etc., on the phenotype. Some phenotypic assays are discussed below.
[0040] Cytopathic Effect Assay (CPE Assay)
[0041] Determination of the antiviral activity of a compound was done as described in Pauwels R. et al. (J Virol Methods 1988; 20(4):309-21). Various concentrations of the test compounds were brought into each well of a flat-bottom microtiter plate. Subsequently, HIV and MT4 cells were added to a final concentration of 200-250 50% cell culture infectious doses (CCID 50 )/well and 30,000 cells/well, respectively. After 5 days of incubation (37° C., 5% CO 2 ), the cytopathic effect of the replicating virus was determined by the tetrazolium colorimetric MTT method. The dose protecting 50% of the cells from virus cytopathic effect was defined as the EC 50 , while the dose achieving 90% protection was defined as the EC 90 .
[0042] Reporter Gene Assay
[0043] The reporter gene assay used MT4-LTR-EGFP cells. Upon infection by HIV-1, the expression of the viral that product increases transcription from the HIV-1 LTR promoter, leading to high-level expression of the reporter gene product. The assay procedure was similar to the CPE assay, except for the end reading of the assay, which was performed on day 3 by measuring the relative fluorescence of treated cultures and comparing this with the relative fluorescence of untreated cultures. The EC 50 or the EC 90 of a compound was defined as the concentration that inhibited the relative fluorescence by 50% or 90% respectively.
[0044] Antiviral Assay wth PBMC Cultures
[0045] The purification and activation of PBMCs as well as the antiviral assays were carried out as described (CDER. Guidance for Industry Points to Consider in the Preclinical Development of Antiviral Drugs. 1990). The assay measured the extent that a drug inhibits HIV p24 antigen production by peripheral blood mononuclear cells (PBMC) cultures acutely infected with a viral strain. The susceptibility determination uses phytohaemaglutinine (PHA)-stimulated PBMCs from normal donors. In the in vitro infection experiments 1000 CCID 50 per million PHA-stimulated PBMCs was used. Cultures were split ½ every 3 to 4 days and compound was added together with the addition of new medium.
[0046] The p24 antigen production was measured using a commercial kit, according to the manufacturer protocol (NEN), at the moment that the p24 production of untreated infected cultures is maximal; i.e. between 7 and 11 days after infection. The % p24 production was calculated by means of following equation:
% p 24 = 100 × [ p 24 ] Sample - [ p 24 ] Mock_Control [ p 24 ] HIV_Control - [ p 24 ] Mock_Control
where [p24] Sample is the p24 concentration in an infected treated culture, [p24] HIV — Control is the p24 concentration in an infected untreated culture and [p 24] Mock — Control is the p24 concentration in a mock-infected culture. The dose achieving 50% p24 production according to the above formula was defined as the EC 50 , while the dose achieving 10% p24 production according to the above formula was defined as the EC 90 .
[0047] Antiviral Assay with monocytes/macrophages
[0048] The assay measured the extent that a drug inhibits HIV p24 antigen production by primary monocytes/macrophages acutely infected with HIV-1/BaL (300 CCID 50 /ml). The susceptibility determination used monocytes/macrophages isolated from PBMCs from normal donors by plastic adherence. Every 5 days cultures were fed with complete medium containing the appropriate compound concentrations. The p24 antigen production was measured at day 14 after virus challenge and EC 50 and EC 90 values were calculated.
[0049] Recombinant Virus Assays
[0050] A recombinant virus assay (RVA) starts with the amplification of viral target sequences by means of PCR. The amplicons are incorporated into a proviral laboratory clone deleted for the sequences, present in the amplicon. This generates a stock of recombinant viruses. The viruses are tested for their ability to grow in the presence of different concentrations of drugs. Results are obtained by calculating EC 50 values for each inhibitor and by reporting the results as EC 50 values, expressed in μM concentrations, or by computing the ratio of the EC 50 values found for the recombinant virus to the EC 50 values found for a wild type susceptible laboratory virus tested in parallel. In the latter case, resistance is expressed as “fold-resistance” (fold change in susceptibility, FC) compared to a wild-type susceptible HIV-1 strain.
[0051] The use of reporter gene systems for susceptibility testing allows the implementation of laboratory automation and standardization (Pauwels, et al., J. Virol. Methods 20, 309-321 (1988); Paulous, S., et al., International Workshop on HIV Drug Resistance, Treatment Strategies and Eradication, St. Petersburg, Fla., USA. Abstr. 46 (1997); and Deeks, S. G., et al., 2nd International Workshop on HIV Drug Resistance and Treatment Strategies, Lake Maggiore, Italy. Abstr. 53 (1998)).
[0052]
[0053] The Antivirogram® assay (Virco) (WO 97/27480) is based on homologous recombination of patient derived HIV-1 gag/PR/RT sequences into a proviral HIV-1 clone correspondingly deleted for the gag/PR/RT sequences. A similar assay (Phenosense® ViroLogic, WO 97/27319) is based on enzymatic ligation of patient-derived PR/RT sequences into a correspondingly deleted proviral vector carrying an indicator gene, luciferase, inserted in the deleted HIV-1 envelope gene. Another assay was developed by Bioalliance (Phenoscript, WO 02138792). The development of high throughput phenotyping and genotyping assays has allowed the establishment of a database containing the phenotypic resistance data and the genotypic sequences of over 30,000 clinical isolates.
EXPERIMENTAL PART
Example 1
The Identification of Mutational Patterns in HIV-1 Protease and the Correlated Phenotypic Resistance
[0054] Plasma samples from HIV-1-infected individuals from routine clinical practice were obtained and shipped to the laboratory on dry ice and stored at −70° C. until analysis. Viral RNA was extracted from 200 μL patient plasma using the QIAAMP® Viral RNA Extraction Kit (Qiagen, Hilden, Germany), according to the manufacturers instructions. cDNA encompassing part of the pol gene was produced using Expand™ reverse transcriptase (Boehringer Mannheim). A 2.2 kb fragment encoding the protease and RT regions were amplified from patient-derived viral RNA by nested polymerase chain reaction (PCR) using PCR primers and conditions as described. (Hertogs K., et al., Antimicrob. Agents Chemother. 42: 269-276 (1998), WO 01/81624). This genetic material was used in phenotyping and genotyping experiments.
[0055] Phenotypic analysis was performed using the recombinant virus assay (Antivirogram®)(WO 97127480). MT-4 cells (Harada S., et al, Science 229: 563-566 (1985).) were co-transfected with pol gene PCR fragments and the protease-RT deleted HIV-1 molecular clone, pGEM3ΔPRT. This resulted in viable recombinant viruses containing protease/RT from the donor PCR fragment. After homologous recombination of amplicons into a PR-RT deleted proviral clone, the resulting recombinant viruses were harvested, titrated and used for in vitro susceptibility testing to antiretroviral drugs. The results of this analysis were expressed as fold change in susceptibility, reflecting the fold change in mean EC 50 (μM) of a particular drug when tested with patient-derived recombinant virus isolates, relative to the mean EC 50 (μM) of the same drug obtained when tested with a reference wild-type virus isolate (IIIB/LAI).
[0056] Genotyping was performed by an automated population-based full-sequence analysis, through a dideoxynucleotide-based approach, using the BigDye™ terminator kit (Applied Biosystems, Inc.) and resolved on an ABI 377 DNA sequencer.
[0057] The genotypes are reported as amino acid changes at positions along the protease gene compared to the wild-type (HXB2) reference sequence. Analysis by VirtualPhenotype™ interpretational software (WO 01/79540) allowed detection of mutational patterns in the database containing the genetic sequences of the clinical isolates and linkage with the corresponding resistance profiles of the same isolates.
Example 2
Susceptibility Analysis of HIV-1 Variants Constructed by Site-directed Mutagenesis
[0058] Mutations in the protease or RT coding region were created by site-directed mutagenesis, using the QuikChange® Site-Directed Mutagenesis Kit (STRATAGENE®), of a wild-type HXB2-D EcoRI-PstI restriction enzyme fragment, encompassing the HIV-1 pol gene and cloned into pGEM3 (Promega). All mutant clones were verified by DNA sequence analysis. PCR fragments were prepared from the mutated clones and the altered protease coding regions were transferred into HIV-1 HBXB2-D by homologous recombination as described above. The susceptibility of these recombinant viruses to drugs was determined by the MT-4 cell CPE protection assay.
Example 3
In vitro Selection of Resistant Strains
[0059] MT4-LTR-EGFP cells were infected at a multiplicity of infection (MOI) of 0.01 to 0.001 CCID 50 /cell in the presence of inhibitor. The starting concentration of the inhibitor was two to tee times the EC 50 , a suboptimal concentration. The cultures were sub-cultivated and scored microscopically on virus-induced fluorescence and cytopathicity every 3-4 days. The cultures were sub-cultivated in the presence of the same compound concentration until signs of virus replication were observed. The escaping virus was further cultivated in the presence of the same inhibitor concentration in order to enrich the population in resistant variants. If full virus breakthrough was observed the supernatant was collected and stored (new virus strain), Afterwards, the same virus was challenged with a higher compound concentration in order to select variants able to grow in the presence of as high as possible inhibitor concentrations. From the new viruses, a virus stock was grown in the absence of inhibitor. In vitro drug selection experiments starting from wild-type HIV-1 under pressure of compound 1, compound 2, and Nelfinavir (NFV) have been performed. Tables 1, 2, 3, 4, and 5 show the genotypic and phenotypic characterization of the selected strains.
TABLE 1 Characterization of the strains isolated from HIV-1/LAI in the presence of compound 1 In vitro selection Experimental conditions Starting strain HIV/ HIV-1/ HIV-1/ HIV-1/ LAI LAI LAI LAI Compound — Compound 1 Compound 1 Compound 1 Concentration (nM) — 30 100 100 Days — 45 97 188 Protease Genotype Mutations — R41T R41T R41T K70E K70E Phenotype In vitro susceptibility to PIs N, median EC50 (nM), median FC Compound 1 N 37 7 6 3 EC50 3.2 7.7 26 44 FC 1 2 8 10 Indinavir N 16 3 3 2 EC50 28 33 98 140 FC 1 1 4 5 Ritonavir N 16 3 3 2 EC50 31 32 21 46 FC 1 1 1 1 Nelfinavir N 11 3 4 2 EC50 30 32 18 37 FC 1 1 1 1 Saquinavir N 46 2 6 3 EC50 7.8 30 35 150 FC 1 4 4 20 Amprenavir N 67 3 6 3 EC50 36 38 29 39 FC 1 1 1 1 Lopinavir N 11 3 5 3 EC50 7.9 27 32 47 FC 1 3 4 6
[0060]
TABLE 2
Characterization of the strains isolated from
HIV-1/LAI in the presence of compound 1
In vitro selection
Experimental conditions
Starting strain
HIV-1/
HIV-1/
HIV-1/
HIV-1/
HIV-1/
LAI
LAI
LAI
LAI
LAI
Compound
—
Comp 1
Comp 1
Comp 1
Comp 1
Concentration (nM)
—
30
100
100
200
Days
—
70
139
195
328
Protease Genotype
Mutations
—
S37S/N
S37N
S37N
R41R/K
R41S
R41S
K70E
K70E
K70E
K70E
Phenotype
In vitro susceptibility to PIs
N, median EC 50 (nM), median FC
Compound 1
N
5
1
1
1
1
EC50
2.6
6.5
2.5
4.7
0.4
FC
1
3
1
2
0.2
IDV
N
4
1
1
2
1
EC50
12
18
6.3
9.1
5.5
FC
1
2
1
1
0.5
RTV
N
3
1
1
2
1
EC50
33
47
22
14
31
FC
1
1
1
0.4
1
NFV
N
4
1
1
2
1
EC50
38
39
9.7
9.5
1.9
FC
1
1
0.3
0.3
0.1
SQV
N
3
1
1
1
1
EC50
5.6
6.0
0.7
0.9
4.0
FC
1
1
0.1
0.2
1
APV
N
5
1
1
2
1
EC50
20
56
24
14
15
FC
1
3
1
1
1
LPV
N
5
1
1
2
1
EC50
4.6
17
2.8
3.9
1.1
FC
1
4
1
1
0.2
[0061]
TABLE 3
Characterization of the strains isolated from
HIV-1/LAI in the presence of compound 2
In vitro selection
Experimental conditions
Starting strain
HIV-1/LAI
HIV-1/LAI
HIV-1/LAI
HIV-1/LAI
Compound
—
Compound 2
Compound 2
Compound 2
Concentration (nM)
—
100
100
100
Days
—
116
200
264
Protease Genotype
Mutations
—
G16G/H
G16E
R41I
R41I
R41I
Phenotype
In vitro susceptibility to PIs
N, median EC 50 (nM), median FC
Compound 2
N
2
2
1
EC50
12
6.9
61
FC
1
1
5
IDV
N
4
1
1
EC50
12
19
47
FC
1
2
4
RTV
N
3
2
1
EC50
33
22
23
FC
1
1
1
NFV
N
4
2
1
EC50
38
16
14
FC
1
0
0
SQV
N
3
1
EC50
5.6
45
FC
1
8
APV
N
5
2
1
EC50
20
14
8.4
FC
1
1
0
LPV
N
5
2
1
EC50
4.6
<0.9
18
FC
1
0
4
[0062]
TABLE 4
Characterization of the strains isolated from
HIV-1/LAI in the presence of compound 1
In vitro selection
Experimental conditions
Starting strain
HIV-1/
HIV-1
HIV-1
HIV-1
HIV-1
LAI
Compound
—
—
Comp 1
Comp 1
Comp 1
Concentration (nM)
—
—
20
40
40
Days
—
—
94
161
175
Protease Genotype
Mutations
—
—
R41G/R
R41G
R41G
V82V/I
V82I
V82I
Phenotype
In vitro susceptibility to PIs
N, median EC 50 (nM), median FC
Compound 1
N
5
1
1
1
1
EC50
2.6
3.4
1.1
2.6
1.9
FC
1
1
0
1
1
IDV
N
4
1
1
1
1
EC50
12
2.4
3.1
2.1
3.9
FC
1
0
0
0
0
RTV
N
3
1
1
1
1
EC50
33
22
4.2
6.3
1.7
FC
1
1
0
0
0
NFV
N
4
1
1
1
1
EC50
38
31
5.7
11
16
FC
1
1
0
0
0
SQV
N
3
1
1
1
1
EC50
5.6
8.9
0.9
1.0
0.8
FC
1
2
0
0
0
APV
N
5
1
1
1
1
EC50
20
26
7.3
6.6
9.4
FC
1
1
0
0
0
LPV
N
5
1
1
1
1
EC50
4.6
6.8
2.0
1.8
1.0
FC
1
1
0
0
0
[0063]
TABLE 5
Characterization of the strains isolated from
HIV-1/LAI in the presence of nelfinavir (NFV)
In vitro selection
Experimental conditions
Starting strain
HIV-1/
HIV-1/
HIV-1/
HIV-1/
HIV-1/
LAI
LAI
LAI
LAI
LAI
Compound
—
NFV
NFV
NFV
NFV
Concentration (nM)
—
1000
3000
9000
9000
Days
—
35
69
11l
140
Protease Genotype
Mutations
—
L10F
L10F
L10F
D30N
D30N
D30N
D30N
R41R/K
R41R/K
K45I/K
K45I/K
M46I
M46I
M46I
M46I
V77I
V77I
V77I
I84V/I
I84V
I85V/I
I85V/I
N88D/N
N88D
N88D
Phenotype
In vitro susceptibility to PIs
N, median EC 50 (nM), median FC
IDV
N
4
1
1
1
EC50
12
7.9
100
28
FC
1
1
8
2
RTV
N
3
1
1
1
1
EC50
33
19
27
86
170
FC
1
1
1
3
5
NFV
N
4
1
1
1
EC50
38
330
7200
6800
FC
1
9
200
200
SQV
N
3
1
1
1
1
EC50
5.6
1.8
2.5
15
34
FC
1
0
0
3
6
APV
N
5
1
1
1
1
EC50
20
28
59
95
190
FC
1
1
3
5
10
LPV
N
5
1
1
1
1
EC50
4.6
7.7
24
39
56
FC
1
2
5
8
10
The in vitro antiviral activity of compound 1, compound 2, Nelfinavir, and current PIs against the selected strains was evaluated in acutely infected MT4 cells. Median EC 50 values together with the number of determinations (N), and the fold change in EC 50 as compared to wild type (FC) are reported. | The present invention is directed to the field of nucleic acid diagnostics and the identification of base variation in target nucleic acid sequences. More particularly, the present invention relates to the use of such genotypic characterization of a target population of HIV and the subsequent association, i.e., correlation, of this information to phenotypic interpretation in order to correlate virus mutational profiles with drug resistance. The invention also relates to methods of utilizing the mutational profiles of the invention in drug development, i.e., drug discovery, drug design, drug modification, and therapy, treatment design, clinical management and diagnostic analysis. | 2 |
TECHNICAL FIELD
The invention relates generally to systems for enabling hot installation of peripheral devices on and hot removal of peripheral devices from a computer bus and, more specifically, to an apparatus and a method for implementing a local proactive hot swap request/acknowledge scheme.
BACKGROUND OF THE INVENTION
Numerous apparatuses and methods for enabling hot installation of peripheral devices, control circuits and power supplies on and hot removal of same from computer buses are known in the art. Historically, in order to minimize the potentially detrimental effects of plugging into a bus, the preferred procedure has been to shut down the bus, thereby preventing a newly installed device from disrupting data flow on the bus. In contrast, "hot plugging," or "hot swapping," methods provide both power and data transfer interconnections between a computer bus and a newly installed device without requiring power to be removed from the bus. Hot plugging is commonly implemented in fault tolerant computer systems, which normally employ device or field replaceable unit redundancy coupled with operational comparison and checking logic to ensure correct operation. When a fault is detected, an indication of the failing device is provided to service personnel, who then simply remove the failing device and install a replacement therefor. Such removal and installation procedures are performed without regard to bus activity; therefore, both the bus architecture and device electronics must be carefully designed to achieve such hot plugging capability.
In many hot plug schemes, there is no provision for indicating to the system that a drive is to be installed on or removed from the bus. In other words, a drive is simply installed or removed without first "consulting" with the system to determine whether such installation or removal will adversely affect the system. For example, a common prior art method of implementing hot pluggable small computer systems interface (SCSI) drive systems relies on a SCSI bus reset after a drive has already been removed or inserted. Such interface systems suffer several deficiencies.
For example, initiating a SCSI reset in response to the occurrence of a hot plug event causes a considerable time delay where the host operating system is stalled while waiting for data transactions to resume with the SCSI host adapter subsystem. This delay is believed to be unacceptable for certain operating systems. Furthermore, not providing an electrical power decoupling interface for each SCSI drive is considered by many skilled artisans to be electrically unreliable. SCSI drives monitor their +5 volt and +12 volt power forms and can reset themselves if a fault condition beyond their threshold range is detected. Electrically installing a SCSI drive causes a momentary power glitch which can appear to adjacent local physical drives as a power fault. In addition, removal of a drive that is not redundant, as well as removal of a drive during a diagnostics or configuration/maintenance program, will typically result in system failure. User error could easily result in such an action. Finally, electrically introducing a "bad" drive (i.e., one that fails normal inquiry and/or initialization) may also cause system failure.
Clearly, therefore, a priori knowledge that a device is to about to be installed on or removed from an active bus would reduce system complexity and increase system reliability because such knowledge would (1) allow the system to determine how to deal with the additional or missing device and (2) enable the bus to be placed in a known electrical state prior to the electrical connection or disconnection of the device.
One known method of ameliorating the foregoing problems is to include in a computer system a proactive software interface, which enables the user to inform the system that a device is to be installed or removed prior to its respective installation or removal. Though such software interfaces do communicate a priori knowledge of the impending installation/removal of a device prior to the actual installation/removal, such software interfaces may not be implemented in many cases.
Therefore, what is needed is an apparatus and a method for implementing a fault tolerant hot swap request/acknowledge scheme for enabling hot swapping of a device on a computer bus without adversely affecting the integrity of the bus and/or the computer system.
SUMMARY OF THE INVENTION
The foregoing problems are solved and a technical advance is achieved by an apparatus and a method for implementing a local proactive hot plug request/acknowledge scheme. In a departure from the art, each hot pluggable device installable on a computer bus, such as a SCSI bus, is provided with a physical user interface comprising a mechanical request initiator, such as a button or two-position switch, which may be depressed or switched to generate a hot swap request to a controller associated with the bus prior to actual installation of the device on, or removal of the device from, the bus. Upon receipt of the request, the controller determines whether the hot swap may be performed, provides a visual indication of its determination via the user interface and, if installation or removal is not imprudent, performs the hot installation/removal in an orderly manner so as not to adversely affect system operations.
In one aspect of the invention, when a drive is to be installed onto an active bus, which installation is referred to as a "hot install," the drive is first physically connected to the bus and the associated user interface button is then depressed. Depression of the button generates a hot install request, in the form of an interrupt signal, and transmits the request to the controller. Upon receipt by the controller of the hot install request, the controller generates an acknowledge signal and transmits the signal to the user interface of the drive to cause an associated light emitting diode (LED) to flash on and off. In this manner, a visual indication that the hot install request has been received and is being processed is provided. The controller then determines whether the drive may be installed on the active bus. If the controller determines that the drive should not be installed on the active bus because, for example, the drive is defective or the host (not shown) is performing maintenance or diagnostics procedures, the controller turns the LED off and the drive remains uninstalled on the bus. Alternatively, if the controller determines that the drive may be installed on the bus, it signals this determination by illuminating the LED and installing the drive on the bus in an orderly manner.
In another aspect of the present invention, when a drive is to be removed, from the active bus, which removal is referred to as a "hot removal," the associated user interface button is depressed prior to physically, and thereby electrically, disconnecting the drive from the bus. Depression of the button generates a hot removal request, in the form of an interrupt signal to the controller. Upon receipt by the controller of the hot removal request, the controller generates an acknowledge signal to the user interface of the drive to cause the associated LED to flash on and off. In this manner, a visual indication that the hot removal request has been received and is being processed is provided. The controller then determines whether the drive may be removed from the active bus without adversely affecting system functions. If so, then the controller electrically disconnects the drive from the bus in an orderly manner. Once the drive is electrically disconnected from the bus, the controller generates a signal to the user interface to turn the LED off, indicating thereby that the drive may be physically disconnected therefrom.
A technical advantage achieved with the present invention is that it can determine whether a device to be removed from the bus is actually redundant and/or not critical to system operation. The results of the determination can also be indicated visually before such removal takes place.
Another technical advantage achieved with the present invention is that it can determine, before the installation of a device on the bus, whether the device is defective and will therefore be detrimental to the system. If the device is found defective, then installation can be prevented.
Another technical advantage achieved with the invention is that it provides a priori knowledge to the bus that a device is about to be removed or installed, thereby enabling the bus to be placed in a known state and a determination to be made as to how such installation or removal is to be dealt with.
A further technical advantage achieved with the invention is that it need not be implemented in a proprietary environment and may be implemented in a PC environment.
Still a further technical advantage achieved with the invention is that, in a SCSI drive system environment, it provides an electrical power decoupling interface for each SCSI drive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram of a computer system embodying features of the present invention.
FIGS. 2 and 3 are flowcharts illustrating control logic for performing hot installation of a drive onto and hot removal of a drive from the system of FIG. 1.
FIG. 4 is a schematic block diagram of an alternative embodiment of the system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a schematic block diagram of a computer subsystem 10 embodying features of the present invention. The subsystem 10, which, for illustrative purposes is considered to be a SCSI drive subsystem, is connected to a main system 11, in this case a server. The subsystem 10 comprises at least one SCSI drive 12 contained within a mechanical drive carrier 14. In a preferred embodiment, the SCSI drive 12 is connectable to a SCSI bus 16, located on a SCSI backplane 18, via special complementary connectors (not shown) mounted on the carrier 14 and a drive bay 20, which bay 20 is electrically connectable to the bus 16. The bus 16 is further connected to the server 11 via a backplane controller 22 and a SCSI controller 24 for purposes that will subsequently be described in detail. In the preferred embodiment, the backplane controller 22 need only comprise sufficient intelligence to provide a control interface between the drive 12 and the SCSI controller 24. In accordance with a feature of the present invention, a user interface comprising a request initiator, such as a mechanical switch or button 26, and a visual indicator, such as a light emitting diode (LED) 28, associated with the SCSI drive 12 is mounted on the user-accessible front panel of the carrier 14.
Although for purposes of explanation, only one SCSI drive is shown in FIG. 1 as being connectable to the bus 16, it should be understood that a plurality of SCSI drives, each being contained in a mechanical drive carrier upon which is mounted a user interface, may be connected to the bus 16.
In one aspect of the present invention, when a user wants to install the SCSI drive 12 onto the bus 16 while the bus 16 is active (a "hot install"), the user first connects the carrier 14 to the bay 20 on the backplane 18 to physically connect the drive 12 to the bus 16 and then depresses the button 26 on the front panel of the carrier 14. Depression of the button 26 generates a hot install request, in the form of an interrupt signal, to the controller 24 via a line 32. Although not shown, it should be understood that debouncing and decoding of the interrupt signal may be performed by special circuitry on the backplane 18. Responsive to receipt of the hot install request, under the control of control logic 30 embodied therein, the SCSI controller 24 generates an acknowledge signal to the drive carrier 14, via a line 34, to cause the LED 28 to flash on and off. In this manner, a visual indication that the hot install request has been received and is being processed is provided to the user. As will be described in detail with reference to FIG. 2, the controller 24, again under the control of control logic 30, determines whether the drive 12 may be installed on the active bus 16. If the SCSI controller 24 determines that the drive 12 may not be installed on the active bus 16 because, for example, the drive 12 is defective or the host (not shown) is performing maintenance or diagnostics procedures, the SCSI controller 24 turns the LED 28 off, using signals on the line 34, and the bay 20 remains "cold." In other words, while the drive 12 may remain physically connected to the bus 16, it is not electrically connected thereto and hence cannot be communicated with. Alternatively, if the SCSI controller 24 determines that the drive 12 may be installed on the bus 16, it signals this determination to the user by illuminating the LED 28, using signals on the line 34, and then installs the drive 12 on the bus 16 in an orderly manner such that the subsystem 10 and host may communicate therewith, i.e., the bay 20 is "hot."
Similarly, in another aspect of the present invention, prior to removal of the drive 12 from the active bus 16 (a "hot removal"), the user depress the button 26 on the front panel of the carrier 14 prior to physically disconnecting the carrier 14 from the bay 20. Depression of the button 26 generates a hot removal request, in the form of an interrupt signal on the line 32, to the controller 24. Again, although not shown, it should be understood that debouncing and decoding of the interrupt signal may be performed by special circuitry on the backplane 18. Responsive to receipt of the hot removal request, the SCSI controller 24 generates an acknowledge signal to the drive carrier 14 via the line 34 to cause the LED 28 to flash on and off. In this manner, a visual indication that the hot removal request has been received and is being processed is provided to the user. As will be described in detail with reference to FIG. 3, under the control of the control logic 30, the SCSI controller 24 determines whether the drive 12 may be removed from the subsystem 11 without adversely affecting system 10 functions. If so, the SCSI controller 24 electrically disconnects the drive 12 from the active bus 16 in an orderly manner. Once the drive 12 is electrically disconnected, the SCSI controller 24 generates signals to the carrier 14 on the line 34 to turn the LED 28 off, indicating to the user that the bay is cold and the carrier 14 may be physically disconnected therefrom.
FIGS. 2 and 3 are flowcharts of control logic implemented by the SCSI controller 24 for performing hot installation and hot removal of the drive 12, respectively, in accordance with the present invention. In step 200, the controller awaits receipt of an interrupt from the carrier 14 on the line 32. As previously discussed, such an interrupt is generated when the button 26 is depressed to initiate a hot install/remove request. Upon receipt of an interrupt, execution proceeds to step 204, in which a determination is made whether the interrupt is a hot install request. If the interrupt is not a hot install request, i.e., it is a hot removal request, execution proceeds to step 304 (FIG. 3). Otherwise, execution proceeds to step 206, in which a signal is generated to the carrier 14 to cause the LED 28 to flash on and off to acknowledge receipt of the hot install request. In step 208, a determination is made whether the system 10 can accept an additional drive at the present time. If not, execution proceeds to step 210, in which the SCSI controller 24 turns the LED 28 off and the bay 20 remains cold, and then returns to step 200 to await additional interrupts. The fact that the system 10 is performing routine maintenance or diagnostics procedures, for example, may prevent it from being able to accept an additional drive.
If in step 208 it is determined that the system is capable of accepting an additional drive, execution proceeds to step 212, in which the drive 12 is electrically connected to the active bus 16. In step 214, a determination is made whether the drive 12 passes inquiry by the controller 24. Such inquiry typically includes at least a determination by the SCSI controller 24 as to physical parameters (such as the number of bytes or sectors) of the drive 12. If in step 214 it is determined that the drive 12 does not pass inquiry, execution proceeds to step 216, in which the drive 12 is electrically disconnected from the bus, and then to step 210, in which the LED 28 is turned off, indicating that the bay is cold. Finally, execution returns to step 200.
If in step 214 it is determined that the drive 12 does pass inquiry, execution proceeds to step 218, in which the SCSI controller 24 waits for the drive 12 to spin up, and then to step 220, in which a determination is made whether the drive 12 can be initialized. If in step 220 it is determined that the drive 12 cannot be initialized, e.g., it is defective, execution proceeds to step 216, in which the drive 12 is electrically disconnected from the active bus 16, and then to step 210, in which the LED 28 is turned off, indicating that the bay 20 is cold. Finally, execution returns to step 200.
If in step 220 it is determined that the drive 12 can be initialized, execution proceeds to step 222, in which the SCSI controller 24 changes the LED 28 from a flashing state to a continuous on state, indicating that the bay 20 is hot, and the drive 12 is installed on the active bus 16 in a known manner. Execution then returns to step 200.
If in step 204, it is determined that the interrupt is not a hot install request, i.e., it is a hot removal request, execution proceeds to step 304 (FIG. 3). In step 304, the SCSI controller 24 acknowledges receipt of the interrupt by flashing the LED 28. In step 306, a determination is made whether the drive 12 may be removed without adversely affecting the system 10, i.e., whether the drive is redundant, or a spare, or not in use. If in step 306 it is determined that the drive 12 is not redundant or a spare, execution proceeds to step 308, in which the controller illuminates the LED 28, indicating that the bay 20 is hot and that the carrier 14 should not be disconnected from the bay 20, and then returns to step 200.
If in step 306 it is determined that the drive is redundant or a spare, execution proceeds to step 310. In step 310, a determination is made whether the system 10 is capable of removing the drive 12. For example, the system 10 may be incapable of removing a drive while it is running a diagnostics or maintenance program. If in step 310 it is determined that the system 10 is not capable of removing a drive, execution proceeds to step 308, in which the SCSI controller 24 illuminates the LED 28, indicating that the bay is still hot and that the carrier 14 should not be disconnected from the bay 20, and then returns to step 200 (FIG. 2).
If in step 310 it is determined that the system 10 is capable of removing a drive, execution proceeds to step 312, in which the drive 12 is electrically disconnected from the bus 16. In step 314, the SCSI controller 24 waits for the drive 12 to spin down and then proceeds to step 316, in which the SCSI controller 24 turns off the LED 28 to indicate to the user that the bay 20 is cold and the drive 12 may be physically disconnected from the backplane 18. Execution then returns to step 200 (FIG. 2).
Referring to FIG. 4, at the most basic level, the system of the present invention may be used for enabling the hot swapping of any type of storage, power supply, or peripheral devices which lend themselves to a redundant array. In FIG. 4, an alternative embodiment of the subsystem 10 of FIG. 1, designated by reference numeral 400, comprises an array of redundant devices 402a-402c, each including an associated a user interface 403a-403c and connected to a main, or host, system 404 via an intelligent interface 406. As previously indicated, the devices 402a-402c may comprise any number of types of storage, power supply or peripheral devices which lend themselves to a redundant array. Referring to both FIGS. 1 and 4, it should be clear that the combination of the button 26 and the LED 28 of FIG. 1 correspond to the user interfaces 403a-403c of FIG. 4, the SCSI drive 12 corresponds to the devices 402a-402c, the combination of the SCSI bus 16, SCSI backplane 18, backplane controller 22 and SCSI controller 24 of FIG. 1 correspond to the intelligent interface 406 of FIG. 4 and the server 11 of FIG. 1 corresponds to the host system 404 of FIG. 4.
Operation of the system shown in FIG. 4 is nearly identical to the operation of the system of FIG. 1, depending on the identity of the devices 402a-402c. For example, assuming a user wants to initiate a hot removal of the device 402b from the system 404, the user simply depresses a request initiator on the user interface 403b associated with the device 402b, responsive to which action the intelligent interface 406 determines whether the removal of the device 402b would disrupt system operations. The results of the determination of the intelligent interface 406 are then indicated to the user via a visual indicator on the associated user interface 403b, and, assuming that the interface 406 determines that removal would not disrupt system operations, the device 402b is electrically disconnected from the system 404 in an orderly manner.
Alternatively, assuming the user now wants to initiate a hot reinstallation of the device 402b, the user physically connects the device 402b to the interface 406 and then depresses the request initiator on the user interface 403b, responsive to which action, the interface 406 determines whether installation of the device is appropriate, substantially in accordance with the logic illustrated in FIG. 2.
It is understood that the present invention can take many forms and embodiments. The embodiments shown herein are intended to illustrate rather than to limit the invention, it being appreciated that variations may be made without departing from the spirit or the scope of the invention. For example, the subsystem 10 need not be a SCSI subsystem.
Furthermore, the SCSI drive 12 may comprise any other type of device, such as a redundant power supply. In addition, a visual indication means other than the LED 28 may be used, or an indication means other than a visual indication means, e.g., an audio indication means, such as a tone or an alarm, may be used.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, change and substitution is intended in the foregoing disclosure and 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. | Apparatus and method for implementing a local proactive hot plug request/acknowledge scheme is disclosed. In a preferred embodiment, each hot pluggable device installable on a computer bus, such as a SCSI bus, is provided with a physical user interface comprising a mechanical request initiator, such as a button or two-position switch, for allowing a user to generate a hot swap request to a controller associated with the bus prior to actual installation of the device on, or removal of the device from, the bus. Upon receipt of the request, the controller determines whether the requested action may be performed, provides a visual indication of its determination to the user via an LED on the user interface and, if installation or removal is determined to be prudent, performs the hot installation/removal in an orderly manner so as not to adversely affect ongoing system operations. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to injection of a solution into a hot gas.
[0003] The invention is specifically directed to injection of an aqueous solution of urea into an exhaust gas from an engine for example from a diesel engine installed in a vehicle.
[0004] 2. Description of Related Art
[0005] Processes for catalytic reduction of nitrogen oxides in an exhaust gas are known in the art. One is disclosed in DE 4203807, where a urea solution is injected and an evaporator is installed just downstream of the injection. The evaporator is preferably covered by a hydrolysis catalyst to quantitatively decompose the urea and avoid deposit on the downstream reduction catalyst.
[0006] The problem of deposition of urea is also dealt with in Japanese patent JP 8206459. Here the deposition of urea is prevented by mixing a urea solution with water upstream of an injection nozzle. Signals from engine control are used to control the mixing ratio, so when a small amount of urea is required during low load of engine, more water is used in order to prevent blocking with urea in the nozzle.
[0007] Also JP 2002306929 considers solidification of injected urea into an exhaust gas. The nozzle is housed in a cover, and then downstream of this the hot exhaust gas is introduced, and then a catalyst is needed for decomposition of urea.
[0008] Another approach to solving the problem of urea deposit is disclosed in JP 2003278530, where the nozzle is surrounded by a thick wall, and the nozzle tip is surrounded by a cover with a deflecting bottom, after which the urea solution is introduced to the exhaust gas.
[0009] To avoid fouling by urea in a selective catalytic reduction unit in exhaust gas in vehicles, U.S. Pat. No. 6,203,770 discloses a process, where the urea is decomposed in a separate chamber before the solution is sprayed into the exhaust gas.
[0010] A process for injection of a urea solution into exhaust gas is disclosed in EP 1 052 009. In this process a side stream is conducted through a porous body acting as an evaporator or through a catalytic reactor, where hydrolysis of urea takes place before the side stream is combined with the main stream. This process requires control of the side stream flow and an evaporating and/or hydrolysing device to create a mixture of ammonia and exhaust gas upstream of a selective catalytic reduction of nitrogen oxides.
[0011] In WO 2005/103 459 exhaust gas is added a reducing agent by injection into a smooth shell surrounded by spacers pressing against the enlarged shell when hot.
[0012] To obtain turbulence in an exhaust gas for improved mixing between an injected reducing agent and the gas, an elaborate device is installed as disclosed in WO 03/036 054.
[0013] A common disadvantage of known art is that additional equipment is required in form of evaporator, hydrolysis reactor, water tanks, thick housing, exhaust gas injection device, mixers or separate chamber and some of them even result in risk of cooling down the urea solution, which should have been thermally decomposed. The additional equipment occupies space in an exhaust gas pipe, which is a problem especially in vehicles, where only limited space is available.
[0014] The object of the invention is to provide an apparatus for urea solution injection with subsequent evaporation and thermal decomposition of urea without incomplete evaporation or deposition of incomplete decomposed urea and without requirement of additional space in an exhaust gas channel.
SUMMARY OF THE INVENTION
[0015] The invention provides a method and a system for injection of a solution of a compound into a gas at elevated temperature, evaporating the solution and decomposing the compound in the gas at the elevated temperature. The method comprises injecting the solution into an injection channel being provided for into at least a portion of an outer channel and being surrounded by and spaced apart from the outer channel passing the gas along space between inner wall of the outer channel and outer wall of the injection channel and along inner space of the injection channel, evaporating the solution in or on an inner surface of the injection channel and decomposing the compound in or on the inner surface of the injection channel or in the gas.
[0016] The invention is especially related to a method and a system for injection of a solution of a compound into a gas, where the solution is an aqueous solution of urea and the gas is an exhaust gas from a combustion taking place in a diesel engine installed in a vehicle, a vessel or a power plan.
[0017] The invention is related to a method and a system for injection of a solution into a gas into an injection channel, where the injection channel is a cylindrical channel, a cylindrical corrugated channel, a channel with grooved inner surface or an at least partially tapered channel concentrically installed in an outer channel.
[0018] The invention is especially useful in exhaust gas pipes in diesel driven vehicles and vessels, where space is limited, for reducing the content of nitrogen oxides by urea solution injection substantially without urea deposition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cross section of an exhaust gas channel with a urea injection system according to the invention.
[0020] FIG. 2 is a sketch showing a cross section of an injection system.
[0021] FIG. 3 is a sketch showing a cross section of the injection system according to one embodiment of the invention.
[0022] FIG. 4 is a sketch showing a cross section of the injection system according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] In diesel driven engines combustion takes place with a certain amount of excess air. This results in formation of nitrogen oxides, NO x in the exhaust gas, which is a serious pollution for the environment.
[0024] NO x can be reduced by ammonia, NH 3 , which however is difficult to store especially in vehicles, and an aqueous solution of urea, H 2 NCONH 2 is therefore used as a reducing agent.
[0025] The ammonia is formed when urea decomposes as it is sprayed out and mixed with the hot exhaust gas according to the following reaction:
H 2 NCONH 2 +H 2 O→2NH 3 , +CO 2
[0026] Urea decomposes completely only if the temperature exceeds 200° C. Thus 200° C. is the lowest temperature at which urea can be injected to the exhaust gas.
[0027] If the urea solution is not evaporated and decomposed instantly when leaving the tip of the injection nozzle, some of the urea solution will hit the inner-surface of the exhaust gas channel. This is normally colder than the exhaust gas, as the exhaust gas channel is surrounded by ambient air, and when hitting the surface, the solution will remain liquid and will not decompose, it can even create a solid deposition on the inner surface.
[0028] When all the urea solution does not evaporate, this liquid will be running along the channel and will be having difficulties to evaporate. The solution could escape through small leakages in the exhaust gas channel and deposit on the outer surface of the channel. Escaped solution might even drip from the leakage and deposit below this leakage.
[0029] If deposition of urea occurs in smaller channels, such as in cars or vans, it will decrease the flow area in the exhaust gas pipe resulting in higher pressure drop and higher linear gas velocity in the pipe. This creates the risk of urea deposition on a downstream reduction catalyst, especially when starting with cold engine and exhaust gas system.
[0030] Further, urea in droplets is not decomposed to ammonia, which should have contributed to reduce NO x to N 2 .
[0031] The invention provides a method and apparatus for injection of a urea solution into an exhaust gas or a flue gas without risk of deposition of urea solution on the inner-surface of the channel, wherein the exhaust gas flows. It provides further for improved mixing of the solution and exhaust gas and improved evaporation of the solution.
[0032] This is obtained by installing an injection channel around the tip of the injection nozzle. The injection channel is installed with a certain distance from the surrounding outer channel, and the hot exhaust gas is flowing on both sides of the injection channel keeping it warm. Liquid urea solution evaporates and decomposes, when it hits the hot injection channel, as it has the same temperature as the exhaust gas.
[0033] The installed injection channel is a corrugated cylindrical channel, helically grooved channel or at least a partly tapered channel, which improves the mixing and the evaporation and creates less tension on the channel when heated.
[0034] The injection channel is kept at a certain distance from the outer channels by spacers and is kept in position by arresting devices. The arresting devices can be the injection nozzle at the inlet end and a thermowell at the outlet end. They can also be some more and bigger spacers, which extend into a flange connection on the outer exhaust gas channel or which are welded to the inner surface of the outer channel at one end of the injection channel.
[0035] The injection nozzle is preferably insulated to maintain the conditions of the urea solution until it is injected into the hot exhaust gas, thereby avoiding evaporation of the water and risking blockage of the injection nozzle.
[0036] The invention is very useful with exhaust gas temperatures between 100° C. and 600° C.
[0037] To obtain a favourable flow area in the annular space between the two channels it has been found that the ratio of the diameter of the injection channel and outer channel should be 0.5-1.0, preferably 0.6-0.9.
[0038] The invention is described in more detail by FIGS. 1, 2 , 3 , and 4 and illustrated by experiments.
[0039] On FIG. 1 exhaust gas 1 is flowing in outer gas channel 2 and an aqueous solution of urea 3 is injected by injection nozzle 4 into the exhaust gas 1 . Around the nozzle 4 an injection channel 5 is installed. It is spaced apart from the outer channel 2 and kept in position by spacers 6 . This enables the exhaust gas 1 to flow on both sides of the injection channel 5 , which thereby is kept at the same temperature as the exhaust gas 1 . The injection channel 5 prevents not-evaporated solution with not-decomposed urea to hit the cold inner-surface of the outer channel 2 , which is surrounded by atmospheric air at ambient temperature.
[0040] The injection channel 5 is concentrically installed in the exhaust gas pipe 2 .
[0041] In this embodiment of the invention, the injection channel is kept in position by the injection nozzle 4 and a thermowell 7 . The injection nozzle 4 is insulated in order to maintain the temperature of the solution and thereby avoid crystallisation or evaporation of water in the urea solution before injection into the exhaust gas.
[0042] FIG. 2 is a very schematic drawing showing how the injection channel 5 is kept in position and spaced apart from the exhaust gas pipe 2 by three spacers 6 .
[0043] The shape of the injection channel 5 can be a corrugated pipe as shown on FIGS. 3 and 4 . This has the advantage that the surface of the injection channel is larger than the surface of a smooth pipe with the same diameter. Further, it can freely expand inside the much colder exhaust gas pipe 2 with less tension on the outer channel 2 from the spacers 6 .
[0044] In another embodiment of the invention the inner surface of the injection channel is grooved, preferably the groove is helical. Consequently, the residence time of the possible droplets increases in the warm injection channel and more droplets will evaporate before leaving the injection channel.
[0045] In another embodiment of the invention, the injection channel is tapered. Thereby, the possible droplets leave the injection channel at a higher linear velocity and are less inclined to hit the colder inner wall of the outer exhaust gas channel and remain as droplets.
[0046] In a preferred embodiment of the invention, where it is installed in an exhaust gas pipe in a van and where the pipe typically has a diameter of 110 mm, the length of the injection channel 5 is 250-350 mm, preferably 290-310 mm, the outer diameter of injection channel 5 is 80-90 mm, and the thickness of the injection channel 5 is typically 2 mm.
[0047] The spacer 6 typically has a length of 8-12 mm, the height is 1 mm less than the gap between the outer channel 2 and the injection channel 5 . The width of the spacer 6 is typically 1-2 mm. The injection channel 5 is made from stainless steel such as SS 316 .
[0048] Requirement of cleaner environment has lead to cleaning of exhaust gas from combustion engines. Often the nitrogen oxides are removed by reduction to nitrogen by injection of an aqueous solution of urea. Performance of this reduction process is considerably improved by installing the reduction system of the invention in exhaust gas channels, especially in diesel driven vans, lorries, cars and vessels and in power plants.
[0000] Test Results
[0049] Tests were carried out with an exhaust gas from a diesel engine. An aqueous solution of urea was injected into a glass pipe and the flow could be observed.
[0050] Downstream of the urea solution injection, a nitrogen oxide (NOx) reduction catalyst was installed and the concentration of NOx in the exhaust gas was measured upstream and downstream of the catalyst.
[0051] First tests were performed in the “empty” glass pipe and then tests were performed with the injection channel of the invention installed.
[0052] Photos were taken of the flow in the glass pipe during the tests.
[0053] The test equipment had following characteristics:
[0054] The glass tube was 570 mm long with a diameter of 130 mm. The injection channel was 300 mm long and having a diameter of 84 mm.
[0055] The distance between nozzle holes and outlet end of injection channel was 200 mm.
[0056] The injection nozzle was equipped with 4 holes each having a diameter of 0.55 mm.
[0057] The injection channel was kept apart from the outer glass channel by 3 spacers, each 10 mm long, 14.5 mm high and 1.5 mm wide.
[0058] The channel was kept in position by 3 higher spacers, 19.5 mm high extending into a flange connection on the exhaust gas pipe.
[0059] The test was performed with 1020 kg/h exhaust gas and urea solution with 32.5% by weight.
[0060] The temperature of the gas was 300° C. and the urea solution had strength of 32.5% by weight.
[0061] The concentration of NO x was 703 ppm inlet of the catalyst. The catalyst was a Denox catalyst, DNX™ from Haldor Topsøe A/S.
[0062] First test was run with 36 g/min urea solution injected into the glass exhaust pipe. The NO x concentration was measured to 74 ppm outlet of the catalyst. Traces of urea solution were seen along the wall of the glass exhaust pipe.
[0063] Second test was run with 71 g/min urea solution injected into the glass exhaust pipe. The NO x concentration was measured to 74 ppm outlet of the catalyst. Urea solution was seen flowing along the glass wall.
[0064] Third test was run with an injection channel of the invention installed. 36 g/min urea solution injected into the glass exhaust pipe and the NO x concentration was measured to 56 ppm outlet of the catalyst. Only a few drops of urea solution were seen on the glass wall.
[0065] Fourth test was run with an injection channel of the invention installed. 70 g/min urea solution injected into the glass exhaust pipe and the NO x concentration was measured to 56 ppm outlet of the catalyst. Droplets of urea solution were seen, however, no liquid solution was seen flowing along the wall of the glass exhaust pipe.
[0066] Tests 1 and 3 were executed with the same amount of injected liquid, but without and with injection channel installed, respectively, thereby the effect of the injection channel could be seen. Without injection channel installed, liquid urea solution was still present in the exhaust gas, whereas with the injection channel installed only few droplets of solution remained in the exhaust gas.
[0067] Similarly, tests 2 and 4 were executed with the same, but increased amount of injected liquid and without and with injection channel installed, respectively. Without injection channel installed, liquid urea solution was running on the exhaust gas pipe, whereas with the injection channel installed only droplets of solution remained in the exhaust gas.
[0068] Thereby, it is clearly seen that an injection channel prevents that the injected solution remains as a liquid in the exhaust gas pipe. At the same time the NO x conversion is increased. | The invention provides a method and a system for injection of a solution of a compound into a gas at elevated temperature, evaporating the solution and decomposing the compound in the gas at the elevated temperature, comprising injecting the solution into an injection channel being provided into at least a portion of an outer channel and being surrounded by and spaced apart from the outer channel, passing the gas along space between inner wall of the outer channel and outer wall of the injection channel and along inner space of the injection channel, evaporating the solution in and on inner wall of the injection channel and decomposing the compound in and on the inner wall of the injection channel and in the gas. The solution can be an aqueous solution comprising urea or ammonia, the gas is an exhaust gas from combustion and the injection channel typically is a cylindrical channel concentrically installed in the outer channel. | 8 |
FIELD OF THE INVENTION
The invention relates to a process for improving the filling capacity of tobacco, in particular cut tobacco leaf, in which raw tobacco is moistened, stripped and cut, and, after impregnation with a vaporizable expanding agent, is subjected to either a reduction in pressure, an increase in temperature or both.
BACKGROUND
At harvesting, tobacco leaves contain a considerable quantity of water. After harvesting, this water is removed by various drying processes, as a result of which the leaf structure shrinks. During the usual processes for preparing tobacco for the manufacture of cigarettes and cigars, the tabacco regains, if any, only a small part of the original volume, so that a considerable loss in the filling capacity of the tobacco results. Due to this shrinkage the tobacco has a higher volume density than that required for the manufacture of cigarettes of satisfactory quality.
Numerous processes are known to improve the filling capacity of tobacco. This process is also known as tobacco expansion. It is common to these processes that the tobacco which is to be expanded is impregnated under defined pressure and temperature conditions with a volatile auxiliary. This auxiliary or flowing agent is then vaporized by supplying heat, reducing the pressure or both. The increase in the volume of the auxiliary, which then takes place, effects the expansion of the tobacco. The known processes for expanding tobacco differ primarily in the nature of the auxiliaries (blowing agents) which are employed. For example, the process according to German Patent Specification No. 1,917,552 uses volatile organic liquids, the process according to German Patent Specification No. 2,143,388 uses a mixture of ammonia and carbon dioxide, the process according to German Offenlegungsschrift No. 2,503,636 uses carbon dioxide and the process according to German Offenlegungsschrift No. 2,903,300 uses nitrogen or argon.
A substantial disadvantage of the processes mentioned above is that, although they lead to a useful expansion of the tobacco, the taste of the smoke from the tobaccos thus expanded is considerably impaired by the process. Not only is the taste intensity diminished, but the tobaccos treated in this way also have unfavorable taste features which, according to the statements of experts, can be described by the occurrence of less desirable taste notes, described as bitter, metallic, musty or rancid. Since the expanded tobaccos did not have these undesirable taste characteristics before their treatment, obviously they are caused by the treatment.
It is a generally known practice to treat tobacco leaves, before cutting, to improve or enrich the taste, with substances, such as sugar, liquorice, cacao, fruity syrups and the like. It is also known to add aroma substances to the finally cut tobacco for this purpose. For this purpose, natural and synthetically produced essences of any type, identical to the natural ones, or individual aroma substances, such as menthol or vanillin, are employed. The list of the substances and essences which can be used for this purpose is extensive. See e.g., the listing by Leffingwell et al., Tobacco Flavouring for Smoking Products, 1972. However, tests have shown that, in the case of expanded tobacco, the above described undesired taste properties caused by the expansion can be avoided, eliminated or covered only to a very unsatisfactory extent, if at all, by the conventional additions of aroma substances or flavorings either to the tobacco leaf or to cut tobacco.
SUMMARY OF THE INVENTION
The taste characteristics of tobacco expanded by being subjected to either a reduction in pressure, an increase in temperature or both after having been impregnated with a vaporizable expanding agent are improved by adding an anti-oxidant to the tobacco prior to the expansion. Additional anti-oxidant synergists can be added.
DESCRIPTION
Surprisingly, it has now been found that the formation of the above-described undesired taste features caused by the expansion can be completely prevented, by adding an anti-oxidant to the tobacco before expansion.
To achieve the desired effect, it is absolutely necessary to add these substances to the tobacco before the expansion step, for example during or after the moistening or stripping of the tobacco leaves, preferably after stripping or after cutting. A later addition of the anti-oxidant to already expanded cut tobacco does not have any influence on the undesired taste notes.
Ascorbic acid has proved to be most suitable for the present purpose, and is therefore the preferred anti-oxidant but other substances which are known to prevent or delay the autoxidation of foodstuffs and essences also give a taste-improving effect. Substances having such properties are known; listings are to be found, for example, in Aebi et al., Kosmetika, Riechstoffe and Lebensmittelzusatzstoffe, [Cosmetics, Fragrances and Food Additives], Thieme Verlag, 1978, pages 86-102.
The taste-preserving effect of the present invention is the more unexpected, because these substances, to which an activity preventing the oxidation of foodstuffs and essences is ascribed, occur in tobacco as natural constituents. Examples of such constituents are ascorbic acid, pectins, aminoacids, in particular proline, caffeic acid, ferulic acid and chlorogenic acid, and also quercetin derivatives, such as rutin. Other examples include alpha-tocopherol and gamma-tocopherol. Therefore, it was not expected that a later or additional application of such substances would have a taste-preserving effect. In particular, the taste-preserving effect of ascorbic acid was surprising, since no activity is ascribed to this substance in the abovementioned listing by Leffingwell et al.
Examples of suitable anti-oxidant which do not occur naturally in tobacco include 2-tert, butyl-4-hydroxy-anisole and 3,5-di-tert.-butyl-4-hydroxy-toluene. In addition, compounds such as eugenol and isoeugenol are also acceptable. It is uncertain whether these two compounds occur naturally in tobacco.
According to the invention, the taste-preserving effect can be achieved by small added quantities. Thus, added quantities of 0.001% by weight to less than 0.1% by weight, in particular 0.001 to less than 0.1% by weight, relative to the dry tobacco weight (weight prior to moistening), are sufficient to obtain the taste-preserving activity.
Preferably, the substances employed as the anti-oxidants are natural tobacco constituents like those mentioned above. The addition of ascorbic acid is particularly preferred.
In the process of the invention, substances can also be employed which are known to promote or boost the activity of anti-oxidants for foodstuffs and aroma substances or essences. Such substances, termed synergists, are know; listings are likewise to be found in the abovementioned publication. Monobasic or polybasic monohydroxy- or polyhydroxy-carboxylic acids, such as lactic acid, tartaric acid, citric acid or the like, have proved to be most suitable for the present purposes. The added quantity of these substances can vary over a range from 0.001% to 2% by weight, relative to dry tobacco weight. The preferred range is 0.05 to 2% by weight. Moreover, a combination of ascorbic acid and citric acid is particularly preferred.
Further preferred features of the process of the invention will be evident from the examples which follow and the claims.
EXAMPLE 1
5 kg of a stripped Virginia tobacco leaf mixture was sprayed with 0.4 liters of water and thus brought to a tobacco moisture content of about 20%. The tobacco was then cut and subjected to an expansion process with liquid CO 2 as the blowing agent. Filter cigarettes of 84 mm length were then produced from the finished expanded tobacco. The taste of these cigarettes was assessed by an expert team in comparison with a cigarette of the same, but unexpanded tobacco mixture. In the view of the experts, the taste of the smoke from the cigarette containing the expanded tobacco was altogether more flat, and, in addition, had marked unpleasant bitter, metallic, musty and rancid taste notes, which the untreated tobacco did not have.
EXAMPLE 2
5 kg of the tobacco mixture used in Example 1 were sprayed with a solution of 4 g of ascorbic acid in 0.4 liters of water. This tobacco was then treated further as described in Example 1. The taste of the cigarettes produced from this expanded tobacco was rated by an expert team, in comparison with the cigarette from Example 1, as being more aromatic and qualitatively altogether substantially better, and there were no unfavorable taste properties at all.
EXAMPLE 3
5 kg of the tobacco mixture used in Example 1 were sprayed with a solution of 2 g of ascorbic acid and 10 g of citric acid in 0.4 liters of water. The tobacco was then treated further as described in Example 1. The taste of the test cigarettes produced from this expanded tobacco was rated, in comparison with the cigarette from Example 1, as being more aromatic, having less irritant and being qualitatively substantially better. Also, in this cigarette, the undesired taste features typical of the cigarette from Example 1 were no longer noticeable.
EXAMPLE 4
5 kg of the stripped tobacco mixture used in Example 1 were sprayed with a solution of 0.25 g of 3,5-di-tert.-butyl-4-hydroxy-toluene (BHT) in 50 g of ethanol. After evaporation of the ethanol, the tobacco was then sprayed with 0.4 liters of water and treated further as described in Example 1. The taste of the cigarettes produced from this expanded tobacco was rated by an expert team, in comparison with the cigarette from Example 1, as being more aromatic and altogether substantially better. There were no unfavorable taste notes at all.
EXAMPLE 5
250 g of the expanded tobacco from Example 1 were sprayed with a solution of 0.1 g of ascorbic acid in 10 ml of water. After careful drying of the tobacco thus treated to the original moisture content, cigarettes were produced. Compared with the cigarettes from Example 1, the taste of the smoke from these cigarettes did not show any improvement in taste at all; the unpleasant taste notes described were still clearly perceivable.
This example shows that the process according to the invention for preserving the tobacco aroma has the desired effect only if it is applied before the expansion process.
Although in the foregoing examples the anti-oxidant was added between the stripping and cutting steps, it may also be added after cutting.
Modification and variations of the invention will be apparent to those skilled in the art. Applicants intend to cover all such equivalent modification and variations as fall within the true spirit and scope of the invention. | The impairment of the taste of smoke, observed in processes for improving the filling capacity of tobacco by expansion of the tobacco with a vaporizable expanding agent, can be avoided if an anti-oxidant, in particular ascorbic acid, is added to the tobacco before the expansion. In addition, anti-oxidant synergists can also be added. | 0 |
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/171,656, filed Jun. 5, 2015, the entirety of which is incorporated by reference herein.
[0002] This application is also related to U.S. Pat. Nos. 6,154,898, 7,503,083, 8,607,376, 9,015,870, and 9,015,876, the entire disclosures of which are incorporated by reference herein.
FIELD OF THE INVENTION
[0003] Embodiments of the present invention are generally related to sink drain closures.
[0004] More specifically, some embodiments of the present invention are directed to selectively closable stoppers used in sinks or other fluid basins.
BACKGROUND OF THE INVENTION
[0005] Sink drain closures are sometimes comprised of a selectively movable drain stopper that has a first portion used to seal the drain and a second portion operatively interconnected to a mechanism that facilitates movement of the drain stopper. An example of a common sink drain closure is shown in FIG. 1 . FIG. 1 shows a sink 2 with interconnected to a wastewater drain system 6 of a dwelling. The wastewater drain system 6 is interconnected to a body 10 that is held to the sink 2 with a flange 14 . The body 10 includes a threaded portion 18 that selectively receives the flange 14 , wherein the body 10 is secured to the sink 2 with the seal 22 and nut 26 engaged to the threaded portion 18 , and abutted against an outer surface of the sink 2 . In other versions, the flange 14 is integrated to the body 10 .
[0006] As shown in FIG. 1 , a drain stopper 30 is placed within the body 10 . Operation of the drain stopper 30 to control fluid flow from the sink is achieved by providing a ball rod 34 that is inserted into the body 10 . A first end 38 of the ball rod 34 interfaces with the second portion 40 of the drain stopper 30 such that when the ball rod 34 is rotated about a ball 42 seated in the body 10 , the drain stopper 30 will move. As those of ordinary skill in the art will appreciate, movement of the ball rod 34 is achieved by movement of a link 46 interconnected to a second end 50 of the ball rod with a clip 54 .
[0007] Common sink drain closures are expensive to manufacture and/or to install, and tend to experience decreased functionality after long-term use. They are also not easily cleaned or accessible for repair and replacement.
[0008] Thus it is a long felt need to provide a sink drain closure that is easy to install and replace. The following disclosure describes an improved sink drain stopper adapted for interconnection to a sink and which includes an insert that allows for selective alteration of the aesthetic appearance of the sink.
SUMMARY OF THE INVENTION
[0009] It is one aspect of embodiments of the present invention to provide a sink drain closure that is inexpensive to manufacture and highly efficient to use and operate. It is another aspect to provide a sink drain closure that provides enhanced access to valve closure elements. That is, embodiments of the present invention include easily-removable parts that allow access to a fluid control valve positioned within the wastewater plumbing found below the sink.
[0010] More specifically, the fluid control valve comprises a drain stopper with a diameter greater than that of an opening in a valve seat integrated into the body. The drain stopper is, thus, adapted to close the opening to fluid flow. The valve element is interconnected to a valve stem that extends downwardly through the opening in the valve seat. A lower end of the valve stem is connected to a ball rod used to selectively move the drain stopper and open/close the fluid control valve.
[0011] Some embodiments also provide a strainer element that extends across a port in the bottom of the sink to prevent large particulate matter to enter the wastewater plumbing. The strainer of one embodiment is incorporated into an insert selectively interconnected to a flange that connects the sink to the wastewater plumbing. Strainers of some embodiments of the present invention include a plurality of holes. The holes are large enough to allow water therethrough, but are designed to prevent hair, Q-tips, wedding rings, etc. from entering into the wastewater plumbing.
[0012] It is another aspect of some embodiments of the present invention to provide a drain stopper that is concealed within the wastewater drain plumbing. For example, some embodiments employ a valve seat associated with the internal surface of the wastewater drain pipe. The valve seat selectively receives a drain stopper that is moved in the same or similar fashion as prior art systems. Here, however, the drain stopper and associated seal interact with the seat and is completely concealed from the user. Accordingly, this aspect of the present invention eliminates the unaesthetic qualities of prior art drain stoppers, e.g., they do not sit flush with the bottom surface of the sink when opened.
[0013] Stated differently, the prior art drain stoppers when an open configuration, provide an unsightly, loose-fitting appearance.
[0014] It is yet another aspect of some embodiments the present invention to provide a sink drain closure system that is easy to replace or repair. Those of ordinary skill in the art will appreciate that if the prior art drain stoppers become damaged, or if the homeowner wishes to change the aesthetic appearance of the sink fixtures, the drain stopper and associated strainer must be replaced. For example, changing the sink flange (i.e., the flange associated with a strainer) from chrome to a brushed-nickel finish would be a time-consuming and expensive task. Conversely, embodiments of the present invention are easily repaired by simply replacing an insert selectively interconnected to the sink flange. Again, only the insert would need to be replaced as the drain stopper and associated components are completely concealed. Indeed, the shape, color, form, etc. of the drain stopper is irrelevant in some instances as it is never visible during use. Thus some embodiments of the present invention avoid the expense associated with manufacturing an aesthetically pleasing drain stopper, e.g., one made of chrome.
[0015] It is still yet another aspect of embodiments of the present invention to provide a drain stopper that provides a tight seal. More specifically, the drain stoppers of the prior art employ a seal that interfaces with an inner surface of the strainer. Thus, the drain stopper seal must be dimensioned such that it easily fits within the sink strainer, which often renders the drain stopper seal ineffective. Conversely, embodiments of the present invention employ a seal that tightly engages a seat position in the drain plumbing, thereby providing an enhanced seal that prevents water from exiting the sink.
[0016] Thus it is one aspect of the present invention to provide a wastewater drain system, comprising: a body having a first, threaded end and a second end adapted for interconnection to wastewater drain pipes of a structure, the body having an opening for receipt of a ball rod; a flange interconnected to the first end of the body; a seal positioned about the body; a nut positioned about the body, the nut and the seal adapted to be abutted against an exterior of a fluid receptacle, wherein the flange is abutted against an interior of the fluid receptacle, and wherein the body is secured to the fluid receptacle by the flange and the nut; a stem having a proximal end and a distal end, the distal end operatively interconnected to an end of the ball rod, wherein the proximal end includes a stopper; an insert selectively interconnected to the flange; and wherein the stem can be moved with the ball rod from a first position of use to engage the stopper against a seat positioned in the body to prevent fluid flow through the wastewater drain system, and a second position of use that separates the stopper from the seat to allow fluid flow through the wastewater drain system.
[0017] Thus it is another aspect of the present invention to provide a wastewater drain system interconnected to a sink drain port, comprising: a body having a first, threaded end and a second end adapted for interconnection to wastewater drain pipes of a structure, the body having an opening for receipt of a ball rod; a stem having a proximal end and a distal end, the distal end operatively interconnected to an end of the ball rod, wherein the proximal end includes a stopper; and an insert associated with the drain port and selectively interconnected to the body.
[0018] The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. That is, these and other aspects and advantages will be apparent from the disclosure of the invention(s) described herein. Further, the above-described embodiments, aspects, objectives, and configurations are neither complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible using, alone or in combination, one or more of the features set forth above or described below. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description of the Invention and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detail Description, particularly when taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] 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 of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
[0020] FIG. 1 is a partial perspective view of a common wastewater drain system;
[0021] FIG. 2 is a perspective view of a drain closure system of one embodiment of the present invention;
[0022] FIG. 3 is a cross-sectional view of FIG. 2 showing a stopper closed;
[0023] FIG. 4 is a cross-sectional view of FIG. 2 showing the stopper open;
[0024] FIG. 5 is a detailed cross-sectional view showing the upper end of the embodiment shown in FIG. 2 ;
[0025] FIG. 6 is a cross-sectional view of another embodiment of the present invention that employs an insert having external threads;
[0026] FIG. 7 is an exploded perspective view of another embodiment of the present invention that employs an external stopper;
[0027] FIG. 8 is a top perspective view of the embodiment shown in FIG. 7 ;
[0028] FIG. 9 is a cross-sectional view of FIG. 7 ; and
[0029] FIG. 10 is a cross-sectional view of FIG. 7 , wherein the stopper is opened.
[0030] To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein:
[0000]
#
Component
2
Sink
6
Wastewater drain system
10
Body
14
Sink flange
18
Threaded portion
22
Seal
26
Nut
30
Drain stopper
34
Ball rod
38
First end
40
Second portion
42
Ball
46
Link
50
Second end
54
Clip
110
Body
114
Sink flange
118
Threaded portion
122
Seal
126
Nut
130
Drain stopper
132
Nut
134
Ball rod
140
Distal end
142
Ball
146
Link
154
Clip
158
Rod
162
Thumbscrew
166
Knob
170
Valve stem
174
Seat
180
Insert
184
Upper seal
188
Holes
192
Seal
194
Insert wall
196
Inner surface
197
Lower surface
198
Shoulder
200
Lower surface
204
Shoulder
206
Flange wall
207
Groove
208
Boss
209
Recess
210
Body
214
Sink flange
222
Seal
226
Nut
230
Drain stopper
270
Valve stem
274
Seat
280
Insert
310
Body
314
Sink flange
326
Nut
330
Drain stopper
332
Seal
334
Ball rod
340
Distal end
342
Threaded portion
343
Opening
370
Valve stem
380
Insert
382
Hub
386
Drain stopper seal
[0031] It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.
DETAILED DESCRIPTION
[0032] FIGS. 2-5 show a drain closure system of one embodiment of the present invention. The drain closure system is comprised of a body 110 having a threaded portion 118 that terminates at a sink flange 114 . As those of ordinary skill in the art will appreciate, the body of this and other embodiments of the present invention described herein may be made of multiple pieces. The body 110 also receives a nut 132 that secures a ball rod 134 , wherein a portion of the ball rod 134 is positioned within the body 110 . The body 110 is interconnected to the sink, wherein the flange 114 is in contact with a lower surface of sink. Next, a nut 126 and associated seal 122 are interface with a threaded portion 118 of the body 110 and tighten against a lower outer surface of the sink to secure the body 110 to the sink. After the body 110 is secured to the sink, it is also interconnected to the wastewater drain plumbing of the dwelling. The ball rod 134 is interconnected to a link 146 via a clip 154 , or other device. The link 146 is secured to a rod 158 with a thumbscrew 162 , or other device. The rod terminates at a knob 166 , wherein movement of the rod 166 will selectively move the ball rod 134 and, thus, a portion of the ball rod 134 positioned within the body 110 . The interconnection between the ball rod 134 and the body 110 should be well known by those of ordinary skill in the art.
[0033] The end of the ball rod 134 positioned in the body is interconnected to a distal end 140 of a valve stem 170 . The distal end 140 of some embodiments is flared, or otherwise configured, to prevent hair and other debris from getting hung up on the ball rod 134 (see FIG. 4 ). The valve stem 170 also includes a proximal end comprised of a drain stopper 130 . As shown in FIGS. 3 and 4 , the drain stopper 130 cooperates with a seat 174 located within the body 110 to selectively allow fluid out of the sink.
[0034] The drain stopper 130 , seat 174 , etc. are concealed by an insert 180 . The insert 180 includes an upper surface 184 with a plurality of holes 188 that allow water, but not large items from entering the drain plumbing. The insert has a wall 194 that accommodates a seal 192 that cooperates with an inner surface 196 of the body to secure the insert 180 the body 110 . The wall 194 has a lower surface 200 that engages a shoulder 204 of the body 110 or the flange 114 . Because the seal 192 does not permanently secure the insert 180 the body 110 , if the insert becomes damaged, stained, or marred, or if the user wishes to change the aesthetic appearance of the sink, the insert 180 can be quickly removed and replaced without replacing the remainder of the wastewater system.
[0035] Again, the insert 180 of this embodiment of the present invention will selectively interconnects to a drain flange and associated drain plumbing by way of a seal 192 that selectively engages the inner surface 196 of the drain flange wall 206 , i.e., an interference fit (see FIG. 5 ). The seal 192 may fit within a groove integrated into the insert wall, or within outwardly extending protrusions on the insert wall. Also, multiple seals can be employed, and an enlarged seal may be employed. Those of ordinary skill in the art should appreciate that other interconnection methods or schemes are contemplated. For example, the interconnection methods described in U.S. Pat. Nos. 6,154,898, 7,503,083, 8,607,376, 9,015,870, 9,015,876, and insert interconnection methods similar thereto, may be used to selectively interconnect the insert 180 to the drain flange 114 without departing from the scope of the present invention. Furthermore, some embodiments the present invention: 1) do not employ a seal, and rely on adhesives to secure the flange to the drain flange; 2) do not employ an insert wall, wherein a circular plate is adhered or otherwise interconnected to the drain flange; 3) employ a flange with a downwardly-extending lip for selective engagement onto an outer edge of the drain flange; 4) employ a cylindrical insert wall that selectively engages seals or other interconnection device is associated with the sink strainer or drain plumbing; or 5) employ mating devices that selectively engage with corresponding mating features on the train strainer, i.e., a bayonet fitting or snap in connection.
[0036] FIG. 2 shows another feature of some embodiments of the present invention. As shown, the flange 114 is interconnected to the threaded portion 118 of the body by way of a cylindrical, semi-cylindrical, or conical wall 206 having the inner surface 196 described above. At least one groove 207 is provided in the wall 206 . Water, which does not exit the sink via the openings 188 in the insert 180 , can exit the sink through any gap between the insert flange 180 and the sink drain flange 114 and into the drain plumbing via the groove(s) 207 .
[0037] As discussed above, FIGS. 3 and 5 show the wastewater drain with the drain stopper 130 in a closed position. Here the drain stopper 130 is abutted against the seat 174 which prevents fluid from entering the body 110 . This configuration is achieved by pulling the knob 166 upwardly to move the attached rod 158 and link 146 upwardly. Movement of the rod 158 upwardly rotates the end of the ball rod 134 positioned within the body 110 about a ball 142 downwardly, which pulls a distal end 140 of the valve stem 170 downwardly.
[0038] FIG. 3 shows another feature provided by some embodiments of the present invention that facilitates installation. Here, a boss 208 that receives the nut 132 is positioned within a recess 209 that locates an outer surface of the boss 208 at a dimension equal to or less than the outer dimension of the body 110 . This embodiment facilitates installation by allowing the body 110 to be dropped into the sink outlet. The nut 132 may have outer protrusions, i.e., wings, that facilitate tightening. In contrast, the prior art system shown in FIG. 1 has a larger boss, which does not fit through the drain outlet. To install the prior art system a plumber must position an upper edge of the body through the drain outlet and fasten the sink flange thereto. Then, the nut 22 is used to secure the body 10 to the sink 2 . As those of ordinary skill in the art will appreciate, this is a two-hand or two-person operation.
[0039] FIG. 4 shows the wastewater drain system in an open position wherein the rod 158 has been pushed downwardly to rotate the end of the ball rod 134 upwardly to push the valve stem 170 upwardly, thereby moving the attached valve stem 170 away from the seat 174 to open the fluid flow path from the sink to the body 110 .
[0040] FIG. 6 shows another embodiment of the present invention where the insert 280 is selectively interconnected to a sink flange 214 . Other features of this embodiment are similar to those employed by the embodiments described above. FIG. 6 also shows that sink the flange 214 does not need to be integral to the body to 10, but may be threateningly engaged thereto. The remaining operation of this embodiment of the present invention is similar to or same as that described above, wherein a drain stopper 230 , a valve stem 270 , a seat 274 , a seal 222 , and a nut 226 are provided.
[0041] FIGS. 7-10 show another embodiment of the present invention wherein the drain stopper 330 is external to the body 310 . Here, the drain stopper 330 comprises a downwardly-extending stem 370 and a threaded lower portion 342 . The threaded portion 342 is operatively interconnected into the stem 370 , thereby allowing the length between the stopper 330 and a distal end 340 to be altered if needed. The threaded portion 342 also includes an opening 343 for receipt of an end of the ball rod 334 positioned within the body 310 . Here, the sink flange 314 is selectively interconnected to or integrated with the body 310 .
[0042] This embodiment also includes an insert 380 with a hub 382 that is attached, e.g., glued, to the flange 314 . The insert 380 may also include a wall that selectively interconnects to the sink flange or body as is shown in the embodiments discussed above. The hub 382 provides a cylindrical opening for receipt and securement of the stem 370 as shown in FIGS. 8 and 9 . Upon pulling a knob upwardly, (see FIG. 2 , for example,) the stem 370 and threaded portion 342 are pulled downwardly, which pulls the stopper 330 and attached seal 386 into engagement with the insert 380 to close the body 310 to the flow.
[0043] The knob is pushed downwardly, the end of the ball rod 334 moves upwardly, which moves the stem 370 upwardly to separate the seal 386 from the insert 380 allow fluid to flow into the body.
[0044] While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims. Further, it is to be understood that the invention(s) described herein is not limited in its application to the details of construction and the arrangement of components set forth in the preceding description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. | A wastewater drain assembly is provided that includes a selectively openable drain stopper. The wastewater drain assembly is interconnected to a fluid basin wherein a flange, which is interconnected to wastewater plumbing, is situated within the sink. The flange receives an insert that has a portion that conceals the flange. | 4 |
[0001] This application claims priority under 35 USC 119(e) to provisional application No. 60/282,428, which was filed on Apr. 9, 2001, the entire contents of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to fibrous substrates useful in the manufacture of carbon fiber/carbon matrix composites, and to carbon fiber/carbon matrix composites manufactured therefrom. Representative of such composites are aircraft and high performance automotive brake discs made by depositing carbon matrices on carbon fiber substrates of this invention and subsequently carbonizing the combinations to provide carbon matrices that are reinforced with carbon fibers.
[0004] 2. Related Art
[0005] Many advances have been made over the years in the art relating to brake discs.
[0006] U.S. Pat. No. 5,388,320 describes the manufacture of carbonizable needle-punched filamentary structures (typically, annular performs) made up of layers of unidirectional filaments and staple fibers. These structures can be used to make shaped articles (typically, brake discs) of carbon reinforced with carbon fibers. As taught in column 7 of the patent, some of the arc segments used to make up the structures are cut in such a way that the majority of the filaments extend substantially radially of the eventual annulus, while others are cut so that the majority of the filaments extend substantially chordally of the annulus. The former segments have greater dimensional stability in the radial direction and the latter segments have greater dimensional stability in the chordal direction.
[0007] U.S. Pat. No. 5,546,880 describes fibrous substrates for the product of carbon fiber reinforced composites comprising multilayered annular shaped fibrous structures, suitable for use in the manufacture of friction discs, made from multidirectional fabric, that is, fabric having filaments or fibers extending in at least two directions.
[0008] The present invention involves the recognition that, in carbon fiber composite friction linings, the orientation of the fiber at the friction surface plays a major role in the wear characteristics of the material. When fibers of opposing direction on the friction surfaces slide against each other, mechanical wear takes place and the fiber bundles are torn form the friction surface. This fiber pull-out leads to breakdown of the surrounding matrix of carbon. As more areas of fiber pull-out occur on the friction surface, the matrix surrounding these fibers also breaks down to fill the voids created. This results in a reduction in the overall thickness of the frictional material.
SUMMARY OF THE INVENTION
[0009] This invention addresses the need of both brake manufacturers and their customers, by increasing the field life (via reduction of the wear rate) of carbon fiber friction materials and thereby reducing the cost of ownership.
[0010] Methods for manufacturing annular preforms made from tows of oxidized polyacrylonitrile continuous filaments are described in U.S. Pat. No. 5,388,320, the entire contents of which are hereby expressly incorporated by reference. In the new preform technology of the present invention, fiber orientation in the preform is in the radial direction. This means that the continuous fibers run mainly from the inner diameter to the outer diameter of the annular disc. By orienting the fibers in this fashion, fiber pull-out is minimized, thereby reducing mechanical wear. Testing has shown that by using this preform fiber architecture, wear rates can be reduced up to 40 percent while maintaining disc strength and integrity.
[0011] One embodiment of this invention is a carbon fiber brake preform comprising an annular disc built up of fabric arc segments composed of from 90 to 70 weight-% continuous fibers and from 10 to 30 weight-% staple fibers. A typical annular disc of this invention may, for instance, be composed of 85 weight-% continuous fibers and 15 weight-% staple fibers. Preferably, both the continuous fibers and the staple fiber are oxidized polyacrylonitrile fibers. In this preform, at least 80% of the continuous fibers in the fabric segments are arranged to be located within 60° of radially from the inner diameter to the outer diameter of the annular disc. Thus, for instance, the fabric arc segments may be arranged with substantially all of their continuous fibers oriented in the radial direction and parallel to the segment arc bisector, or the fabric arc segments may be arranged in alternating layers in which, respectively, approximately half of their continuous fibers are oriented at a +45 degree angle with respect to the segment arc bisector and approximately half of their continuous fibers are oriented at a −45 degree angle with respect to the segment arc bisector.
[0012] Another embodiment of this invention is a method for making a preform composite. The method includes the steps of: a.) providing a needle-punched nonwoven fabric comprising a major portion of unidirectional continuous fiber and a minor portion of staple fiber; b.) making from this fabric a plurality of segments having the outside diameter and the inside diameter of the preform to be manufactured from the fabric; c.) arranging the segments in a multilayered intermediate to a weight and dimension calculated to provide a desired preform density for the application; d.) heating the multilayered intermediate to a temperature above 1500° C. in an inert atmosphere for an amount of time sufficient to convert the fibers to carbon; and e.) densifying the carbonized product by carbon deposition to the desired preform density. The segments may be arranged in step c.) with their continuous fibers oriented in the radial direction and parallel to the segment arc bisector or in alternating layers in which their continuous fibers are oriented alternatively at a +45 degree angle with respect to the segment arc bisector and at a −45 degree angle with respect to the segment arc bisector. The carbonized product may be densified in step e.) using Chemical Vapor Infiltration/Chemical Vapor Deposition. A typical density for a finished disc produced by this method is in the range 1.70-1.80 g/cc.
[0013] Still another embodiment of this invention is a method of reducing wear in an annular brake disc which comprises manufacturing said disc from preforms reinforced with a plurality of continuous fibers in which at least about 80% of the continuous fibers are aligned in a generally radial manner, for instance within 60° of the radii of the annular brake disc. In two specific cases, the continuous fibers are located on the radii of the annular brake disc or the continuous fibers are located at angles of 45° from the radii of said annular brake disc. Using this method, wear of the brake disc may be reduced, for example, by 25% or more compared to wear of an otherwise comparable brake disc made from preforms in which half of the continuous fibers are located outside of the 120° arcs bisected by the radii of each of the preform segments.
[0014] Finally, this invention provides a shaped fibrous fabric structure having an annular disc configuration and being formed of multiple, successively-stacked layers of abutting fabric arc segments composed of from 90 to 70 weight-% continuous fibers and from 10 to 30 weight-% staple fibers, the fabric arc segment layers being interconnected by at least a portion of the staple fibers, wherein at least 80% of the continuous fibers in the fabric arc segments are located within 60° of radially from the inner diameter to the outer diameter of the annular disc. The fabric arc segments may be arranged with their continuous fibers oriented in the radial direction and parallel to the segment arc bisector, or they may be arranged in alternating layers in which their continuous fibers are oriented alternatively at a +45 degree angle with respect to the segment arc bisector and at a −45 degree angle with respect to the segment arc bisector.
[0015] Implementation of these new fiber preform architectures (radial and +/−45°) enables the brake manufacturer to produce fewer friction linings to meet existing airline requirements. In addition, the brake manufacturer will be able to meet increasing demand without further capital investment by utilizing the excess production capacity created by this technology.
[0016] Additional advantages of the present invention will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The drawings that accompany this application are presented by way of illustration only, and do not limit the scope of the present invention.
[0018] [0018]FIGS. 1A and 1B are top plan views of two different fabric segment orientations that may be used in accordance with the present invention.
[0019] [0019]FIG. 1C is a top plan view of prior art fabric segment orientations.
[0020] [0020]FIG. 2 illustrates, in a schematic perspective view, a preform of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] [0021]FIGS. 1A and 1B illustrate preform fabric segments that may be used according to the present invention, while FIG. 1C illustrates prior art preform segments such as those shown in FIG. 5 of U.S. Pat. No. 5,388,320. In all of these Figures, the fields of horizontal lines represent continuous fibers. FIG. 1A depicts a fabric segment in which a continuous fiber is situated in the radius of a segment, while FIG. 1B depicts fabric segments oriented such that their radii describe an angle of 45° with respect to the direction of the continuous fibers in the fabric. FIG. 1C, which is illustrative of the prior art, includes a fabric segment oriented such that its radius describes an angle of 90° with respect to the direction of the continuous fibers in the fabric. The presence of such fabric segments (that is, 90° orientation) in a preform provides carbon fiber/carbon matrix composites that are subjected to greater frictional wear than are similar composites manufactured in accordance with the present invention.
[0022] The Fabric
[0023] The following process may be used to manufacture fabric segments in accordance with the present invention. A carded web is crosslapped to achieve a desired areal weight, and then needle punched to form a staple fiber web fabric. The staple fiber web could alternatively be formed by airlaying the staple fibers. Separately, large continuous tows are spread, using a creel, to form a sheet of the desired areal weight. The sheet is processed through a needle loom to impart integrity to the continuous fiber fabric. This fabric is known as a continuous tow fabric. Then the staple fiber web is needle punched into the continuous tow fabric to form what is called a duplex fabric. The +45°, −45°, and radial segments used in accordance with the present invention are cut from the duplex fabric.
[0024] One aspect of this invention is manufacturing the preform from segments that have been cut from nonwoven fabric composed mainly of unidirectional continuous fiber. The nonwoven fabric will also contain a minor but significant percentage (typically, from 10 to 30 weight-%) of staple fiber, which provides structural integrity upon needle-punching. Excellent results may be obtained with a fabric made up, for example, of 85 weight-% unidirectional continuous fiber and 15 weight-% staple fiber. Generally, the fabric is composed of a carded needled punched staple web which has been needled to a layer of needle punched continuous tow. The resulting fabric is known as a duplex fabric.
[0025] The fiber used to produce this nonwoven fabric must be of a carbonaceous nature. Oxidized polyacrylonitrile (OPAN) fiber is particularly preferred, although other conventional fibers including thermoset pitch fibers, unoxidized polyacrylontrile fibers, carbon fibers, graphite fibers, ceramic fibers, and mixtures thereof, may be used. In accordance with the present invention, the fiber is used as a strand of continuous filaments, generally referred to as a “tow”. The staple fiber used in this invention may be selected from the same types of fibers as the continuous fiber. It need not necessarily be the same as the continuous fiber. However, OPAN fiber is preferred for the staple fiber too.
[0026] In implementing the present invention, segments having a segment arc of, for example, 68 degrees are cut from the fabric sheet, with the segment having the outside diameter and the inside diameter of the preform to be manufactured. Sixty-eight degree arcs are preferred, since this arc dimension minimizes butt joint overlap within the parts being manufactured. However, other arc dimensions may be used if desired.
[0027] The inside and outside diameters of the arc segments are chosen based upon the preform to be manufactured. For instance, rotor preforms can be manufactured from segments having an inside radius of 5.5 inches and an outside radius of 10.5 inches. Stator preforms can be manufactured from segments having an inside radius of 4.875 inches and an outside radius of 9.75 inches. Those skilled in the art will have no difficulty in setting the appropriate inside and outside diameters for the specific preform type to be manufactured.
[0028] These segments are then needled together following a helical lay-up pattern to a specified weight and dimension, based upon the desired preform density for the application. The fabric layers are interlocked by the staple fibers, which are transported by the needles into the z-direction.
[0029] Needling
[0030] Needling may be carried out with an annular needling machine such as that described in U.S. Pat. No. 5,388,320, the entire disclosure of which is hereby expressly incorporated by reference. Annular needling is the process of continuously placing individual fabric segments (one at a time) onto a rotating closed cell polymeric foam ring having the inside diameter and outside diameter of the desired annular shape to which the segments are needled. One example of such a ring has an inside diameter of 10 inches and an outside diameter of 20 inches. However, those skilled in the art will appreciate that such dimensions can be varied widely, depending upon the shape to be manufactured. The segments are laid end to end and are needled together following a helical lay-up pattern to a desired weight and dimension.
[0031] The foam ring base provides the rigid structure on which the first few layers of segments are needled. The needles penetrate through the layers of fabric and into the foam ring. These segments layers are mechanically bonded to the foam ring as z-direction fibers (mainly the staple fibers) are transported through the fabric layers into the foam. This provides the integrity needed to assemble the subsequent layers of segments as the structure is manufactured. As the layers of segments are built, the segments are no longer needled into the foam ring but into the previous layers of segments by mechanically interlocking fiber bundles between the fabric layers.
[0032] Preforms
[0033] This layer needling process forms a thick annular ring called a preform. As the preform grows in thickness, it is lowered to maintain the same needle penetration depth from layer to layer. The resultant preform is composed of many layers of segments that are mechanically bonded together during the needling process. Typical preforms are made up of from 15 to 35 layers. However, those skilled in the art will appreciate that fewer or many more layers may be used, depending upon the shape to be manufactured. The foam ring is removed at the end of the preforming process. A resulting preform ( 20 ) is depicted in FIG. 2, made up of multiple segments ( 21 ) each having a thickness ( 28 ). In FIG. 2, the segments are characterized by radial tow ( 25 ). They are joined to segment layers above and below by staple fibers ( 26 ) that have been needled into the z-direction (that is, perpendicular to the planes of the segments).
[0034] Two preform architectures using this new concept of radially oriented fibers at the friction surface have been manufactured in accordance with the present invention. One preform architecture of this invention provides segments in which the continuous fibers are oriented parallel to the segment arc bisectors. These segments are referred to as radial segments, and are depicted in FIG. 1A. The other preform architecture of this invention provides preforms manufactured from alternating layers of fabric segments that are angled—within a specified range—with respect to the continuous fibers derived from the unidirectional tow. FIG. 1B illustrates +45 degree fiber oriented segments and −45 degree fiber oriented segments. The “−45” degree fiber oriented segments used in accordance with this invention can be made by changing the die cut angle, as shown in FIG. 1B, or simply by inverting “+45” degree segments.
[0035] The first preform architecture is manufactured from segments with all of the continuous fibers oriented in the radial direction. This means that the unidirectional tow fibers run parallel to the segment arc bisector. In combination with the, e.g., 68 degree arc of the segment, the bias from layer to layer of the preform is set to inhibit linear faults forming along the fiber length in the radial direction.
[0036] The second preform architecture is manufactured using two different segment types. In the first segment type, the unidirectional tow fibers run at a +45 degree angle to the segment arc bisector and in the second segment type, the unidirectional tow fibers run at a −45 degree angle to the segment arc bisector. The segment lay-up for this preform follows a +/−45 degree orientation. This lay-up pattern is repeated throughout the layering of the preform. This preform architecture provides a more desirable bias from layer to layer to improve overall mechanical properties of the composite disc.
[0037] The preforms manufactured from these architectures are heat-treated to a very high temperature, for instance to above 1500° C., in an inert atmosphere to convert the fibers to carbon. The precise temperature and length of time can be varied widely, so long as it provides carbonization of the fibers in the preform. The preforms are then densified using conventional processes to deposit carbon matrices in the fibrous preform substrates.
[0038] Densification
[0039] Deposition of carbon on the substrate is effected by in situ cracking of a carbon bearing gas. This process is referred to as Carbon Vapor Deposition (CVD) or Carbon Vapor Infiltration (CVI)—these terms are interchangeable for purposes of the present invention. Alternatively, the substrate can be repeatedly impregnated with liquid pitch or carbon bearing resin and thereafter charring the resin.
[0040] Carbon vapor infiltration and deposition (CVI/CVD) is a well known process for depositing a binding matrix within a porous structure. The terminology “carbon vapor deposition” (CVD) generally implies deposition of a surface coating, but the term is also used to refer to infiltration and deposition of a matrix within a porous structure. As used herein, the terminology CVI/CVD is intended to refer to infiltration and deposition of a matrix within a porous structure. The technique is particularly suitable for fabricating high temperature structural composites by depositing a carbonaceous or ceramic matrix within a carbonaceous or ceramic porous structure. These composites are particularly useful in structures such as carbon/carbon aircraft brake discs, and ceramic combustor or turbine components. The generally known CVI/CVD processes may be classified into four general categories: isothermal, thermal gradient, pressure gradient, and pulsed flow.
[0041] In an isothermal CVI/CVD process, a reactant gas passes around a heated porous structure at absolute pressures as low as a few millitorr. The gas diffuses into the porous structure driven by concentration gradients and cracks to deposit a binding matrix. This process is also known as “conventional” CVI/CVD. The porous structure is heated to a more or less uniform temperature, hence the term “isothermal,” but this is actually a misnomer. Some variations in temperature within the porous structure are inevitable due to uneven heating (essentially unavoidable in most furnaces), cooling of some portions due to reactant gas flow, and heating or cooling of other portions due to heat of reaction effects. In essence, “isothermal” means that there is no attempt to induce a thermal gradient that preferentially affects deposition of a binding matrix. This process is well suited for simultaneously densifying large quantities of porous articles and is particularly suited for making carbon/carbon brake discs.
[0042] In a thermal gradient CVI/CVD process, a porous structure is heated in a manner that generates steep thermal gradients which induce deposition in a portion of the porous structure. The thermal gradients may be induced by heating only one surface of a porous structure, for example by placing a porous structure surface against a susceptor wall, and may be enhanced by cooling an opposing surface, for example by placing the opposing surface of the porous structure against a liquid cooled wall. Deposition of the binding matrix progresses from the hot surface to the cold surface.
[0043] In a pressure gradient CVI/CVD process, the reactant gas is forced to flow through the porous structure by inducing a pressure gradient from one surface of the porous structure to an opposing surface of the porous structure. Flow rate of the reactant gas is greatly increased relative to the isothermal and thermal gradient processes, which results in increased deposition rate of the binding matrix. This process is also known as “forced-flow” CVI/CVD. An annular porous wall may be formed, using this process, from a multitude of stacked annular discs (for making brake discs) or as a unitary tubular structure.
[0044] Finally, pulsed flow CVI/CVD involves rapidly and cyclically filling and evacuating a chamber containing the heated porous structure with the reactant gas. The cyclical action forces the reactant gas to infiltrate the porous structure and also forces removal of the cracked reactant gas by-products from the porous structure.
[0045] In all of these variants of the CVI/CVD process, carbon deposition is continued until a preset density is achieved for the friction material application. Following the densification process, a final heat treatment may be performed to set the thermal, mechanical, and frictional properties desired for the composite.
EXAMPLES
Example 1
[0046] A preform is manufactured totally from segments in which the continuous fibers are oriented parallel to the segment arc bisector. These segments are referred to as radial segments, and are depicted in FIG. 1. Needling is carried out with a conventional annular needling machine. Individual fabric segments are placed one at a time onto a rotating closed cell polymeric foam ring having the inside diameter and outside diameter of the annular shape of the preform being manufactured. The segments are laid end to end and needled together following a helical lay-up pattern to a desired weight and dimension. As the preform grows in thickness, it is lowered to maintain the same needle penetration depth from layer to layer. The resultant preform is composed of many layers of segments that are mechanically bonded together during the needling process. The foam ring is removed at the end of the performing process. The resulting preform is depicted schematically in FIG. 2.
Example 2
[0047] A preform was manufactured from alternating layers of +45 degree fiber oriented segments and −45 degree fiber oriented segments. An oxidized polyacrylonitrile fiber sold under the trade name Panox by SGL was used for both the continuous fiber and the staple fiber. The fabric was a duplex fabric composed of a carded needle punched staple web which had been needled to a layer of needle punched continuous tow. Segment thickness in the free stage form before the preform assembly needling process was 3-4 mm. Two different size segments were used in the manufacture of the preforms of this Example. Rotor preforms were manufactured from segments having an inside radius of 5.5 inches and on outside radius of 10.5 inches. Stator preforms were manufactured from segments having an inside radius of 4.875 inches and an outside radius of 9.75 inches. Both segments types were manufactured using the 68 degree arc. The number of segment layers in the preforms used in this Example ranged form 26 to 32. These segments were derived from +45 degree and −45 degree segments like those depicted in FIG. 1B. In this embodiment of the invention, the continuous fibers were at a +45 degree fiber angle to the segment arc bisector in half of the layers of the preform, and each of the +45 degree segment layers was separated from other +45 degree segment layers by a −45 degree segment layer. The −45 orientation was achieved by inverting +45 degree segments.
[0048] Needling was carried out with a conventional annular needling machine. Individual fabric segments were placed one at a time onto a rotating closed cell polymeric foam ring having the inside diameter and outside diameter of the annular shape of the preform being manufactured. The segments were laid end to end and needled together following a helical lay-up pattern to a desired weight and dimension. As the preform grew in thickness, it was lowered to maintain the same needle penetration depth from layer to layer. The resultant preform was composed of many layers of segments that are mechanically bonded together during the needling process. The foam ring was removed at the end of the preforming process. The resulting preform is depicted schematically in FIG. 2.
[0049] The preforms manufactured from these architectures were heat-treated to a approximately 1500° C., in an inert atmosphere, to convert the fibers to carbon. The performs were then densified with a mixed hydrocarbon gas, using a forced flow CVI/CVD process to deposit carbon matrices in the fibrous preform substrates. Finally, the densified preforms were heated again to above 1500° C. to set desired thermal, mechanical, and frictional properties for the composite.
Example 3
[0050] Full size aircraft brake discs were made following the +/−45 degree architecture procedure of Example 2. The discs were configured in standard B767-300 geometry. The full scale brake was of a four rotor configuration. That is, the brake was composed of 4 rotors, 3 stators, 1 pressure plate, and 1 backing plate. The approximate dimensions of the components were as follows:
Outside Diameter Inside Diameter Thickness Brake part (inches) (inches) (inches) Rotor 18.13 11.00 1.06 Stator 16.75 10.00 1.06 Pressure plate 16.75 10.00 0.97 Backing plate 16.75 11.00 0.80
[0051] These discs were subjected to a Wear test designed to mimic a standard commercial aircraft usage spectrum, including cold taxi stops (representing pre-takeoff taxi stops), a landing stop, and a series of hot taxi stops (representing post-landing taxi stops as the aircraft approaches the gate). Wear test landing energies are distributed between various energy levels representing the variations in aircraft loadings which occur in actual commercial service.
[0052] The Wear test was run as follows:
[0053] Sequence #1—nine cold taxis, 50% service energy (1.463 Mft-lbs) landing stop, seven hot taxis. (Sequence repeated 120 times.)
[0054] Sequence #2—nine cold taxis, 75% service energy (2.194 Mft-lbs) landing stop, seven hot taxis. (Sequence repeated 60 times.)
[0055] Sequence #3—nine cold taxis, 100% service energy (2.925 Mft-lbs) landing stop, seven hot taxis. (Sequence repeated 20 times.)
[0056] Each test was run once in a Single Rotor Brake configuration and once in a Full Brake configuration. For the Single Rotor Brake test, the resulting wear was only 84 micro-inches/surface/sequence, and for the Full Brake test, the resulting wear was only 92 micro-inches/surface/sequence. In comparison, conventional B767 brake discs show a wear in these tests of 154 micro-inches/surface/sequence.
[0057] It is to be understood that the foregoing description and specific embodiments are merely illustrative of the principles of the invention. Modifications and additions to the invention may easily be made by those skilled in the art without departing from the spirit and scope of the invention as it is recapitulated in the appended claims. | Carbon fiber brake preforms ( 20 ), specifically, annular discs built up of fabric arc segments ( 21 ) composed of continuous fibers ( 25 ) and staple fibers ( 26 ). Most of the continuous fibers ( 25 ) in the fabric segments ( 21 ) are arranged to be located within 60° of radially from the inner diameter to the outer diameter of the annular disc ( 20 ). The fabric arc segments have substantially all of their continuous fibers oriented in the radial direction and parallel to the segment arc bisector, or the segments are arranged in alternating layers in which, respectively, half the continuous fibers are oriented at a +45 degree angle with respect to the segment arc bisector and half the continuous fibers are oriented at a −45 degree angle with respect thereto. Methods for making preform composites comprise providing needle-punched nonwoven fabric of unidirectional continuous fibers and staple fibers, making a plurality of fabric segments, arranging the segments in a multilayered intermediate, heating the multilayered intermediate to convert the fibers to carbon, and densifying the carbonized product. In brake discs made as described, fiber pull-out is minimized, reducing mechanical wear. The disclosed preform fiber architecture reduces wear rates while maintaining brake disc strength. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 12/308,307, which is a U.S. national stage application of PCT/US2005/046772, filed on Dec. 21, 2005, which claims the benefit of provisional Application No. 60/638,177 filed Dec. 23, 2004. Each of these applications in incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to an integrated nucleic acid test cartridge capable of performing extraction, amplification and detection together. It also relates to devices and methods for nucleic acid extraction alone, or extraction and amplification combined. Furthermore, it relates to devices and methods for amplification and detection combined. The cartridge may be equipped with a sensing means including enabling optical and electrochemical detection methods and it may also be equipped with a wax or absorbent filter extraction feature to separate target nucleic acid from the sample. The cartridge can perform various methods of amplification including polymerase chain reaction, rolling circle amplification and strand displacement amplification. The present invention also addresses novel amplification methods and reagents comprising single modified primers or pairs of modified primers, depending on the selected amplification method. Furthermore the present invention provides for integrated electrophoretic separation for primers from amplicons during a nucleic acid test.
BACKGROUND OF THE INVENTION
General Background on the Value of Nucleic Acid Testing
[0003] Applications of nucleic acid testing are broad. The majority of current commercial testing relates to infectious diseases including Chlamydia, gonorrhea, hepatitis and human immunodeficiency virus (HIV) viral load; genetic diseases including cystic fibrosis; coagulation and hematology factors including hemochromatosis; and cancer including genes for breast cancer. Other areas of interest include cardiovascular diseases and drug resistance screening, termed pharmacogenomics. The majority of testing currently occurs in centralized laboratories using non-portable and operationally complex instruments. Presently, tests generally require highly skilled individuals to perform the assays. As a result, the time taken between obtaining a sample suspected of containing a specific nucleic acid fragment and determining its presence or absence is often several hours and even days. However, as with other kinds of blood tests, physicians and others often require results more quickly and obtainable in a convenient user-friendly format. Consequently, there is a need for a portable analysis system capable of performing nucleic acid testing quickly and conveniently. A discussion of prior art relating to various aspects of nucleic acid testing is provided in the following sections.
Methods to Characterize Genetic Information
[0004] The clinical manifestation of a particular genetic characteristic can be different with different types or classes of genetic based diseases. This translates into different approaches to measure the genetic characteristic including SNP mutation detection, gene copy mutations and gene overexpression mutations. For example, some diseases such as hemochromatosis, cystic fibrosis or the oncogene p53, have one or a few very specific mutations which affect only a specific nucleotide. Considering hemochromatosis, there are two specific mutations. The clinical manifestation of this disease is an accumulation of iron in various tissues, which can be fatal if untreated. The most prevalent mutation is the G to A transition at nucleotide 845 in the gene, also known as (C282Y). See OMIM: Online Mendelian Inheritance in Man database, which can be found at the U.S. National Center for Biologic Information internet site. The second most prevalent mutation in the same hemochromatosis gene is a C to G transversion in exon 2, known as H63D. These are known as single nucleotide polymorphisms (SNPs). As every individual has two copies of each gene, the possible combinations of these genes are two wild type (homozygous wild type), two mutated genes (homozygous mutant) or one wild type and one mutated gene (heterozygous). In the case of hemochromatosis, individuals who are homozygous mutant exhibit the disease state, heterozygous individuals can be susceptible for some aspects of the disease as they accumulate higher levels of iron than do homozygous wildtype individuals. Also, for the purpose of determining if an individual is a carrier of the disease to their offspring, the ability to determine that an individual is heterozygous can be useful.
[0005] As a result, in testing for a genetic disease like hemochromatosis, it is useful to be able to have at least four analytical means or channels for detection. Here, one channel detects the presence of wild type C282, a second channel detects the presence of the mutant Y282 gene, a third channel detects the presence of the wildtype H63 gene and the fourth channel detects the presence of the mutant D63 gene. FIG. 12 provides a table of possible outcomes from a hemochromatosis test of this type and shows that it is possible to differentiate between homozygous or heterozygous, and that homozygous channels generate roughly twice the level of expression and thus signal in the test. Note that it is also useful to have one or more additional channels to use as positive and negative controls.
[0006] Some genetic mutations include multiple copies of the gene being present in the genome, causing a disease state in a patient. As an example the oncogene ZNF217 mapped within 20q13.2 has been found in multiple copies in individuals with colon cancer (Rooney et al., 2004, J. Pathol. Vol 204(3):282). Genetic triplication of the alpha-synuclein gene (SNCA) has been reported to cause hereditary early-onset Parkinsonism with dementia (Chartier-Harlin et al., 2004, Lancet, vol 364(9440):1167). Yamashita et al., 2004, European Neurology, vol 52(2): 101, have found that there is an increase in adult-onset Type III spinal muscular atrophy related to increased gene copies of the survival motor neuron (SMN2) gene. These gene copy mutations can be detected by using one or more required genes, such as the housekeeping genes (e.g. actin or glyceraldehyde˜3-phosphate dehydrogenase). Overexpression mutations typically generate increased levels of mRNA and these can be detected.
Methods and Apparatuses for Extraction of Nucleic Acid
[0007] Nucleic acids found in cells can be deoxyribonucleic acid or ribonucleic acid and can be genomic DNA, extrachromosomal DNA (e.g. plasmids and episomes), mitochondrial DNA, messenger RNA and transfer RNA. Nucleic acids can also be foreign to the host and contaminate a cell as an infectious agent, e.g. bacteria, viruses, fungi or single celled organisms and infecting multicellular organisms (parasites). Recently, detection and analysis of the presence of nucleic acids has become important for the identification of single nucleotide polymorphisms (SNPs), chromosomal rearrangements and the insertion of foreign genes. These include infectious viruses, e.g. HIV and other retroviruses, jumping genes, e.g. transposons, and the identification of nucleic acids from recombinantly engineered organisms containing foreign genes, e.g. Roundup Ready™ plants.
[0008] The analysis of nucleic acids has a wide array of uses. For example, the presence of a foreign agent can be used as a medical diagnostic tool. The identification of the genetic makeup of cancerous tissues can also be used as a medical diagnostic tool, confirming that a tissue is cancerous, and determining the aggressive nature of the cancerous tissue. Chromosomal rearrangements, SNPs and abnormal variations in gene expression can be used as a medical diagnostic for particular disease states. Further, genetic information can be used to ascertain the effectiveness of particular pharmaceutical drugs, known as the field of pharmacogenomics. Genetic variations between humans and between domestic animals can also be ascertained by DNA analysis. This is used in fields including forensics, paternity testing and animal husbandry.
[0009] Methods of extracting nucleic acids from cells are well known to those skilled in the art. A cell wall can be weakened by a variety of methods, permitting the nucleic acids to extrude from the cell and permitting its further purification and analysis. The specific method of nucleic acid extraction is dependent on the type of nucleic acid to be isolated, the type of cell, and the specific application used to analyze the nucleic acid. Many methods of isolating DNA are known to those skilled in the art, see for example the general reference Sambrook and Russell, 2001, “Molecular Cloning: A Laboratory Manual”. For example, the prior art contains examples of chemically-impregnated and dehydrated solid-substrates for the extraction and isolation of DNA from bodily fluids that employ lytic salts and detergents and which contain additional reagents for long-term storage of DNA samples e.g. U.S. Pat. No. 5,807,527 detailing FTA paper and U.S. Pat. No. 6,168,922 detailing Isocard Paper. The prior art also contains examples of particle separation methods, e.g. U.S. Pat. No. RE37,891.
[0010] Methods of isolating RNA, particularly messenger RNA (mRNA) are well known to those skilled in the art. Typically, cell disruption is performed in the presence of strong protein denaturing solutions, which inactivate RNAses during the RNA isolation procedure. RNA is then isolated using differential ethanol precipitation with centrifugation. As is well known, RNA is extremely labile and is sensitive to alkaline conditions, as well as RNAses, which degrade RNA. RNAses are ubiquitous within the environment and it has been found that they are difficult to remove from solutions and containers used to isolate RNA.
Methods and Apparatuses for Amplification of Nucleic Acid
[0011] Polymerase Chain Reaction (PCR) is inhibited by a number of proteins and other contaminants that follow through during the standard methods of purification of genomic DNA from a number of types of tissue samples. It is known that additional steps of organic extraction with phenol, chloroform and ether or column chromatography or gradient CsC1 ultracentrifugation can be performed to remove PCR inhibitors in genomic DNA samples from blood. However, these steps add time, complexity and cost. This complexity limits incorporation into a simple disposable cartridge useful for nucleic acid analysis. Therefore, the development of new simple methods to overcome inhibitors found in nucleic acid samples used for nucleic acid amplification processes is desirable.
[0012] Nucleic acid hybridization is used to detect discernible characteristics about target nucleic acid molecules. Techniques like the “Southern analysis” are well known to those skilled in the art. Target nucleic acids are electrophoretically separated then bound to a membrane. Labeled probe molecules are then permitted to hybridize to the nucleic acids bound to the membrane using techniques well known in the art. This method is limited, because the sensitivity of detection is dependent on the amount of target material and the specific activity of the probe. As the probe's specific activity may be fixed, to improve the sensitivity of these assays, methods of amplifying nucleic acids are employed. Two basic strategies are employed for nucleic acid amplification techniques; either the number of target copies is amplified, which in turn increases the sensitivity of detection, or the presence of the nucleic acid is used to increase a signal generated for detection. Examples of the first approach are polymerase chain reaction (PCR), rolling circle (see U.S. Pat. No. 5,854,033), and nucleic acid system based amplification (NASBA). Examples of the second include, cycling probe reaction, termed CPR (see U.S. Pat. No. 4,876,187 and U.S. Pat. No. 5,660,988) and SNPase assays, e.g. the Mismatch Identification DNA Analysis System (see U.S. Pat. No. 5,656,430 and U.S. Pat. No. 5,763,178).
[0013] The PCR reaction is well known to those skilled in the art and was originally described in U.S. Pat. No. 4,683,195. The process involves denaturing nucleic acid, a hybridization step and an extension step in repeated cycles and is performed by varying the temperature of the nucleic acid sample and reagents. This process of subjecting the samples to different temperatures can be effected by placing tubes into different temperature water baths, or by using peltier-based devices capable of generating heating or cooling, dependent on the direction of the electrical current as described in U.S. Pat. No. 5,333,675 and U.S. Pat. No. 5,656,493. Many commercial temperature cycling devices are available, sold for example by Perkin Elmer, Applied Biosystems and Eppendorf. As these devices are generally large and heavy they are not generally amenable to use in non-laboratory environments, e.g. at the point-of-care.
[0014] A microfabricated device for performing the polymerase chain reaction is described in U.S. Pat. No. 5,639,423 though it is silent on providing an integrated means for extracting nucleic acids. A device for performing the polymerase chain reaction is described in U.S. Pat. No. 5,645,801 which has an amplification chamber that can be mated in a sealable manner to a chamber for detection. U.S. Pat. No. 5,939,312 describes a miniaturized multi-chamber polymerase chain reaction device. U.S. Pat. No. 6,054,277 describes a silicon-based miniaturized genetic testing platform for amplification and detection. A polymer-based heating component for amplification reactions is described in U.S. Pat. No. 6,436,355. U.S. Pat. No. 6,303,288 describes an amplification and detection system with a rupturable pouch containing reagents for amplification. U.S. Pat. No. 6,372,484 describes an apparatus for performing the polymerase chain reaction and subsequent capillary electrophoretic separation and detection in an integrated device.
[0015] There are several nucleic acid amplification technologies that differ from the PCR reaction in that the reaction is run at a single temperature. These isothermal methods include the cycling probe reaction, strand displacement, Invader™, SNPase, rolling circle reaction and NASBA. U.S. Pat. No. 6,379,929 describes a device for performing an isothermal nucleic acid amplification reaction.
[0016] More recently, a strategy for performing the polymerase chain reaction isothermally has been described by Vincent et al., 2004, EMBO Reports, vol 5(8), see also US Application 20040058378. A DNA helicase enzyme is used to overcome the limitations of heating a sample to perform PCR DNA amplification.
Enzymes Used for the Polymerase Chain Reaction (PCR)
[0017] The polymerase chain reaction (PCR) is based on the ability of a DNA polymerase enzyme to exhibit several core features, which include its ability to use a primer sequence with a 3′-hydroxyl group and a DNA template sequence and to extend a newly synthesized strand of DNA using the template strand, all well known to those skilled in the art. In addition, DNA polymerases used in the PCR reaction must be able to withstand high temperatures (e.g. 90 to 99° C.) used to denature double stranded DNA templates, as well as be inactive at lower temperatures (e.g. 40 to 60° C.) at which DNA primers hybridize to the DNA template. Further, to have optimal DNA synthesis at a temperature near to the hybridization temperature (e.g. 60 to 80° C.).
[0018] In addition to these core characteristics, DNA polymerases also exhibit proofreading capabilities, which are due to the 3′-5′ exonuclease activity inherent in most DNA polymerases. For the purpose of single nucleotide polymorphism (SNP) detection based on differential primer extension using PCR (also called 3′-allele specific primer extension), it is a disadvantage to use an enzyme that exhibits a 3′-5′ exonuclease activity, as the terminal 3′ nucleotide can be excised from a standard nucleic acid primer, permitting synthesis of both alleles.
[0019] Zhang et al., (2003, Laboratory Investigation, vol 83(8):1147) describe the use of a terminal phosphorothioate bond to overcome the limitations of DNA polymerases used for 3′-5′ exonuclease activity. The phosphorothioate bond is not cleaved by 3′-5′ exonucleases. This prevents DNA polymerases with 3′-5′ exonuclease activities from removing the terminal mismatch and proceeding with DNA elongation, alleviating the lack of discrimination observed with normal DNA.
[0020] Another characteristic of DNA polymerases is their elongation rate. Takagi et al., (1997, Applied and Environmental Microbiology, vol 63(l1): 4504) teach that Pyrococcus sp. Strain KOD1 (now Thermococcus kodakaraensis KOD1), Pyrococcus furiosus , Deep Vent (New England Biolabs, Beverly, Mass.), and Thermus aquaticus have elongation rates of 106 to 138, 25, 23 and 61 bases/second, respectively. The processivity rates of these enzymes are also described, and behave similarly to the elongation rates. Clearly, Thermococcus kodakaerensis KOD1 has much higher elongation and processivity rates compared to the other well-known enzymes, which would make this enzyme beneficial in applications where sensitivity and speed are an issue. Further, Thermococcus kodakaerensis KOD1 possesses an exonuclease activity which would be detrimental for use in a 3′-allele specific primer extension assay used for SNP analysis.
Design of Synthetic Oligonucleotides
[0021] Regarding the design of synthetic oligonucleotides for use in amplification reactions, Rychlik et al., (1989, Nucleic Acids Research, vol 17(21):8543-8551) and Rychlik ( 1995 , Molecular Biotechnology, vol 3: 129-134), describe selection criteria and computer programs to design probes and primers, including primers for in vitro amplification of DNA. Both teach that primers should not generate secondary structure or exhibit self-hybridization.
[0022] PCR primers designed as molecular beacons (Bonnet et al., 1999, Proc. Natl. Acad. Sci. USA, vol 96: 6171-6176) have a short region at both the 5′ and 3′ ends which are complementary generating what is known as hairpin loop structures, to quench the fluorescent signal by placing the donor and quencher molecules in close physical proximity to each other. After polymerization and incorporation into a newly synthesized double stranded molecule, the donor and quencher molecules are physically distant to each other, permitting the generation of a fluorescent signal. The region of complementarity is short and typically has only about 5 nucleotides which are complementary, preferably generating a hairpin stem. Tsourkas et al., 2003, Nucleic Acids Research, vol 31(4):1319-1330, teaches that molecular beacons with longer stem lengths have an improved ability to discriminate between targets over a broader range of temperatures. However, this is accompanied by a decrease in the rate of molecular beacon-target hybridization. Molecular beacons with longer probe lengths tend to have lower dissociation constants, increased kinetic rate constants and decreased specificity. Therefore, having longer stem loops will have an impact on reducing the efficiency of hybridization kinetics, which in turn will reduce the levels of PCR amplification. Therefore, PCR using a stem loop structure is generally undesirable in the art. Kaboev et al., (2000, Nucleic Acids Research, vol 28(21):e94) teaches that designing a PCR primer with a stem loop structure by adding additional sequences to the 5′-end of the primer, which are complementary to the 3′-end. This reference also teaches that adding this secondary structure increases the specificity of the PCR reaction, though it does use a PCR primer that permits the generation of single stranded tails. Further, Kaboev does not teach that the generation of the secondary structure prevents the hybridization of the single stranded regions to a capture moiety.
Detection Methods
[0023] Conventional detection methods for the final step in a nucleic acid analysis are well known in the art and include sandwich-type capture methods based on radioactivity, colorimetry, fluorescence, fluorescence resonance energy transfer (FRET) and electrochemistry. For example, jointly owned U.S. Pat. No. 5,063,081 covers a sensor for nucleic acid detection. The sensor has a permselective layer over an electrode and a proteinaceous patterned layer with an immobilized capture oligonucleotide. The oligonucleotide can be a polynucleotide, DNA, RNA, active fragments or subunits or single strands thereof. Coupling means for immobilizing nucleic acids are described along with methods where an immobilized nucleic acid probe binds to a complimentary target sequence in a sample. Detection is preferably electrochemical and is based on a labeled probe that also binds to a different region of the target. Alternatively, an immobilized antibody to the hybrid formed by a probe and polynucleotide sequence can be used along with DNA binding proteins. The '081 patent incorporates by reference the jointly owned U.S. Pat. No. 5,096,669 which covers a single-use cartridge for performing assays in a sample using sensors. These sensors can be of the type described in '081.
[0024] Other divisional patents related to '081 include U.S. Pat. No. 5,200,051 which covers a method of making a plurality of sensors with a permselective membrane coated with a ligand receptor that can be a nucleic component. U.S. Pat. No. 5,554,339 covers microdispensing, where a nucleic acid component is incorporated into a film-forming latex or a proteinaceous photoformable matrix•for dispensing. U.S. Pat. No. 5,466,575 covers methods for making sensors with the nucleic component incorporated into a film-forming latex or a proteinaceous photoformable matrix. U.S. Pat. No. 5,837,466 covers methods for assaying a ligand using the sensor components including nucleic components. For example, a quantitative oligonucleotide assay is described where the target binds to a receptor on the sensor and is also bound by a labeled probe. The label is capable of generating a signal that is detected by the sensor, e.g. an electrochemical sensor. U.S. Pat. No. 5,837,454 covers a method of making a plurality of sensors with a permselective membrane coated with a ligand receptor that can be a nucleic component. Finally, jointly owned U.S. Pat. No. 5,447,440 covers a coagulation affinity-based assay applicable to nucleotides, oligonucleotides or polynucleotides. These jointly owned patents are incorporated herein by reference.
[0025] It is noteworthy that jointly owned U.S. Pat. No. 5,609,824 discloses a thermostated chip for use within a disposable cartridge applicable to thermostating a sample, e.g. blood, to 37° C. Jointly owned U.S. Pat. No. 6,750,053 and pending US 20030170881 address functional fluidic elements of a disposable cartridge relevant to various tests including DNA analyses. These additional jointly owned patents and applications are incorporated herein by reference. Several other patents address electrochemical detection of nucleic acids, for example U.S. Pat. No. 4,840,893 discloses detection with an enzyme label that uses a mediator, e.g. ferrocene. U.S. Pat. No. 6,391,558 discloses single stranded DNA on the electrode that binds to a target, where a reporter group is detected by the electrode towards the end of a voltage pulse and uses gold particles on the electrode and biotin immobilization. U.S. Pat. No. 6,346,387 discloses another mediator approach, but with a membrane layer over the electrode through which a transition metal mediator can pass. U.S. Pat. No. 5,945,286 is based on electrochemistry with intercalating molecules. U.S. Pat. No. 6,197,508 discloses annealing single strands of nucleic acid to form double strands using a negative voltage followed by a positive voltage. Similar patents include U.S. Pat. No. 5,814,450, U.S. Pat. No. 5,824,477, U.S. Pat. No. 5,607,832 arid U.S. Pat. No. 5,527,670 which disclose electrochemical denaturation of double stranded DNA. U.S. Pat. No. 5,952,172 and U.S. Pat. No. 6,277,576 disclose DNA directly labeled with a redox group.
[0026] Several patents address devising cartridge-based features or devices for performing nucleic acid analyses, these include for example a denaturing device U.S. Pat. No. 6,485,915, an integrated fluid manipulation cartridge U.S. Pat. No. 6,440,725, a microfluidic system U.S. Pat. No. 5,976,336 15 and a microchip for separation and amplification U.S. Pat. No. 6,589,742.
[0027] Based on the forgoing description there is a need for a convenient and portable analysis system capable of performing nucleic acid testing.
OBJECTS OF THE INVENTION
[0028] An object of the invention is to provide an integrated nucleic acid test cartridge capable of performing extraction, amplification and detection.
[0029] A further object of the invention is to provide an integrated nucleic acid test cartridge with optical and electrochemical detection.
[0030] A further object of the invention is to provide an integrated nucleic acid test cartridge with an extraction step based on filter extraction or on particle transit through a layer that is immiscible with an aqueous fluid.
[0031] A further object of the invention is to provide an integrated nucleic acid test cartridge capable of performing extraction and amplification.
[0032] A further object of the invention is to provide an integrated nucleic acid test cartridge capable of performing amplification and detection.
[0033] An object of the invention is to provide an integrated cartridge for nucleic acid testing that operates in conjunction with a reader instrument.
[0034] An object of the invention is to provide an integrated nucleic acid testing system and method suitable for analyses performed at the bedside, in the physician's office and other locations remote from a laboratory environment where testing is traditionally performed.
[0035] An object of the invention is to provide a device and method of nucleic acid extraction from a sample with a purification step involving particle transit through a layer that is immiscible with an aqueous fluid.
[0036] An object of the invention is to provide a device and method of filter-based nucleic acid extraction from a sample with an elution step prior to amplification.
[0037] An object of the invention is to provide a simple method and component for separating nucleic acid from a sample suitable for integration into a device for performing genetic analyses.
[0038] An object of the invention is to provide electrophoretic separation of primers from amplicons after amplification capable of integration with a nucleic acid testing cartridge.
[0039] An object of the invention is to provide a DNA polymerase enzyme that generates the most synthesis in the shortest time period, therefore a DNA polymerase with an elongation rate of over 100 bases per second or a processivity rate of over 300 bases.
[0040] It is another object of the invention to provide a DNA polymerase enzyme that functions in a miniaturized thermocycler device in a short time period.
SUMMARY OF THE INVENTION
[0041] The invention comprises reagents and methods for the amplification of nucleic acid sequences and their use in the detection of nucleic acids. In one embodiment, the invention is a self-annealing oligonucleotide primer for use in a nucleic acid amplification assay, comprising: a primer region; a polymerase blocking region; and a single stranded hybridization region, wherein said primer predominantly comprises a secondary structure in solution in a first temperature range and not in a second, higher temperature range and said primer is capable of binding a target nucleic acid in said second temperature range and not in said first temperature range, and said secondary structure involves one or more self-complimentary regions between portions of said primer region and portions of said single stranded hybridization region which hybridize, in at least one of an intra-molecular and an inter-molecular manner, in said first temperature range and not in said second temperature range.
[0042] In another embodiment, the method of the invention comprises a method of performing a nucleic acid amplification assay comprising: (a) combining reagents, DNA polymerase, a target nucleic acid, and a modified primer, said modified primer comprising a sequence of bases complimentary to a first region of said target nucleic acid, a polymerase blocking region, a single stranded hybridization region attached to said polymerase blocking region, and a detectable label, said primer predominantly having a secondary structure in solution in a lower temperature range and not in an elevated temperature range, wherein said secondary structure involves annealing one or more self-complimentary regions between portions of said primer region and portions of said single stranded hybridization region, wherein said modified primer is capable of priming said target nucleic acid and hybridizing with an oligonucleotide complimentary to said single stranded hybridization region at a first elevated temperature range, and substantially not in a second lower temperature range; (b) cycling the mixture of (a) at said first temperature range to provide multiple copies of an amplicon incorporating said modified primer, wherein said incorporated primer is capable of hybridizing with an oligonucleotide complimentary to said single stranded hybridization region in said first elevated temperature range and in said second lower temperature range; (c) reducing the temperature of the mixture to the second temperature range; (d) exposing said mixture to a capture oligonucleotide complimentary to said single stranded hybridization region; (e) hybridizing said single stranded hybridization region of said amplicon incorporating said modified primer, with said capture oligonucleotide, and (f) detecting said label associated with said hybridization.
[0043] In yet another embodiment, the method of the invention comprises a method of performing a nucleic acid amplification assay comprising: (a) combining reagents, DNA polymerase, a target nucleic acid, a modified primer and a second primer, said modified primer comprising a sequence of bases complimentary to a first region of said target nucleic acid, a polymerase blocking region and a single stranded hybridization region attached to said polymerase blocking region, said primer predominantly having a secondary structure in solution in a lower temperature range and not in an elevated temperature range, wherein said secondary structure involves annealing one or more self-complimentary regions between portions of said primer region and portions of said single stranded hybridization region, wherein said modified primer is capable of priming said target nucleic acid and hybridizing with an oligonucleotide complimentary to said single stranded hybridization region at a first elevated temperature range, and substantially not in a second lower temperature range, said second primer comprising a sequence of bases complimentary to a second region of said target nucleic acid and having a detectable label; (b) cycling the mixture of (a) at said first temperature range to provide multiple copies of an amplicon incorporating said modified primer and said second primer, wherein said incorporated modified primer is capable of hybridizing with an oligonucleotide complimentary to said single stranded hybridization region in said first elevated temperature range and in said second lower temperature range; (c) reducing the temperature of the mixture to the second temperature range; (d) exposing said mixture to a capture oligonucleotide complimentary to said single stranded hybridization region; (e) hybridizing said single stranded hybridization region of said amplicon incorporating said modified primer, with said capture oligonucleotide; and (f) detecting said label associated with said second primer incorporated into said amplicon.
[0044] In certain embodiments, the target nucleic acid is selected from the group consisting of deoxyribonucleic acid and ribonucleic acid and modifications and derivatives thereof and in others, the target nucleic acid is extracted from blood, a buccal swab, tissue, a bodily fluid, an environmental sample, a surface of a material, a plant, an animal, a bacteria and a fungi.
[0045] In some embodiments of the invention, the reagents comprise reagents for a polymerase chain reaction amplification. In certain embodiments, the DNA polymerase is Taq polymerase. In other embodiments, the DNA polymerase is thermococcus kodakiensis polymerase.
[0046] In some embodiments, the primer is selected from the group deoxyribonucleic acid, ribonucleic acid, peptide nucleic acid, PEG-modified nucleic acid and hexa-polyethylene glycol modified nucleic acid.
[0047] In other embodiments, the polymerase blocking region is a phosphoramidite and in still others, the polymerase blocking region comprises 18-O dimethoxyltritylhexaethyleneglycol,1-[(2-cyanoethyl)-(N,N-diisopropyl)]-phosphoramidite.
[0048] In certain embodiments, the single stranded hybridization region is selected from the group consisting of nucleic acids, ribonucleic acids, peptide nucleic acids, modified nucleic acids. In other embodiments, the sequence of bases complimentary to a first region has a reactive 3′-hydroxyl.
[0049] According to some embodiments of the invention, the detectable label is selected from the group consisting of biotin, streptavidin, FAM, DNP, cholesterol, and a DNA glycoconjugate.
[0050] In certain embodiments, the detectable label is biotin. The detection may be electrochemical, an optical method, colorimetric, fluorescent, and/or enzymatic.
[0051] In certain embodiments of the invention, the capture oligonucleotide is immobilized on an optical surface. In others, the capture oligonucleotide is immobilized on a bead. In still other embodiments, the capture oligonucleotide is immobilized on an electrode. In some embodiments, the single stranded hybridization region of the modified primer hybridizes to the capture oligonucleotide.
[0052] In some embodiments, the cycling is isothermal. In other embodiments, the cycling is between a first and second temperature.
[0053] In certain embodiments, the label is exposed to a second moiety which has a second label, said second moiety binding specifically to the first label, wherein detection involves detection of said second label. In other embodiments, the label is exposed to a second moiety which has a second label, said second moiety binding specifically to said first label, wherein detection involves detection of said second label, wherein said label is selected from the group alkaline phosphatase, glucose oxidase, sarcosine oxidase, cholesterol oxidase, uricase, L-amino acid oxidase, D-amino acid oxidase, urease, ascorbate oxidase, horseradish peroxidase and luciferase. In certain embodiments, the label is biotin and is exposed to a streptavidin-labeled alkaline phosphatase and detection of said label is based on detection of alkaline phosphatase activity. In still other embodiments, the label is biotin and is exposed to a streptavidin-labeled alkaline phosphatase and detection of biotin is based on detection of said alkaline phosphatase, wherein alkaline phosphatase converts p-aminophenol phosphate to p-aminophenol and is detected electrochemically.
[0054] The present invention particularly addresses expanding opportunities for point-of-care diagnostic testing, i.e. testing that is rapid, inexpensive and convenient using small volumes of accessible bodily fluids such as for example blood or buccal cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIG. 1 shows nucleic acid purification in a tube using a lytic buffer layer, a wax layer and magnetic beads.
[0056] FIG. 2 shows a polyacrylamide gel of PCR products with and without beads and with and without blood, and also purified DNA controls.
[0057] FIG. 3 shows a polyacrylamide gel of PCR products with beads and blood.
[0058] FIG. 4( a )-( d ) show different perspectives of the filter holder.
[0059] FIG. 5 shows PCR amplification of a buccal swab sample isolated from a filter.
[0060] FIG. 6 shows a topological representation of the integrated single-use device and its interaction with the instrument.
[0061] FIG. 7( a ) shows a schematic of the PCR amplification method, FIG. 7( b ) shows a schematic of PCR amplification without a self-annealing primer and FIG. 7( c ) shows a schematic of PCR amplification with a self-annealing primer.
[0062] FIG. 8( a ) shows a typical chronoamperometry output for PCR plus conjugate and conjugate alone, and FIG. 8( b ) shows a typical chronoamperometry output for control plus conjugate and conjugate alone.
[0063] FIG. 9( a ) shows chronoamperometry of different amplicon concentrations and FIG. 9( b ) shows a plot of the steady-state current signal versus amplicon number.
[0064] FIG. 10 shows a schematic for rolling circle amplification (RCA).
[0065] FIG. 11 shows a schematic for strand displacement amplification (SDA).
[0066] FIG. 12( a )-( b ) show two perspectives of an electrophoresis component for integration into a single-use device for nucleic acid testing.
[0067] FIG. 13( a )-( g ) show an electrophoretic separation using a component for integration into a single-use device for nucleic acid testing.
[0068] FIG. 14 shows an electrophoretic separation of a primer and an amplicon using a component (as shown in FIG. 13 ) for integration into a single-use device for nucleic acid testing, confirmed by a second electrophoresis gel.
[0069] FIG. 15 shows an oligonucleotide primer lacking CLAM-like features.
[0070] FIG. 16( a ) shows the CLAMI primer and FIG. 16( b ) shows the CLAM2 primer.
[0071] FIG. 17( a ) shows an optical detection-based single-use cartridge where an optical sensor is integrated into the device and FIG. 17( b ) shows an optical single-use cartridge where the sensing region is a cuvette feature permitting detection with a light source and detector integrated into the instrument.
[0072] FIG. 18 shows an extraction device containing a filter region integrated into a single use cartridge for nucleic acid testing.
[0073] FIG. 19 shows a two-part cartridge with a separate extraction component that can mate with the amplification and detection component.
[0074] FIG. 20 shows a two-part cartridge with a separate detection component that can mate with the extraction and amplification component.
[0075] FIG. 21( a ) shows a cartridge and instrument separately and FIG. 21( b ) shows the cartridge inserted into the instrument.
[0076] FIG. 22 shows examples of optical detection chemistries.
[0077] FIG. 23 shows an extraction and amplification component where a silicon chip provides one of the walls forming the extraction and amplification chambers.
[0078] FIG. 24 shows a single-use device with electrophoretic separation of unused primers after amplification.
[0079] FIG. 25( a )-( b ) show a cleavage reaction creating a “trigger event” for further amplification and detection.
[0080] FIG. 26 shows a schematic of the PCR amplification method which differentiates between mutant and wild-type SNP sequences.
[0081] FIG. 27 provides a table of possible signal outcomes from a hemochromatosis test.
[0082] FIG. 28( a )-( b ) show two views of a buccal sample device for direct application of a buccal sample to a PCR chamber. This extraction and amplification device attaches to the detection cartridge.
[0083] FIG. 29( a )-( b ) show a comparison of signal which increases relative to the amount of control oligonucleotide.
[0084] FIG. 30( a )-( b ) show the ability of the cartridge to discriminate between wild-type and mutant SNP sequences of hemachromatosis.
[0085] FIG. 31 shows an autoradiograph of 32P radiolabelled synthetic oligonucleotides demonstrating that the ExoI enzyme is an active 3′->5′ exonuclease, which has the ability to reduce the molecular weight down to about 6-7 nucleotides in length.
[0086] FIG. 32( a ) shows PCR with phosphorothioate primers discriminating between wt/mut DNA templates using a 10% non-denaturing polyacrylamide gel; 6 uL sample+1.6 uL LD→6 uL loaded in each well (45 min SYBR Gold stain, photo-negative, experiment HFE 84-2, T hyb 68° C. The seven columns were loaded as follows; 1 wildtype-selective PCR primer present with wildtype DNA template, generates anticipated ˜150 bp band; 2 wildtype-selective PCR primer present with mutant DNA template, does not generate anticipated −150 bp band; 3 a 10 base-pair ladder, prominent bands at 100, 330 and 1660 bases; 4 mutant-selective PCR primer present with wildtype DNA template, does not generate anticipated ˜150 bp band; 5 mutant-selective PCR primer present with mutant DNA template, generates anticipated −150 bp band; 6 a 10 base-pair ladder, prominent bands at 100, 330 and 1660 25 bases; and 7 both selective PCR primers present with wildtype DNA template, does not generate any band. FIG. 32( b ) shows the related chronoamperometry plot.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Nucleic Acid Separation Methods and Apparatuses Based on Magnetic Particles
[0087] The present disclosure demonstrates a rapid and simple protocol for isolating genomic DNA from whole blood for the primary purpose of performing an amplification reaction, e.g. polymerase chain reaction (PCR). The present method has the advantage of exhibiting a significant reduction in the common inhibitors of PCR, e.g. hemoglobin, found in prior art rapid DNA extraction protocols. In blood samples, added anticoagulation reagents such as chelating agents, heparin, EDTA and citrate can also act as inhibitors. The present method eliminates these inhibitors and other naturally occurring chelating agents as well as enzymes and proteins that can damage nucleic acid templates. It is important to note that this technique is also applicable to other sources of nucleic acid material, e.g. buccal swabs, urine, and other tissue samples, and can also be used in conjunction with other amplification methods.
[0088] By contrast with the prior art, for example that found in Dynabeads Genomic DNA Blood kit (Prod. No. 634.02, Dynal Biotech Corp.), and also US patent 2003/0180754A1 where nucleic acid extraction takes 30-40 minutes, the present method reduces the time required for reproducible DNA extraction to less than about 5 minutes and preferably and typically to about 2 minutes. This is a significant improvement when considering genetic analyses where the speed with which a result is obtained is crucial, e.g. the identification of highly infectious agents. It is also applicable to testing in the physician's office environment, or even at the bedside, where it is desirable to obtain a sample from a patient and deliver a result during a single physician visit.
[0089] The present method preferably uses coated beads, with an inner-core that is a paramagnetic material and a lysing and binding buffer. When a lysed cell solution containing genomic DNA is mixed with beads of the preferred embodiment, the surface chemistry on the beads weakly binds DNA with low specificity due to a strong negative surface charge, thus creating a bead-DNA complex. The preferred surface coating is a carboxylic acid coated surface and the paramagnetic beads typically have a 2.8 um diameter, though beads in the diameter range of about 0.1 to 100 um can be employed. Alternative anionic coatings for the beads include the following materials including very small diameter glass beads (e.g. Glass Milk), Whatman phosphocellulose and DEAE resin (e.g. DE52).
[0090] While non-magnetic beads may be used, it is certainly advantageous to use magnetic beads as these beads may be drawn to the side of a reaction vessel and held against the side by means of a magnet. This can occur within a short period of time, provides a means for concentrating the bead in one location and provides a means for moving and manipulating the beads. The magnetic field may be provided by a permanent magnet or by electromagnetic means, as is well known in the art.
[0091] In an example that uses a standard polypropylene PCR tube, a standard lytic buffer (Dynal Biotech Corp.) containing; water 60-100% wt, sodium chloride (NaCl) 10-30%, lithium chloride (LiCI) 5-10%, tris-HC1 1-5%, lithium dodecylsulfate (LIDS) 0.1-1%, EDTA 0-1%, and dithiothreitol (DTT) 0-0.1%; was modified to include NaOH reagent at a final alkaline concentration of 0.65M. Other lytic buffers known in the art may also be used with the appropriate addition of base, e.g. NaOH. Whole blood (10 uL) was then added directly to the alkaline-modified lytic buffer with Dynabeads (23 uL). This induced the lysis of blood cells in about 15 seconds of manual pipette mixing, followed by about 15 seconds of dwell time for the adsorption of genomic DNA onto the beads. The bead-DNA complex was then captured against the side of a tube with a permanent magnet, which takes less than about 15 seconds. The entire supernatant of lysed cells was then removed by pipette. A wash buffer 50 uL), e.g. Dynal wash buffer (from a Dynal kit) was introduced by pipette and used to rinse the bead-DNA pellet that was captured against the tube wall. The wash solution was then entirely removed by pipette while the pellet remained captured against the tube wall. The remaining bead-DNA pellet (1-2 uL equiv. volume) was then removed and added to a new tube with a PCR cocktail (˜25 uL) comprising polymerase enzyme, primers, dNTPs and buffer along with a mineral oil overlay (˜10 uL) and placed into a conventional thermocycler. The total duration of this extraction process was found to be about two minutes. Note that it is demonstrated below that this novel purification protocol overcomes the problem associated with inhibitors of a PCR reaction remaining in the extract.
[0092] In a preferred embodiment, the extraction method employs alkaline lytic buffer, magnetic beads and also a wax or oil-filtering medium. Again, the method can be performed as a manual procedure, as described here, or as the basis of an automated analysis in a disposable device. The use of wax or oil as a filtering medium overlaying the lysed-cell bead-DNA complex mixture eliminated the need for further fluid movement and assisted in purifying the bead-DNA complex. For instance, blood was combined with the lytic buffer and beads and the resulting DNA-bead complex was pelleted and drawn through an upper filtering layer with a permanent magnet, thus selectively separating the complex from the bulk of solution. This is illustrated in detail in FIG. 1 .
[0093] FIG. 1 shows a tube 1 contains a wax filtering medium 2 above a lytic buffer 3 and magnetic beads 4 . Typically the tube is stored at ambient temperature, so the tube is first heated to melt the wax. Generally, this is a temperature change to above about 35° C. Blood 5 is introduced with a pipette 6 and the blood is well mixed so that cells lyse in the buffer. Nucleic acid 7 then binds to the beads via non-specific surface bonds. A magnet 8 is then used to draw the beads and some extra lysed material and buffer to side of the tube to form a pellet. The magnet is then moved along side the tube to draw the pellet upwards through the wax layer. It has surprisingly been found that this effectively filters the pellet, as excess aqueous fluid is excluded by the greater surface tension of the wax. Optionally, after this step, the wax may be re-hardened by removing the heat. The resulting bead-nucleic acid pellet remains trapped in a thin layer of wax easily accessible at the side of the tube, while the lytic buffer and blood remains trapped below the wax. The bead-nucleic acid pellet can then be removed from the side of the tube and introduced to a new tube with the PCR cocktail present. The nucleic acid elutes off the bead during the first heating cycle of PCR, as it has been found that water at a temperature of above 800 C is sufficient for elution. It has also been found that neither the beads nor the wax interfere with PCR.
[0094] Ideal characteristics of waxes for this application include waxes which melt from a solid to a liquid at between 25 to 450 C. Further, these preferred waxes do not significantly evaporate at temperatures in the range 60 to 900 C. When these waxes are solid they prevent movement of bead and other solutions that are trapped by their presence, however, when these waxes are in a liquid state their viscosity is sufficiently low to permit passage of magnetic beads under a magnetic field. The waxes also have the property of being compatible with reagents for DNA amplification. Four examples of waxes that can be used in the present invention are heneicosane (98%, m.p. 40-42° C., Sigma), docosane (99%, m.p. 43-450 C, Sigma), tricosane (99%, m.p. 48-50° C., Sigma) and tricosaheneicosane. The preferred wax is heneicosane. Other organic liquids that can be used to form the barrier layer through which the beads pass include silicone oil and mesitylene.
[0095] FIG. 2 demonstrates the successful removal of a purified DNA sample from blood using the beads transiting through wax process, with the presence of the anticipated bands (gel lanes 5 and 6 matching lane 2). This figure shows a polyacrylamide gel of PCR products with and without beads and with and without blood and also purified DNA controls. Note that the band labeled “*” represents the anticipated base-pair length for symmetrical PCR with a modified wild-type Hemachromatosis oligonucleotide primer set prepared on a known wild-type alleles ACD blood tube sample. The positive control (lane 2) also represents genomic DNA purified using a Qiagen commercial kit for sample preparation (wild-type 15 alleles) and the negative control (lane 1) features with no DNA added to the PCR cocktail. In this example, PCR was performed in a conventional thermocycler, with a mineral oil overlay, using 30 cycles. A volume of 10 uL of sample plus 2 uL of loading dye was added into each well of a 10% non-denaturing polyacrylamide gel, 1×TBE buffer, as shown in FIG. 2 .
[0096] FIG. 3 contrasts the successful removal of purified DNA from blood using the beads transiting through wax protocol (gel lanes 1-4) to the protocol without using the wax as a filter medium (gel lane 5). The band labeled “*” represents the anticipated base-pair length for symmetrical PCR with a modified wild-type Hemachromatosis oligonucleotide primer set prepared on a known wild-type alleles ACD blood tube sample. PCR was performed in a conventional thermocycler, with mineral oil overlay, using 30 cycles. A volume of 10 uL of sample plus 2 uL of loading dye was added into each well of a 10% non-denaturing polyacrylamide gel, 1×TBE buffer, as shown in FIG. 3 .
[0097] The principles demonstrated by the above description can be incorporated into an individual nucleic acid extraction device based on manual manipulations of the type shown in FIG. 1 , or into an automatic device as described below, where the user only needs to add the sample to the device and all the other steps are performed automatically.
Nucleic Acid Separation Methods and Apparatuses Based on Absorbent Filters
[0098] An alternative approach to quickly extract and isolate nucleic acids found in bodily fluids is provided. It is based on the use of filter materials. The disclosed devices and processes significantly improve upon the existing art by marrying chemically impregnated solid-substrate technologies to a miniaturized filtering apparatus. It also conveniently minimizes the time for extraction of an amplifiable quantity of genomic DNA from a low volume of bodily fluid. While the device may be used as an individual separation device, it is particularly amenable to integration into a disposable cartridge device for DNA isolation, amplification and optionally detection.
[0099] The individual device can be used, for example, in clinical and research environments as a rapid means for taking a small volume of fluid, such as blood or buccal cells, and quickly isolating DNA amenable to amplification. Alternatively, when incorporated into a disposable cartridge, microfluidic elements are used to automatically move the sample within the cartridge and to affect the extraction process. Both applications are described.
[0100] The primary features of the device and method combine; (i) rapid nucleic acid isolation, typically in less than two minutes, (ii) elements amenable to incorporation in a disposable cartridge, (iii) generation of either bound or unbound nucleic acid in a form compatible with amplification, (iv) utilization of small sample volumes, e.g. blood, buccal cells and tissue, and (v) utilization of small volumes of other liquid reagents to perform the operation.
[0101] Regarding the device, the supporting structure of a low-volume filter holding apparatus was used for the placement of a chemically-impregnated solid-substrate matrix. It functions as a filtering layer that extracts and isolates DNA from an applied sample by retaining these nucleic acids within its matrix. The filtering matrix was impregnated with lytic salts and optionally detergent, which after the binding step is then flushed or washed with a solvent, preferably distilled or sterile deionized water, to remove common inhibitors of amplification and to rinse away denatured proteins. The filter retaining nucleic acids from the sample can then be removed from the supporting apparatus and directly applied to amplifying reagents, e.g. PCR. This can be done using the whole filter disc, or a portion thereof, depending upon the quantitative requirements for DNA. Where desirable the nucleic acid material may be eluted from the filter preferably using deionized water at a temperature in the range 75 to 950 C. Other eluting reagents include dilute neutral buffers, such as 10 mM Tris at pH 7 and 5 mM to 20 mM sodium or potassium phosphate buffers. Alternatively, a filtering matrix can be incorporated in a disposable nucleic acid testing cartridge, as described below.
[0102] The preferred embodiment of the individual extraction device is described as follows: The chemically-impregnated filter is a disc composed of a reproducible thin matrix that is biochemically inert, preferably a commercially available filtering paper. The lytic salts and optionally a detergent are dispensed onto the surface of the filter and then dried within the matrix. As a practical matter, the size of the filter-disc is restricted by the outer-diameter of the filter holder, and must be wider than the channel through which the wash fluid passes. Chemical impregnation is by means of a liquid cocktail containing a chaotropic salt, with or without detergent, a weak basic buffer, and a chelating agent. The cocktail is dispensed onto the filter-disc, dried and then the filter is stored in a sealed environment until use.
[0103] In the preferred embodiment, the filter holder device provides rigid support to the filter-disc (optionally with a placement-assisting gasket) with a central small-diameter channel through which the wash fluid may pass from one side of the filter-disc to the other. The device contains both an inlet and an outlet on opposite sides of the filter-disc to allow for the introduction and later removal of the wash fluid. Its construction material should be biochemically inert, preferably a molded plastic. It is designed to be disposable, but it optionally could be reusable if properly cleaned, e.g. autoclaved. The filter base-pad is a subcomponent that assists in the proper placement of the filter-disc in line with the wash fluid channel. Optionally a filter-positioning gasket may be employed for sizes of filter that are smaller than the internal diameter of the device. For example a thin adhesive layer with a central hole that holds the filter-disc onto the filter base-pad over the channel may be used. In this embodiment, a double-sided adhesive tape with a central hole slightly smaller than the outer-diameter of the filter-disc is preferred. Wash fluid is preferably distilled water and is used to remove chemical inhibitors of amplification.
[0104] As is well known in the art, conditions of sterility and biochemical inertness are intrinsic to the choice of materials employed for the construction of the device, the handling of fluids and the source of the wash fluid. Samples, e.g. bodily fluids, can be introduced to the filter-disc through the inlet of the filter holder, or onto the filter-disc before assembly into the device, provided care is taken to ensure sterility.
[0105] In one embodiment, the filter holder can be a Swinnex filter holder, preferably the 13 mm diameter version (Millipore Corp.), which is also provided with a Teflon™ gasket and is constructed of molded polypropylene. In a preferred embodiment, a modification was performed upon the filter holder where additional acrylic pieces are cut to exactly fit the void spaces inside both the top and bottom pieces of the filter holder. These pieces are preferably held in place with adhesive, e.g. Loctite epoxy glue, and have a drilled central channel of a smaller diameter than the standard device. The inlet to the filter holder can also optionally be modified with an end piece from an Eppendorf 100 μL pipette tip that is held into position with adhesive.
[0106] The filter positioning gasket is preferably a double-sided adhesive tape gasket (iSTAT Canada Ltd.), laser cut to a thickness of about 25 um on a PET film base with about 75 um of a rubber-acrylic hybrid adhesive, sandwiched between two polyester liners for protection. A two-sided adhesive has the advantage of providing a better seal of the filter holder during the washing procedure. Note that the polyester liners are removed during assembly of the device to expose the adhesive.
[0107] The filter disc is preferably Whatman 4 Qualitative Grade plain cellulose paper, (Whatman Inc.), with the following manufacturer's specifications; particle retention greater than 20-25 μm, coarse porosity, filtration speed ASTM 12 sec., Herzberg 37 sec., and a smooth surface. Other similar filter materials and grades may be used include Whatman 3MM, Pall GF A/B, Texwipe (cleaning cloth), Whatman 1, Whatman 3, Whatman 4, Whatman 6 and Pall 1660 membranes.
[0108] Chemical impregnation of the filter is preferably with a liquid cocktail that contains chaotropic salts, preferably a guanidinium salt such as guanidine isothiocyanate, with or without detergent preferably Triton-X100™, a weak basic buffer preferably TRIS, and a chelating agent preferably EDTA. Alternative reagents include guanidinium salts (e.g. guanidinium hydrochloride and guanidinium thiocyanate), non-ionic detergents and chelating materials. The cocktail is applied to Whatman 4 paper in solution for minimal loading of approximately 3.75 μL/cm 2 of 2M guanidine isothiocyanate, 1% Triton XI00, 10 mM TRIS buffered to pH 8.8 and 2 mM EDTA. The cocktail is then dried under a heat lamp (Philips, Heat-Ray 250 w infrared) about 5 cm below the light surface for 3 minutes, then cooled at room temperature for a minimum of 10 minutes and stored in a sterile centrifuge tube until use. Note that where the intended sample material is blood, it has been found that impregnation with a solution of 200 mM NaOH can be substituted for all the reagents used in the cocktail solution. Other strong basic solutions can also be used e.g. KOH.
[0109] By way of demonstration, two different bodily fluids have been used for the extraction of genomic DNA. These are (i) white blood cells within a whole blood sample, that are untreated by either chelating or anticoagulation agents, and (ii) buccal cells obtained from a cheek swab. When utilized as described below, the present device can extract amplifiable DNA from both fluids with a minor variation in the protocol. Based on this disclosure, those skilled in the art will recognize that other types of sample containing nucleic acid may also be extracted by making further minor variations in the protocol.
[0110] The component elements of filter holder are shown in FIG. 4( a ) in side view, FIG. 4( b ) exploded side view, FIG. 4( c ) top view and FIG. 4( d ) with a void volume insert. The device comprises a filter holder top 20 and bottom 21 , an inlet channel 22 , void spaces 23 and 24 , a filter disc 25 on a filter disc base and an outlet channel 26 . In the preferred embodiment, as shown in FIG. 4( d ), a lower volume modification employs a void-filling structures ( 27 , 29 ) and an inlet adaptation element 28 to facilitate better transfer of fluid into the narrower central channel via inlet 22 . The lower volume device requires the filter-disc to be positioned with a filter gasket attached to adaptation element 29 . As a practical matter, the device is prepared in a sterile working environment and tools to prevent cross-contamination of nucleic acids and enzymes are used.
[0111] When using a 13 mm filter-disc 25 , about 3-10 μL of bodily fluid can be applied to the chemically-impregnated filter surface, whereas the lower-volume modified device, with a 4.8 mm filter disc functions well with 1-3 μL of fluid. Sample application can be achieved with the assembled device through the inlet port, or directly onto the filter prior to assembly. Where a buccal swab is acquired with a cotton swab, it can be wiped onto the filter disc or washed onto the filter disc through the inlet port. It has been found that another method for isolating buccal cells is by using a commercial mouthwash, e.g. Scope brand. A few microliters of used mouthwash can then be applied into the device.
[0112] Regarding removal of interferents, it was found that sterile water at ambient temperature performs satisfactorily as a wash fluid as it is capable of flushing interferents through the filter-disc without removing nucleic acids from within the matrix of the disc. When water is pumped from a dispensing tip positioned for a tight seal at the inlet to the filter holder, it flushes through the filter-disc washing the sample and passing through to the outlet. For buccal cell samples, a single flush of 20 μL of sterile water per μl of sample is sufficient. For blood samples, 20 μL of sterile water per μL sample is preferably flushed through the filter and repeated three times. Alternatively a single volume passed forward and backwards thrice is sufficient. As an alternative to sterile water the following sterile buffer solutions may be used, 10 mM Tris at pH 7 and 5 mM to 20 mM sodium or potassium phosphate.
[0113] After the washing procedure the filter-disc retains an amplifiable quantity of DNA. It can then be removed from the filter holder and employed in an amplification reaction. It has been found that a 4.76 mm diameter disc can be employed in a 100 μL PCR amplification directly, whereas a 13 mm disc is optimally cut into smaller portions. In an alternative embodiment the nucleic acid material can be eluted from the filter by using hot deionized water or various buffer solutions and then introduced into an amplification device. In another embodiment the filter process is integrated into a disposable device for nucleic acid testing, as described below. FIG. 5 demonstrates the effectiveness of the method and filter holder device, showing PCR amplification of a buccal swab sample. After the extraction process, the filter was removed from the device and placed into a 100 uL PCR reaction chamber using two primers specific for the hemachromatosis gene (Hfe). Once the amplification process was completed, material was applied to lane 1 of a 10% acrylamide 1×TBE electrophoresis gel. As expected this generated a 390 bp (base pair) fragment indicated by the arrow. Note that control lane 2 contained a 100 bp ladder and lane 3 contained water as a negative control.
[0114] It is understood that the manual procedure described above can form the basis for the design of an extraction module included and integrated within a disposable device for performing genetic analyses, or be a separate module that delivers an extract to a disposable device. Delivery can be for example by pipette transfer or by mating features 500 , 520 and 521 on each that facilitate transfer (see FIGS. 19 and 20 ). Such devices are described in detail in the section addressing an integrated single-use device for nucleic acid testing.
Detailed Description of Amplification Methods
[0115] In the present invention, where electrochemical detection is preferred, the main objective of the nucleic acid amplification step is to generate about a 0.01 picomolar concentration of detectable nucleic acid from the target molecule, as it has been found that this is in the range of the lower detection limit of a sandwich assay with enzymatic amplification and electrochemical detection. The desired one picomolar concentration of fragment is based on Avogadro's number (1 mole=6×10(23) molecules), where 1 pmol equals 6×10(23)×10(−12), or about 10(12) molecules. If, as is known, one microliter of blood contains about 5×10(3) molecules of DNA, then one milliliter, which is a reasonably accessible sample volume, contains 5×10(6) molecules, or roughly about 10(7) molecules. To go from the amount of DNA in 1 ml of blood to 0.01 pmol of DNA requires an amplification of about 10(3) fold. This is certainly achievable using several well-known amplification techniques. Performing a similar calculation, for a different sample types and sample volumes, to determine the degree of amplification will be apparent to those skilled in the art.
[0116] In alternative embodiments of a single-use cartridge where optical detection is used, again the objective of the nucleic acid amplification step is to generate a given molar concentration of detectable nucleic acid from the target molecule so as to be in the range of the lower detection limit of the given optical methods. Such calculations will be familiar to those skilled in the art. It is well known in the art that the ability to determine the concentration of a sample via optical detection is dependent on the background level of noise, the extinction coefficient of the optical compound to be detected, the optical system's electronic gain, the volume of the sample and other parameters. A simple relationship between the compound concentration and the absorbance of the sample can be expressed using the Beer-Lambert law (A=εcl), where A is the absorbence, E is the extinction coefficient, c is the molar concentration of the sample, and 1 is the path length of the sample. Typically the length is 1 cm by definition, (though in the devices described below about 0.02 to about 0.4 cm is more typical). This makes the absorbence related to the concentration using the constant of the extinction coefficient and usually permits detection limits within the pM range.
Polymerase Chain Reaction Amplification
[0117] The polymerase chain reaction (PCR) is well known for its ability to specifically amplify regions of target DNA based on the primer sequences chosen for the PCR reaction. A difficulty with processing this material is in trying to detect the signal based on hybridization homogeneously. By definition, the PCR reaction generates blunt ended double stranded products. However, certain thermostable DNA polymerases possess polyA polymerase activity, which can be used to add an additional A nucleotide. While this has been used commercially for cloning purposes, the single nucleotide overhang is inefficient for hybridization. As another approach to attempt to use the PCR reaction for hybridization, recognition sequences for restriction endonuclease enzymes have been designed into the PCR primers. However, this is limiting, because it requires additional enzymes which typically only generate short overhangs. As with mostly double stranded species, the PCR product is not amenable to hybridization in homogenous reactions. To overcome this limitation, a strategy which uses a limiting amount of one primer over the other has been devised. An alternative is to have promoter regions for bacteriophage RNA polymerases (e.g. SP6). Limiting one of the primers has drawbacks in that the efficiency of the amplification is reduced. Generating RNA with bacteriophage RNA polymerases requires additional reagents and generates labile RNA species for detection.
[0118] Here we describe a novel method of performing a PCR reaction by combining DNA polymerase, a target nucleic acid and amounts of two modified primers where the first modified primer has a sequence of bases to a region of the target. A polymerase blocking region is attached to this primer which is linked to a single stranded hybridization region. The second modified primer has a sequence of bases to a second region of the target and also a polymerase blocking region and a second single stranded hybridization region. A detectable moiety (e.g. biotin, fluorocein) is attached to one or both of the two modified primers. To run the PCR reaction the mixture is cycled to generate multiple copies of an amplicon incorporating the modified primers. In a second step excess unincorporated modified primers, with the detectable moiety, are substantially eliminated from the mixture. Several different methods are available and these are described below. The mixture is then added to a capture oligonucleotide which is complimentary to one or both of the single stranded hybridization regions to permit hybridization with the amplicon. In the last step the moiety associated with this hybridization is detected directly, for example by optical detection of fluorocein. Alternatively, the moiety, e.g. biotin is exposed to and binds with a streptavidin-labeled enzyme, e.g. alkaline phosphatase and the enzyme activity is determined either optically or electrochemically. Again several specific methods are possible and examples of these are described below.
[0119] The reaction sequence is shown in FIG. 7( a ), where 31 is the detection moiety, e.g. biotin, FAM, DNP, cholesterol, fluorocein, 32 is the first single stranded hybridization region, 33 is the polymerase blocking region, e.g. hexaPEG, 34 is the first PCR primer, 35 is the second PCR primer, 36 is the second single stranded hybridization region, 37 is a second detectable moiety, 38 is the double stranded nucleic acid target sequence, 39 is a solid substrate, e.g. bead or surface, and 40 is a hybridization region complementary to 36 .
[0120] The PCR primers, 34 and 35 are preferably synthesized using standard phosphoramidite chemistry and can include any nucleotide or modified base which is amenable to DNA polymerase, except in the polymerase blocking region 33 . An example of a polymerase blocking region sequence can consist of the spacer phosphoramidite 18-O-dimethoxyltritylhexaethyleneglycol,1-[(2-cyanoethyl)-(N,N-diisopropyl)]-phosphoramidite (hereinafter referred to as “HPEG”). This phosphoramidite generates a hexaethyleneglycol spacer region. Other spacer molecules with similar properties can also be used for this purpose. Alternatives to phosphoramidite chemistry can be used including creating a 3′-3′ or 5′-5′ phosphodiester backbone, as well as modified nucleotides as described by Newton et al., (Nucleic acids research 21, 1155-62, 1993) and also U.S. Pat. No. 5,525,494.
[0121] Allowing PCR to proceed using these synthetic oligonucleotide primers in the presence of the appropriate target and DNA polymerase with associated components, generates a newly synthesized DNA molecule with incorporated single stranded regions 32 and 36 . It has been found that while the Taq DNA polymerase may be used, the preferred embodiment uses T. kodakiensis DNA polymerase which exhibits a significantly higher turnover number. This molecule can then be hybridized by means of 36 to a target sequence 40 on a solid support 39 . The binding moiety region can then be used for generating a signal. For example by using biotin as the binding moiety and using streptavidin conjugated to a detection enzyme, e.g. horseradish peroxidase (HRP) and alkaline phosphatase (ALP).
[0122] The PCR primer also preferably contains a terminal phosphorothioate bond, preventing the exonuclease activity of T. kodakiensis KODI DNA polymerase from not discriminating allelelic differences in primers used in SNP analysis based on the terminal base being different.
[0123] In the preferred embodiment using human genomic DNA isolated using the filter holder device described above, two synthetic oligonucleotides (primers 1 and 2) were used to generate a region of the human hemochromatosis gene (hfe) of approximately 390 bp in size. These were oligo 1:
[0000] 5′-ACTTCATACACAACTCCCGCGTTGCATAACT-HPEG-TGGCAAGGGTAAACAGATCC-3′ and oligo 2: 5′-56-FAM-AACAATACCACCGTAGCGATCA-HPEG-AACAATACCACCGTAGCGATCA-3′, where 56-FAM is a fluorescent species and HPEG is a hexa PEG sequence incorporated using an 18-0-dimethoxyltritylhexaethyleneglycol,1-[(2-cyanoethyl)-(N,N-diisopropyl)]-phosphoramidite. In the oligo 1 sequence, the sequence located 5′ to the HPEG spacer, 5′-ACTTCATACACAACTCCCGCGTTGCATAACT-3′ is designated as SEQUENCE ID NO. 1 and the sequence located 3′ to the HPEG spacer, 5′-TGGCAAGGGTAAACAGATCC-3′ is designated as SEQUENCE ID NO. 2. In the oligo 2 sequence, the sequence located 5′ to the HPEG spacer, 5′-AACAATACCACCGTAGCGATCA-3′ is designated as SEQUENCE NO. 3 and the sequence located 3′ to the HPEG spacer, 5′-AACAATACCACCGTAGCGATCA-3′ is designated as SEQUENCE ID NO. 4.
[0124] To demonstrate the use of these primers, a buccal cell DNA sample originating from mouthwash (Scope brand) was used. A volume of 3 μL of this bodily fluid was dispensed onto a 5 mm diameter disc punched from Whatman 4 filter-paper impregnated with 3 μL of lytic salt and detergent solution comprising 2M guanidinium isothiocyanate, 1% Triton-X-100, 10 mM Tris buffer at pH 8.8 and 2 mM EDTA. After extraction, the filter-disc was placed immediately into a 0.5 mL MBP Easystart PCR reaction tube (Fisher Scientific, PN 21-402-49) designed to be filled to 100 μL. The tube is supplied with 50 μL of fluid under a waxlayer to give a final concentration of the following reagents in 100 μL of aqueous solution; 2 mM MgC1 2 , 20 mM Tris pH 8.4, 50 mM KCI and 0.2 mM dNTP. A 47 μL upper-layer reaction mixture was added to give a final reaction concentration of primers 1 and 2 of 0.31 pM, described (Integrated DNA Technologies Inc). This aqueous solution also contained 5U Vent (exo-) polymerase (New England Biolabs) and 0.1% Triton-X-100. The amplification reaction was performed in a Techne Techgene Thermocycler. The sequence was amplified using 3 cycles of 97° C. for 3 min, 60° C. for 1 min and 72° C. for 1 min, followed by 36 cycles of 97° C. for 1 min and 62° C. for 45 s. Samples resulting from the amplification procedure were then tested in single-use cartridges using 100 μL aliquots. A complete description of the design elements of detection cartridge containing an electrochemical sensor is found in jointly owned US 20030170881 incorporated here by reference. A general description of chronoamperometry and other electrochemical methods applicable to sensors incorporated into single-use test cartridges is found in jointly owned U.S. Pat. No. 5,112,455 incorporated here by reference.
[0125] The 100 μL aqueous aliquots were prepared as follows; 14 μL 1M NaCl, 1 μL FITC-ALP conjugate 1/100 dilution, and 10 μL amplified DNA. The FITC-ALP conjugate is a final concentration of 350 ug/ml. Alternatively a control oligonucleotide sequence was used in place of the amplified DNA. The control oligonucleotide sequence was manufactured as a positive control for chronoamperometric detection. This single-stranded sequence is analogous to 36 as shown in FIG. 7( a ) and is complementary to region 40 and contains a 36-FAM fluorescent species. Note that FIG. 7( b ) shows the undesired competition of a standard primer in the detection step, whereas with the clam-like primer, as in FIG. 7( c ) this is obviated. The results from both of these samples are shown in FIGS. 8( a ) and 8 ( b ). FIG. 8( a ) shows the chronoamperometric reading for anti-FITC ALP conjugate alone versus the conjugate with amplicon hybridized to the sensor. FIG. 8( b ) shows the chronoamperometric reading for anti-FITC ALP conjugate alone versus the conjugate with a positive control oligonucleotide sequence.
[0126] The detection cartridge operated as follows, a 20 μL portion of the 100 uL aliquots was loaded into an enzyme-linked DNA hybrid sensor cartridge, as described in jointly owned US 20030170881 and placed into an i-STAT model 300 electrochemical analyzer (i-STAT Corporation). The sensor cartridge contained multiple (2 or 4) amperometric sensors coated with specific DNA oligomers. In this example, the oligomers were 5′-biotinylated oligonucleotides and were bound to streptavidin-coated beads which were adsorbed onto the sensor surface. One of the sensors was coated with the complementary single-stranded DNA oligomer to one of the single-stranded portions of the PCR primers, as a control. Also present within this cartridge was a separate anti-FAM-alkaline phosphatase conjugate.
[0127] In the preferred embodiment, the PCR amplified product and anti-FAM ALP conjugate dissolved into a single solution were brought into contact with the DNA capture sensors. Note that alternatively the PCR product may be contacted with the sensor first, followed by the conjugate. In the preferred embodiment, the double-stranded PCR products, containing both single-stranded hybridization regions, binds to the capture region on the amperometric sensor. Binding of the alkaline phosphatase label can occur either in solution before capture of the PCR product or after it has bound to the bead. After a controlled period of time, typically 5 to 15 minutes and at a controlled temperature preferably 37° C., the solution is moved out of the sensor region and delivered to a waste chamber within the cartridge. A wash solution, containing substrate for ALP, is brought over the sensor washing excess a FAM ALP conjugate away from the sensor region. A trailing portion of the wash solution remains on the sensor and provides an electrogenic substrate for the ALP label. Note that in an alternative embodiment a wash solution may be used first, followed by a second solution containing the substrate. Note also that where an optical sensor or other type of sensor is used, other appropriate substrates are used. In the preferred embodiment, the measured current at the capture sensor is essentially directly proportional to the number of ALP labels present on the sensor. An adjacent amperometric sensor which is not coated with the complementary DNA binding sequence can be used as a control sensor to offset any nonspecific binding of the ALP reagent on the sensors, thus improving the detection limit. Alternatively a capture oligonucleotide with a sequence different from the complimentary DNA binding sequence can be used as a negative control.
[0128] Referring to FIG. 8( a ) and FIG. 8( b ), these show the measured current profiles, or chronoamperometric output, from DNA cartridges. PCR product with conjugate shows an increase in measured current, over conjugate alone, in FIG. 8( a ). Here, competing unbound primers may be reducing signal. A similar increase in signal is observed with the positive-control oligonucleotide sequence that is labeled with 36-FAM species, as shown in FIG. 8( b ). It has also been found that the net current is proportional to the number of PCR amplicons in the sample, see FIG. 9( a ), where the steady-state current is shown to increases with increasing amplicon concentration. These data are plotted in FIG. 9( b ).
[0129] The software used for the instrument 200 and 650 (see FIGS. 6 and 21 ) in this example is a modified i-STAT 300 analyzer (i-STAT Corporation) which performs a series of steps in the detection process. In the first step, the instrument makes contact with and identifies the cartridge, and then conducts a battery check and other internal instrument checks. It then initiates and completes a thermal cycle to heat the sensor chip to 370 C. The liquid containing the amplified target is then pneumatically pushed from conduit 125 into the sensor chamber 126 to permit the capture steps. A push pin 213 in the instrument then makes contact with element 135 during the second motor motion of the instrument causing the analysis fluid 134 to be dispensed from the analysis pack into the analysis into conduit 125 which acts a temporary holding chamber. The temperature set-point for the sensor chip is then increased to 47° C. and a conductivity sensor on the chip is initialized. The target liquid is then pushed back and forth over top of the capture oligonucleotide beads to effect efficient capture of the amplicon. This step takes about 3 to 9 minutes. Note that the conductivity sensor is used to monitor the position of the fluid during this capture process. Before the last two oscillations, the software in the instrument causes the heating of the chip to be turned off and the remaining cycles are conducted at ambient temperature. The liquid containing the uncapture amplicon is then moved slowly to the sample inlet side of the waste chamber 137 , and the sensors are set to collect data at a poise potential of +30 mV vs. Ag/AgC1 electrode (at 2 pA/bit). As this liquid is pushed into the waste chamber a locking wick mechanism closes a vent when it becomes saturated. This mechanism is of the type described in jointly owned US 20030170881 which is incorporated here by reference. The software then causes the instrument to actuate the cartridge such that analysis fluid is drawn across the sensors to wash the remaining unbound material from the capture oligonucleotide, leaving a thin layer of analysis fluid containing p-aminophenol phosphate which can react with the enzyme and be oxidized at the electrodes. Current generated as a function of time is recorded, as shown in FIG. 9( a ), and can be used by the software algorithm to display a result.
[0130] It is known in the art that ExoI can be used to degrade un-incorporated single stranded oligonucleotides in DNA sequencing reactions, however it was not known if unnatural DNA, like the hexa-PEG region would be degraded by the ExoI enzyme. To demonstrate that ExoI works on this unnatural base, the experiment shown in FIG. 31 was performed. This figure shows an autoradiograph of 32P radiolabelled synthetic oligonucleotides after ExoI treatment. In FIG. 31 , the is015 oligonucleotide in lane 1 is the same as oligo 1 above. The oligonucleotides labeled is026 and is027, like is015 contained an HPEG spacer, while the is020 oligonucleotide did not contain an HPEG spacer. FIG. 31 demonstrates that the ExoI enzyme is an active 3′->5′ exonuclease, which has the ability to reduce the molecular weight down to about 6-7 nucleotides in length. Further, it can process past the hexa-PEG region and it is inhibited in the double stranded region of the clam primers. Therefore, it demonstrates that ExoI is not prevented from being an exonuclease with the hexa-PEG region.
[0131] In another embodiment of the invention, gene copy mutations, e.g. ZNF217, are detected by using both the target gene and one or more housekeeping genes, e.g. actin or glyceraldehyde-3-phosphate dehydrogenase. This is accomplished with two sensors in the detection chamber 126 , with one for the target and the other for the housekeeper. Here, PCR primers are used to amplify both the housekeeping gene, as well as the gene of interest. If ZNF217 is present in the same copy number as the housekeeping gene, the level of signals is similar. However, when the ZNF217 gene is present in multiple copies, the level of signal at the ZNF217 sensor is greater than at the ‘housekeeping gene sensor.
[0132] Another embodiment of the invention addresses genetic mutations which causes disease states includes gene expression mutations. Wildenhain et al., (1990, Oncogene, vol 5(6):879), describe the over-expression of the neu protein-tyrosine kinase, pl85neu which is related to breast cancer. The c-Myc oncogene has been identified in many forms of cancer (Waikel et al., 1999, Oncogene, vol 18(34):4870). Other examples of oncogene overexpression were described by Ren (2004, Curr. Opin. Hematoi. Vol 11(1):25). Over-expression mutations typically generate increased levels of mRNA, thus to detect mRNA in this invention, an initial step of cDNA synthesis is used prior to the PCR amplification. The synthesis of eDNA using reverse transcription is well known in the art, including amplification of this material by PCR. Using the PCR amplification previously described, the presence of a quantity of mRNA present in a cell can be determined by measuring the level of the signal. Comparing the signal for a particular oncogene, for example Her2/neu to 5 a housekeeping gene allows the discrimination of oncogene expression at normal levels, or at levels indicative of a disease state, and in particular with breast cancer in the case of Her2/neu.
[0133] FIG. 26 shows an alternative assay method schematic and experimental data for this method are shown in FIG. 32( a ) by gel electrophoresis and FIG. 32( b ) by chronoamperometry. Target nucleic acid (DNA or cDNA) 329 is shown flanked by two regions where PCR and/or Clam primers bind 330 and 333 , with an intervening sequence marked by 331 . During the PCR reaction, three primer sequences 31 , 341 and 37 are added to the reaction mixture, wherein 31 and 341 differ by a single nucleotide at their 3′ end 340 as indicated by 337 and 338 .
[0134] Elements 31 , 341 and 37 act as PCR primers, wherein region 336 for primers 31 and 341 hybridize to region 330 on target molecule 329 . And region 35 of molecule 37 hybridizes to region 333 on target molecule 329 . Primer 37 can function as a complementary PCR primer for primers 31 , 341 or both 31 and 341 . Primer 37 also has the feature of a specific sequence of bases at region 35 wherein it hybridizes to target molecule 329 at location 333 . It has a DNA polymerase blocking group at 33 , another unique region at 36 which will form a single stranded region for later hybridization during detection and an optional binding moiety at 37 .
[0135] Clam primers 31 and 341 have many similar features, but also have some specific differences. Both clam primers 31 and 341 have an optional detectable moiety at 334 . This is for example a biotin molecule on 31 and a FAM tag on 341 . However, these are different for 31 and 341 to allow later discrimination of the molecule. Both clam primers 31 and 341 have different designed single stranded binding regions 32 and 339 respectively. In addition, both clam primers 31 and 341 have DNA polymerase blocking groups 33 and both clam primers 31 and 341 have a point mutation designed into the fourth nucleotide base to assist in the discrimination of single nucleotide polymorphisms, as described by Lee et al., (2004, Nucleic. Acids Research, vol 32(2):681), Newton et al., (1989, Nucleic Acids Research, vol 17(7):2503), and European Patent application No. 89302331.7. As already mentioned, region 336 of both clam primers 31 and 341 bind to region 330 on target molecule 329 , wherein a single nucleotide mutation at 337 or 338 discriminates between a single nucleotide difference. Both clam primers have a modified terminal phosphodiester bond at 340 that is resistant to 3′ to 5′ exonucleases present in certain thermostable DNA polymerases, which further assists in the discrimination of the two different molecules. This modified terminal phosphodiester bond can be a phosphorothioate or peptide nucleic acid (PNA). The Clam primers also have the feature of having intramolecular structure, which prevents the unincorporated single stranded primer molecules from binding to a capture oligonucleotide 40 or 30 at the detection stage, but permits them to hybridize, to the capture oligonucleotides 40 and 30 if incorporated into a newly synthesized PCR amplicons.
[0136] In the first round of PCR after denaturation of the double stranded target to single strands, primer 37 and either clam primers 31 or 341 or both 31 and 341 bind to target molecule 329 .
[0137] When only either clam primer 31 or 341 binds to the target molecule 329 as is the case for a homozygote, the single nucleotide on both copies of two chromosomes are the same. When both 31 and 341 bind to two separate molecules of target 329 as is the case for a heterozygote, one chromosome has one single nucleotide base sequence, whereas the other chromosome has a different single nucleotide base sequence as is found in single nucleotide polymorphisms. This incorporates clam primers 31 or 341 or both 31 and 341 , as well as the PCR primer at the other end, 37 and the newly synthesized intervening region 331 .
[0138] PCR amplification is allowed to proceed for between 15 and 50 cycles to generate newly synthesized amplified molecules. In FIG. 26 we show an amplicon 344 with Clam primer 341 incorporated. This is done for illustrative purposes. If the other mutation were present, or if there was a different sequence on either of the chromosomes, an amplicon with 31 incorporated would be found. For simplicity, only the amplicon with 341 is shown in the figure.
[0139] During the detection step of the process, the newly synthesized PCR amplicon 344 with Clam primer 341 and PCR primer 37 incorporated binds to capture oligonucleotide 40 at region 339 based on the nature of complementary sequences binding to each other. Sequence 339 does not bind to a different physically separated capture oligonucleotide 30 which possesses a different sequence. Both capture oligonucleotides 30 and 40 are bound to a solid.substrate or beads as indicated in 39 .
[0140] The detection of this hybridized complex can either be detected by a conjugate molecule which binds to binding moiety 334 in molecule 37 , or another single stranded oligonucleotide 318 binding at region 343 with region 36 on molecule 344 having its own detectable moiety 342 which can be detected by a conjugate molecule. The conjugate molecule has two features: (i) a region that binds to the binding moiety 334 or 342 , and (ii) a detection region. An example is an antibody specific for the FAM binding moiety, which has been modified with an alkaline phosphatase enzyme as the detection element.
Alternative Amplification Methods
[0141] An alternative embodiment of this method using the same detection cartridge can be used to perform a non-PCR nucleic acid amplification assay. A schematic for rolling circle amplification (RCA) is shown in FIG. 10 and one for strand displacement amplification (SDA) in FIG. 11 . Not that the component elements correspond to those described for PCR as shown in FIG. 7( a ). Both assays require a short ssDNA fragment with a 3′-OH moiety ( 308 and 310 ) made from the target, as shown by means of two different methods in FIG. 25 . FIG. 25( a ) shows a triggering event method, e.g. SNPase and cycling probe, and FIG. 25( b ) 25 shows the Invader™ method.
[0142] The same reagents are used as in the above section, however only one modified primer comprising a sequence of bases to a first region of said target nucleic acid is required. Again the mixture is cycled to provide multiple copies of an amplicon incorporating the 30 modified primer, followed by substantial elimination of any excess unincorporated modified primer from the mixture. Several methods can be used as discussed below. The mixture is then exposed to a capture oligonucleotide complimentary to the single stranded hybridization region, followed by hybridization of the single stranded hybridization region of said amplicon incorporating said modified primer, with the capture oligonucleotide. Again the final step is detecting said moiety associated with said hybridization, e.g. electrochemical detection of an electroactive species generated by alkaline phosphatase. In the preferred embodiment, primers are attached to the polymerase-blocking region which, in turn is attached to a single stranded hybridization region.
[0143] For the rolling circle amplification strategy, the 3′-end of the primer has a blocking region, which could include a phosphate or a dideoxy nucleotide. A cleavage reaction similar to that found for the cycling probe reaction or the SNPase assay occurs, removing the blocking moiety, as shown in FIG. 25( a ), comprising target DNA 300 and reagents 301 , 302 and 309 participating in reaction 306 . Pre-made circular molecules can be added to the reaction mixture. Extensions cannot occur with blocked primers, but do occur to cleaved primer molecules. The cleaved primer generate long single stranded molecules with duplications of specific regions complementary to the pre-made circular molecules. Synthetic oligonucleotides with detectable moieties are included in the mix, wherein the oligonucleotides are complementary to a region of the single stranded DNA, which can be found multiple times along the single stranded DNA. One region of the primer, which is single stranded and unique, binds to a capture oligonucleotide region. As this region is not complementary to the pre-made circular DNA, there is no competition of this region with the capture oligonucleotides. As shown in FIG. 10 , in the rolling circle assay the ssDNA 3′-OH moiety ( 308 , 310 ) binds to the rolling circle reagent ( 311 , 315 ) via reaction 312 . Cycling incorporates a string of moieties 316 attached starting at the 3′ end of 308 or 310 , to produced 314 . Detection of element 314 is achieved by binding its 5′-3′-OH region to complementary element 40 immobilized on bead 39 and labeled polynucleotide 317 complementary to 316 . The label is then recognized by an antibody bound to alkaline phosphatase 318 .
[0144] An alternative embodiment of this method using the same detection cartridge can be used to perform a non-PCR nucleic acid amplification assay. A schematic for strand displacement amplification is shown in FIG. 11 . Note that component elements correspond to those in the PCR as used as in FIG. 7( a ). Similar reagents are used as those described above, however the SDA primer must first be provided in a non-amplifiable format, which is converted to an amplifiable format. One approach to accomplishing this is to provide a primer with a blocked 3′-end block, for example using a 3′-terminal dideoxy sequence. A trigger event then occurs, which cleaves off the blocking 3′-end. One example of a trigger event could be an Invader reaction (Kwiatkowski R W, Lyamichev V, de Arruda M, Neri B. Clinical, genetic, and pharmacogenetic applications of the Invader assay. Mol Diagn. 1999; 4:353-364.), where the flappase activity cleaves at the hybridized junction of the blocked primer with the presence of genomic target nucleic acid, providing an available 3′-10 hydroxy group. This is shown in FIG. 25( b ) with target DNA 300 and reagent comprising 304 , 303 , 305 and 309 participating in reaction 307 .
[0145] Alternatively, another example of a trigger event is a cycling probe reaction (Duck et al., 1990, BioTechniques, vol 9(2): 142), where the presence of the genomic target nucleic acid causes the cycling probe oligonucleotide to be cleaved at a four ribonucleotide sequence on the cycling probe oligonucleotide, in turn generating a free 3′-hydroxyl group. Another similar example is a mismatch to the genomic target nucleic acid and a repair enzyme, which as described for SNPase, generating a free 3′-hydroxyl group.
[0146] After the trigger event, which has generated a free 3′-hydroxyl group in the primer sequence, a complementary strand displacement primer is present. This SD primer is complementary at its 3′ end for the primer described above, which generated a 3′-hydroxyl group. In addition, the SD primer has 3′ to the 3′hydroxyl group complementary oligonucleotide a region that when newly synthesized is cleaved by a Nickase restriction endonuclease, as described in U.S. Pat. No. 5,422,252. This allows the strand displacement reaction to generate many copies of newly synthesized sequence, which form the basis of a non-thio strand displacement amplification as described in U.S. Pat. No. 6,191,267. The next step in the process is to use these amplified newly synthesized fragments, complementary to the strand displacement primers as DNA bridges to generate a signal with the capture oligonucleotide, as described above. This is illustrated in FIG. 11 , where in the strand displacement assay the ssDNA 3′-OH moiety ( 308 , 310 ) binds to a region 320 at the 3′ end of 319 composed of regions 320 , 321 and 322 . An extension reaction 323 then occurs which is then nicked in reaction 324 to produce a short portion of ssDNA 325 which accumulates by virtue of cycling reaction 326 of primer extensions and nicks. Detection of element 325 is achieved by binding a first portion of 325 to complementary 40 immobilized on bead 39 and a second portion of 325 to a labeled polynucleotide 317 . The label is then recognized by an antibody bound to alkaline phosphatase 318 .
[0000] Removal of Primers after Amplification
[0147] We describe several novel approaches to remove unused PCR primers from completed PCR reactions. It has been found that a consequence of seeking to develop systems incorporating rapid PCR reactions, i.e. completed amplification in less than about minutes, that it is necessary to increase the primer concentrations. However, this typically can generate an increased primer background in the detection step, which can reduce signal generation on the capture oligonucleotide. Experiments using purified amplicons and increased unlabelled target oligonucleotides, amongst labeled control oligonucleotides, demonstrated that these background oligonucleotides were able to remove or reduce the signal. One approach or a combination of the approaches described below can be used to reduce the background signal.
[0148] One way for providing for easy removal of primers from the reaction amplification mixture is to use a clam-like oligonucleotide primer. This oligonucleotide predominantly exhibits a certain desired secondary structure in solution, when in a first temperature range, but not in a second higher temperature range. In this example, the oligonucleotide is capable of priming the target nucleic acid in the second temperature range, but not in the first temperature range. This is achieved by designing the oligonucleotide such that the primary structure results in a secondary structure with one or more regions that hybridize, preferably predominantly in an intra-molecular manner, but also in an inter-molecular manner. This can occur in the first temperature range but not in said second temperature range, thus changing the temperature will enable switching the primer between a priming and non-priming form. As a result, lowering the temperature at the end of the amplification reaction effectively removes excess primer from the mixture. It has been found that clam-like primers of this type may be prepared incorporating a polymerase blocking region, a single stranded hybridization region and optionally a detectable moiety. Alternative methods for removing primer at the end of the amplification reaction have also been devised. These are by electrophoresis, post-PCR hybridization and enzymatic conversion.
Electrophoretic Separation
[0149] The first approach described is electrophoretic separation. It is well known that nucleic acids can be separated based on their molecular weight. By exploiting the size differences between the PCR amplicon and the oligonucleotide primers it is possible to rapidly purify the amplicon. In the preferred embodiment, an electrophoresis module is incorporated into a single-use device. For example, the electrophoretic purification module can be situated at a point along a channel in the device at a position convenient to effect purification, as shown in FIG. 12 . The device is comprised of an electrode 50 in a channel of the device and a second electrode 51 in an adjacent cavity 52 . Each electrode is connected to an electrical contact pad 53 . A channel 54 in the device provides a means through which fluid moves from an earlier stage e.g. a PCR amplification step, to a later stage e.g. a detection step.
[0150] The purification module shown in FIG. 12 can be situated on either side of the channel and above or below. It can have two or more electrodes. For example, an additional third electrode can be situated in a position between the two electrodes that are shown. For the two-electrode embodiment shown in FIG. 12 , a capture membrane for the primer sequences is used which effectively irreversibly absorbs the primer. Suitable materials include nitrocellulose, Whatman DE52 membrane, and other DNA binding membranes, well known in the art.
[0151] In one embodiment, solidified gel matrix, e.g. agarose, with an electrophoresis buffer is positioned in the cavity. A sample segment of PCR amplified material is then moved through the channel and positioned over the cavity. Optionally a second pair of conductivity electrodes can be used to sense the position of the material as it moves through the channel, as described in jointly owned U.S. Pat. No. 5,096,669 incorporated herein by reference. Once the sample is positioned appropriately, an electrophoretic charge is applied across the two electrodes, with 50 being negative, and 51 being positive. This causes electrophoretic movement of the molecules in the gel matrix, with the smaller synthetic oligonucleotide primers moving the fastest and the larger per amplicons moving slower. Once the fragments have moved an appropriate distance, i.e. out of the channel and into the cavity, the electrophoretic charge is reversed, causing the fragments to move in the opposite direction. After a certain amount of time and with a particular charge and voltage the larger molecule will have transferred back into the channel, leaving the smaller primer molecules in the gel material. This is thus a way of effecting purification of the amplicons.
[0152] In another embodiment, a third electrode is positioned between the two electrodes shown in FIG. 12 . Here electrodes 50 and 51 are set as negative and positive respectively. After a time when the primer molecules have passed the third middle electrode, but the amplicon has not, electrode 50 is reversed to positive charge, leaving electrode 51 as positive. At this point, the third middle electrode is made negative. This causes the primer to continue moving away from the channel, and reverses the direction of the amplicon back towards the channel.
[0153] FIG. 13 ( a )-(g) illustrates the steps involved using charged dyes in a device. FIG. 13( a ) shows a modified i-STAT cartridge base of the type described in jointly owned U.S. Pat. No. 5,096,669. It has an entry port 71 , a channel 72 , a cavity 73 adjacent to the channel and three electrodes 74 , 75 and 76 , two of which are in the cavity and one in the channel. The cavity contains 1% agarose with buffer as a transparent gel. A sample comprising 5 uL of common electrophoresis loading dyes, bromophenol blue and xylene cyanol, both negatively charged, is added through the entry port and enters the channel as a fluid segment 77 , as shown in FIG. 13( b ). Note that these dyes migrate at roughly 25 to 50 bp sizes, where as with actual DNA separation will be of 50 bp and 300 bp fragment.
[0154] In FIG. 13( c ) a negative potential is applied to 74 and a positive one to 76 , in this case 50V. The charged dyes quickly move into the agarose gel, towards 76 . The two dyes migrate at different rates according to their charge-to-mass ratio through gel. As shown in FIG. 13( d ) the dyes are resolved into two bands 78 and 79 either side of 75 . This takes about three minutes. At this point 74 and 76 were made positive and 75 made negative, thus driving the two migrating dyes in opposite directions as shown in FIG. 13( e ) until the xylene cyanol dye re-enters the channel, FIG. 13( f ). Finally, the xylene cyanol is pneumatically moved down the channel for further downstream applications, as shown in FIG. 13( g ) while the other dye remains in the cavity.
[0155] Clearly, the behavior of the two dyes is representative of different length nucleotide sequences or any other chemical species with different charge-to-mass ratios that could be separated from one another quickly using electrophoresis. Furthermore, the electrophoretic properties and capabilities of this device can be tailored according to gel density, buffer-salt selection, applied potential and duration, physical dimensions and the like, to achieve any desired separation.
[0156] In another embodiment, the original liquid sample is moved out of the region of the channel abutting the cavity and is replaced with a smaller amount of a different liquid prior to reversing the polarity of the electrodes. This can effect a concentration of the amplicon, which in turn can increase hybridization rates at a later stage in the assay process. In another embodiment, the primers are brought in contact with a capture membrane or particle within the cavity, which effects irreversible binding, thus preventing the primer from moving back towards the channel. In another embodiment, the agarose may be replaced with a different matrix including acrylamide, a mixture of agarose and locust bean gum, hydrocolloids, or other appropriate separation media. In another embodiment, the device is manufactured as a subcomponent on silicon and inserted into a micro-device, as shown in FIG. 12 . In another embodiment, to address constraints associated with integration of this separation component into a genetic testing device, the electrophoretic channel may be L-shaped with electrode 75 located at or near the elbow of the ‘L.’ For example FIG. 24 shows the L-shaped channel feature 655 incorporated into an integrated testing device 651 abutting conduit 409 , with electrodes 652 , 653 and 654 with entry port 657 and matrix 656 . Other elements are as for FIG. 19 .
[0157] FIG. 14 demonstrates the operation of the electrophoresis device with an amplicon and primer from a PCR reaction. Lane (A) shows a portion of the PCR reaction product after electrophoresis into gel cavity and back out again and into a fresh second recovery aliquot and applied to a 6% non-denaturing acrylamide gel. Lane (B) shows a portion of sample that remained in original aliquot removed after one direction migration. Lane (C) is a control of equivalent concentration to the sample and lane (D) is a 10 base-pair ladder at a three times greater concentration than in the sample and control. The ladder major species base-pair lengths are 330 , 100 and 10 .
Clam-Like Oligonucleotides
[0158] Normally, for PCR applications reducing the amount of secondary structure is a desirable approach when designing synthetic oligonucleotide sequences, as this helps in reducing non-specific and poor priming of the target. The predicted folding structure of an oligonucleotide that is complementary to the Hfe1 gene, that has a five base pair adenoside spacer sequence and that has a free single stranded region is shown in FIG. 15 . The FIG. 15 sequence is 5′-ACTTCATACACAACTCCCGCGTTGCATAACTAAA-AACTGGCAAGGGTAAACAGATCCCC-3′ (SEQUENCE ID No. 5). As a theoretical prediction of potential molecular folding an RNA folding program (Vienna RNA) predicts an oligonucleotide with single stranded nature at any temperature above 10° C. By designing synthetic oligonucleotides with secondary structure at low temperatures, but which lose their secondary structure during the denaturation step of PCR and PCR hybridization, we can effect hybridization of amplicons but not the primer molecules at the later stage of hybridization and detection. Using the isO15 sequence as a starting point, oligonucleotides with a hairpin loop structure were designed and modeled as shown in FIG. 16( a ) and ( b ). The base pair sequence in FIG. 16( a ) is 5′-TTGCCAGACTTCATACACAACTCCCGCGTTGCATAACTAAAAAGTATGAAGTCTGGC AAGGGTAAACAGATCCCC-3′ (SEQUENCE ID No. 6), and that 30 of FIG. 16( b ) is 5′-ACCCTTGCCAGACTTCATACCCGCGTTGCATAACTAAAAA-GTATGAAGTCTGGCAAGGGTAAACAGATCCCC-3′ (SEQUENCE ID No. 7). In the models of FIG. 16 , a five base pair sequence shown in the box is used to model the effect of an HPEG spacer. Based on the models in FIG. 16 , two oligonucleotides designated CLAM1 and CLAM2 were. The two sequences differ by four nucleotides.
[0000]
CLAM 1:
5′-TTGCCAGACTTCATACACAACTCCCGCGTTGCATAACT-HPEG-
GTATGAAGTCTGGCAAGGGTAAACAGATCCCC-3′
CLAM 2:
5′-ACCCTTGCCAGACTTCATACCCGCGTTGCATAACT-HPEG-
GTATGAAGTCTGGCAAGGGTAAACAGATCCCC-3′
[0159] In the CLAM1 sequence, the sequence located 5′ to the HPEG spacer, 5′-TTGCCAGACTTCATACACAACTCCCGCGTTGCATAACT-3′ is designated as SEQUENCE ID No. 8 and the sequence located 3′ to the HPEG spacer, 5′-GTATGAAGTCTGGCAAGGGTAAACAGATCCCC-3′ is designated as SEQUENCE ID No. 9.
[0160] In the CLAM2 sequence, the sequence located 5′ to the HPEG spacer, 5′-ACCCTTGCCAGACTTCATACCCGCGTTGCATAACT-3′ is designated as SEQUENCE ID NO. 10 and the sequence located 3′ to the HPEG spacer, 5′-GTATGAAGTCTGGCAAGGGTAAACAGATCCCC-3′ is designated as SEQUENCE ID NO. 11.
[0161] These oligonucleotide sequences maintain the key primary sequence features for Hfe1 priming in PCR reactions and for binding to the capture oligonucleotide, but additional sequences have been added to generate intramolecular binding, generating these “clam-like” structures. Note that the HPEG spacer region sequence is indicated with the five ‘A’s and it was anticipated that these sequences will have no secondary structure above about 40° to 45° C.
[0162] FIGS. 7( b ) and 7 ( c ) compare and contrast the differences between using PCR primer sequences with little or no secondary structure and the CLAM PCR primers. At temperatures during PCR, particularly at temperatures at or above hybridization, the CLAM primers do not form secondary structures and once it is incorporated into a PCR amplicon it loses its ability to form a clam structure. At temperatures below PCR hybridization and at temperatures used for hybridization of the capture oligonucleotides, the CLAM PCR primers do form secondary structure. Therefore, unincorporated CLAM PCR primers do not bind to the capture oligonucleotides and do not interfere with signal generation.
[0163] FIG. 7( b ) shows a PCR reaction using a non-CLAM oligonucleotide sequence and hybridizing to a target nucleotide sequence. A sequence like is015 with no secondary structure is used as one of two PCR primers 81 . The PEG spacer generates single stranded regions in the PCR amplicon and excess primer sequences are generated in the reaction 82 . In step 83 , both the PCR amplicon and the unreacted primer sequences can bind to the capture oligonucleotide bound to a solid substrate like a bead. Typically, the unreacted primer is in significant molar excess compared to the PCR amplicon and reduces the signal detection.
[0164] FIG. 7( c ) shows a PCR reaction using a CLAM oligonucleotide sequence hybridizing only the PCR amplicon to a target nucleotide sequence. Using a modification to the isO15 sequence to generate either CLAM1 or CLAM2 sequences, a PCR reaction is performed 81 . At temperatures used in PCR, the secondary structure is eliminated. Once one end of the. CLAM oligonucleotide is incorporated into a PCR amplicon it no longer functions with the secondary structure and provides a single stranded region 82 . In step 83 , the temperature is below that required to generate secondary structure of unincorporated CLAM primer sequences. As a result, CLAM primers that have been incorporated into a PCR amplicon will have single stranded regions capable of binding to the capture oligonucleotide.
Enzymatic Removal
[0165] Two enzymatic approaches have been devised for removal of primers, these relate to TdT-tails on unincorporated oligonucleotides and degradation of unincorporated oligonucleotides. Within a PCR reaction mixture there exist two types of structures, amplicons with single stranded regions, in the example above having an iSp 18 primer and unincorporated synthetic oligonucleotides. The primers on the amplicons only have extending 5′ regions, whereas the unincorporated primers have free 5′ and 3′ single stranded ends. Using enzymes specific to these differences at the 3′ end, strategies to differentially remove these molecules was developed.
[0166] Calf Thymus Terminal deoxynucleotidyl transferase (TdT) enzymatic treatment of the PCR reaction product is specific to single stranded 3′ extensions, thus only the unincorporated primer will generate a newly incorporated tail. By contrast, the amplicon only has single stranded regions with 5′ tails, which are unreactive with TdT.
[0167] While it is inefficient and not unique for a universal capture system, one could use a single nucleotide (dNTP) such as ‘T’ to create an extended T tail at the 3′ end of the PCR primer. Any nucleotide, including modified nucleotides, including ribonucleotides could be used for this application and which function with TdT or poly(A) polymerase. The modified PCR reaction mix with T tailed unincorporated primer sequences can then be exposed to a capture oligonucleotide with a poly(A) sequence. Only unincorporated PCR primers with Ttails will be bound to the capture poly(A) sequence. This enriches the reaction mixture for PCR amplicons with associated poly(T) sequences. The poly(A) capture oligonucleotide can be bound to solid surfaces, beads, in a matrix like agarose, acrylamide, poly vinyl alcohol or other appropriate hydrocolloids.
[0168] An alternative method is based on the use of an endonuclease. As the unincorporated oligonucleotide primer has a free 3′-hydroxyl group and the amplicon does not, a 3′-5′ exonuclease is employed to remove unincorporated oligonucleotide primer. Enzymes including ExoI and ExoT have specific 3′-5′exonuclease activity with single stranded DNA with free 3′-hydroxyl groups. In this embodiment it is preferable to use primers with 5′phosphate groups.
Post-PCR Hybridization
[0169] In the PCR reaction described above, amplicons are generated containing two primers which generate two different single stranded regions. In order to generate a signal, both single stranded regions are necessary, as well as the newly amplified region, which is a bridge between the two single stranded regions.
[0170] In this example, single stranded A region binds to the complementary A prime capture oligonucleotide at the biosensor. The single stranded B region binds to a synthetic oligonucleotide B-prime which has a moiety for the enzymatic conjugate. Alternatively, the enzymatic conjugate binds directly to the B region.
[0171] By first creating a solid substrate with B prime capture oligonucleotides bound to a solid substrate, and in this example in a channel leading to the detection region, and allowing the PCR reaction material to hybridize under the appropriate conditions, any B region oligonucleotides that were not incorporated into amplicons are lost from the channel, enriching the channel for B region oligonucleotides and B region oligonucleotides incorporated into amplicons. Unbound material is washed away.
[0172] The enriched bound B region oligonucleotides and amplicons are then released from the solid support by heat or alkaline conditions. The material is allowed to move towards the detection region of the device. Oligonucleotides with A regions or oligonucleotides incorporated into amplicons will be bound to A prime capture oligonucleotides at the biosensor. The bio sensor can be washed, removing any unincorporated B primers, leaving only fully incorporated amplicons. This effectively removes background from unincorporated oligonucleotides.
Detailed Description of Nucleic Acid Testing Cartridges
[0173] An integrated single-use device for performing a nucleic acid analysis and its interaction with the reading instrument is shown topologically in FIG. 6 . It comprises a housing 100 with an entry port 101 for accepting a sample suspected of containing a target nucleic acid. The entry port leads to a chamber 102 which has a reagent for extracting said target nucleic acid. The reagent 103 can be coated on to the wall of the chamber. The chamber may contain beads 104 , e.g. magnetic beads with a coating suitable for binding nucleic acid. The chamber also preferably contains a wax, which can melt to form a contiguous wax layer 105 in the region of egress to a conduit 106 . Once the preferred magnetic beads have associated with said target nucleic acid a magnetic field is applied to draw them through the wax layer and into the conduit. Note that this applied magnetic field may also be oscillated in the chamber to promote extraction of nucleic acid from the sample. Optionally a wash fluid may be applied to the beads prior to leaving the extraction chamber. A wash fluid chamber 122 is connected between the entry port and the extraction chamber. In addition, a sample and wash fluid waste chamber 123 is connected at the distal end of the extraction chamber, with respect to the entry port. In operation, after the extraction step the beads are held on the wall of the chamber by magnetic means and the wash fluid is then passed from chamber 122 through chamber 102 and into chamber 123 . This displaces unwanted sample material and leaves chamber 102 containing the beads and predominantly wash fluid. The instrument 200 contains an actuating means 211 which is aligned to chamber 122 and provides a force to a flexible diaphragm 124 to expel the wash fluid out of the chamber.
[0174] After washing, the beads then pass through the wax layer and into conduit 106 and then into the amplification chamber 107 . Movement of the beads in the conduit is preferably by the same magnetic means, or can be pneumatic. The amplification chamber is also attached to an amplification reagent holding chamber 108 , which can deliver these reagents to the amplification chamber with the beads, as in the preferred embodiment, or in a separated step before or after the beads enter this chamber. Alternatively, these reagents may reside in this chamber and element 108 omitted. In another alternative where amplification reagents are best dry-stored, chamber 108 may contain diluents and the reagents coated onto the wall of the amplification chamber.
[0175] The amplification reagents as described above can provide for various amplification methodologies, e.g. rolling circle and ligase chain reaction. In the preferred embodiment the reagents incorporate a detectable moiety into an amplified target by means of PCR. Optionally, an applied magnetic field may be used to provide mixing of the beads in the amplification chamber. This is in the same manner as described for the extraction chamber.
[0176] The amplification chamber also has a heating element 109 and a temperature sensing thermistor 110 for controlling the temperature of the amplification chamber and thus effecting conditions suitable for amplification of the target nucleic acid. In the preferred embodiment the amplification chamber is cycled between 680 C and 900 C for thirty cycles. The time duration at each temperature is more than 5 and less than 30 seconds respectively. While the main part of the housing 100 is made of plastic, at least one wall of the amplification chamber is made of an inert material with superior thermal conduction properties, preferably silicon. The reverse side of the silicon has a resistive path 111 and two electrical contact pads 112 and 113 which constitute the heating element 109 . An electric current passing through the resistive path causes heating of the silicon chip and thus the contents of the amplification chamber. The reverse side of the silicon also has a thermistor 110 wired by leads 114 to two electrical contact pads 115 and 116 . The output of the thermistor is used by the instrument to control the current passing through the resistive path and thus the temperature of the amplification chamber.
[0177] The single-use device 100 may also optionally include closure element 117 to seal the entry port. This can be a plastic snap-closure element of the type described in jointly owned U.S. Pat. No. 5,096,669 or the slide closure of jointly owned pending U.S. application Ser. No. 10/658,528.
[0178] The amplification chamber may also be sealed at the ingress and egress by 118 and 119 respectively. This is desirable for ensuring reagents remain in the chamber during temperature cycling. For example, element 118 and 119 may be deformable rubber seals. Actuation can be by pin elements 209 and 210 in the instrument, which move through opening 120 and 121 in the housing to contact 118 and 119 and cause sealing. Pin elements 209 and 210 may be actuated independently or together by the instrument.
[0179] The egress of the amplification chamber is attached to a second conduit 125 containing a sensing region 126 comprising an immobilized capture oligonucleotide 127 and a sensor 128 . The housing 100 contains a second pump means 129 attached to the amplification chamber for moving the amplified target to said sensing region. The pump means comprising an air-filled chamber 130 with a diaphragm 131 . The instrument 200 contains an actuating means 212 for applying a force to element 131 to pneumatically displace air from chamber 130 and thus displace the amplified target towards the sensing region.
[0180] When the amplified target arrives in the detector region it can bind to the capture oligonucleotide and be retained. The detection region also contains a dry reagent layer coated onto the wall 151 . In the preferred embodiment, the moiety associated with the primer (which becomes part of the amplicon) is biotin and the dry reagent 151 is streptavidin-labeled alkaline phosphatase. Dissolution of the reagent with the amplicon causes it to bind to the biotin via the well known biotin-avidin interaction. In operation this step generally takes from about 5 to about 15 minutes. In alternative embodiments the moiety can be 5′ FAM or 15 5′-biotin and the dry reagent anti-FITC-ALP (alkaline phosphatase) or streptavidin-glucose oxidase conjugate.
[0181] A third conduit 132 is attached to the second conduit 125 between the egress of the amplification chamber and the sensing region. It has a chamber 133 with a detection reagent 134 . Optionally, the reagent is contained in a flexible sealed foil pouch 135 and in operation the instrument contains an actuating means 213 which can provide force to the pouch and cause it to rupture by being pressed against a rupturing feature 136 , preferably a sharp plastic point molded into the housing. This caused the detection reagent to move out through the third conduit and into the second conduit. This displaces and washes away any uncaptured amplified target and other material from the sensing region while permitting amplified target to remain bound to the capture oligonucleotide. The housing 200 also contains a waste chamber 137 attached to the second conduit for receiving the displaced material.
[0182] In the final step, the detection reagent reacts with the moiety 138 incorporated into said amplified target 139 to generate a signal at the sensor 140 . In the preferred embodiment where the moiety is biotin and is bound to streptavidin-labeled alkaline phosphatase, the detection reagent is p-aminophenol phosphate which is hydrolysed to form p-aminophenol by the enzyme. This is then electrochemically oxidized at the electrode surface of an amperometric sensor to generate a current proportional to the amount of moiety that is present, as illustrated in figures showing chronoamperometry (current versus time plots).
[0183] The instrument, 200 in FIGS. 6 and 650 in FIG. 21 , used to operate the integrated singleuse device is shown interacting with the test device in FIG. 21 . It includes a port 654 for receiving the single-use device 100 and 651 . The instrument has a keypad 652 for user entries and a display 653 . One or more locating features 202 for locating the device with respect to the instrument to provide for the desired interaction of electrical connecting elements and actuating elements are provided. The instrument contains an electromagnet 203 adjacent to the location of the beads 104 in chamber 103 . The electromagnet may be used to move the beads from the extraction chamber to the amplification chamber and to promote mixing of the beads within each chamber. The instrument includes an actuating means 204 adjacent to the location of the amplification reagent holding chamber 108 which can provide pressure to the chamber and cause the reagent to be displaced into the amplification chamber. The instrument also has a pair of electrical contacts 205 and 206 for contacting element 112 and 113 and a power source for passing a current through 111 . It also includes a pair of electrical contacts 207 and 208 for contacting element 115 arid 116 for contacting the thermistor 110 . Furthermore, the instrument includes suitable electrical circuitry and an embedded algorithm for controlling the temperature of the amplification chamber through these means.
[0184] The instrument includes actuation pin elements 209 and 210 , which move through opening 120 and 121 in the housing to contact and close 118 and 119 to seal the amplification chamber. Suitable electromechanical features are included to effect this actuation along with a controlling algorithm for initiating sealing at the appropriate step in the analysis cycle.
[0185] The instrument also has an electrical connector of the type described in jointly owned It is used to make electrical connection to the sensor 128 in the housing 100 . Where it is desirable to perform the detection step at a controlled temperature, e.g. 37° C., the connector also incorporates heating and thermistor elements, which contact the back side of the silicon chip that provides the substrate for the sensor. These elements are of the same type as described for the amplification chamber. The instrument has amperometric circuitry for controlling the potential of the sensor and measuring current. The instrument also has an embedded algorithm for controlling the entire analysis sequence performed by the instrument on the single-use device to make a nucleic acid determination and display a result on a display screen on the instrument. Where the electroactive species generated or consumed in proportion to the captured target is more appropriately detected by means of potentiometry or conductimetry, alternative circuitry well known in the art is incorporated into the instrument.
[0186] In an alternative embodiment, the single-use device is composed of two separate parts as shown in FIGS. 19 and 20 . FIG. 19 illustrates a separate extraction device 470 and a combined amplification and detection device 471 . The elements in a combined form have the same features as those shown for the integrated device in FIG. 6 , with the exception of features related to transferring extracted material from one to the other. Element 470 comprises an entry port 413 , conduit 411 , wash fluid 417 and waste chambers 418 , a separation region 421 , a terminal portion of the conduit 601 and an egress port 502 which mates with ingress port 502 . It also has mating features 520 and 521 which match one or more opening 500 in 471 . Element 471 has an amplification chamber 410 , conduit 409 , chambers 408 , 409 and sensors 419 , 420 , exit conduit 405 and sealing feature 406 . FIG. 20 is similar to FIG. 19 , with the difference that it comprises a combined extraction and amplification component 472 and a separated detection component 473 . The mating features are appropriately located between the two.
[0187] FIG. 18 shows an additional embodiment where a filter region 421 is integrated into a device that performs extraction, amplification and detection. Other elements are as for FIG. 19 . FIG. 17( a ) shows an optical detection-based single-use cartridge where an optical sensor is integrated into the device that is interrogated by a reflectance method. Light is generated by element 401 and interacts with sensor 403 and is captured by detector 400 . FIG. 17( b ) shows an optical single-use cartridge where the sensing region is a cuvette feature 404 , permitting detection with a light source 402 and detector 400 integrated into the instrument.
[0188] It has been found that where the sample is a buccal swab, the extraction component element, either magnetic or filter based, is unnecessary and the sample may be directly inserted into the amplification chamber. FIG. 28( a ) and FIG. 28( b ) show two views (top and bottom) of a buccal sample device for direct application of a buccal sample to a per chamber. This extraction and amplification device attaches to the detection cartridge, by means of the mating features described above (not shown).
[0189] The general dimensions of the housing 100 are about 6 cm in length, 3 cm in width and 0.3 cm in height. The conduits and other features are preferably rendered in a device base 143 and a device cover 144 which are held together by an intervening double-sided adhesive tape 145 , see FIG. 6 . Where the base and cover are injection molded in plastic, typically ABS or polycarbonate, conduits and recesses to accommodate silicon chips, fluid containing pouched and the like are molded features. In this embodiment the adhesive tape acts as a sealing gasket to confine liquids to the desired conduits and chambers. Detailed discussion of the use of molded cover and base elements along with the use of adhesive tape gaskets is found in jointly owned U.S. Pat. No. 5,096,669 and pending US 20030170881 which are incorporated here by reference.
Detailed Description of Detection
[0190] The preferred method of detection in the single-use cartridge is electrochemical, however other sensing methods including fluorescence, luminescence, colorimetric, thermometric, fiber optics, optical wave guides, surface acoustic wave, evanescent wave, plasmon resonance and the like can be used.
[0191] The preferred sensor 128 comprises an amperometric electrode 300 , which is operated with a counter-reference electrode 301 and is shown in FIG. 6 . The amperometric electrode 300 comprises a 100 um diameter gold layer microfabricated onto a silicon chip 302 . The silicon chip is treated in the first step of manufacture to produce an insulating layer of silicon dioxide on the surface, as is well known in the art. The electrode is connected by means of a conducting line 303 to a connector pad 304 which makes contact with the electrical connector of the instrument. The conducting line is typically coated with an insulating layer of polyimide 305 . Directly over the electrode 300 or at an adjacent location 306 on the chip are adhered polymer particles 307 that have a ligand 308 complimentary to and capable of capturing the amplified target. The counter-reference electrode may be microfabricated on the same silicon chip or one place adjacently in the second conduit 125 . It comprises a silver-silver chloride layer, of 200 um diameter attached by a contact line 309 to a contact pad 310 that makes contact with the instrument connector. Again the line 309 is preferably coated with an insulating layer of polyimide. A detailed description of amperometric sensor microfabrication is found in jointly owned U.S. Pat. No. 5,200,051 which is incorporated here by reference.
[0192] A conductivity sensor comprising two conductive bars 311 and 312 are present on chip 302 , or an adjacent chip 350 , connected to contact pads 313 and 314 by lines 315 and 316 respectively, see FIG. 6 . The conductivity sensor can be used by the instrument to distinguish if liquid or air is in contact with the sensor and thus determine the position of a solution in the second conduit with respect to the sensor 300 . This solution may be one containing the amplified target or the detection reagent. Optionally a conductivity sensor may be incorporated into or adjacent to both the extraction chamber and the amplification chamber to determine the position of a fluid. A detailed description of conductivity sensor microfabrication and use is found in jointly owned U.S. Pat. No. 5,447,440 and U.S. Pat. No. 6,750,053 which are incorporated here by reference.
[0193] In an alternative embodiment of the single-use device 100 a transparent glass window is substituted for the silicon chip 302 and the sensing region of the device forms a cuvette, FIG. 17 . The amplified target capture reagent is immobilized on the glass and in this case the detection reagent contains a molecule that the moiety, e.g. alkaline phosphatase, causes to generate an optically detectable signal, e.g. fluorescence. Such molecules are well known in the art. In all other respects the operation of the single-use device is the same as in the electrochemical detection mode.
[0000] Detailed Description of Nucleic Acid Testing Cycle with Single-Use Device
[0194] The preferred embodiment of an assay cycle using the single-use device 100 in conjunction with the instrument 200 is as follows. An approximately 10 uL blood sample is added to the entry port 101 and is drawn by capillary action into the extraction chamber 102 . An entry port closure element 117 is then used to seal the entry port. Reagents 103 comprising a chaotropic agent, lithium dodecylsulfate and dithiothreitol and a chelating agent, ethylene diamine tetraacetic acid, which are coated on the wall of the chamber dissolve into the blood sample and cause lysis of the cells and permit nucleic acid from within the cells to be liberated and to be adsorbed onto the carboxylate coating on the magnetic beads 104 . A magnetic field can be used to agitate the beads to promote mixing within the chamber and speed up the rate of extraction. This step of the extraction process generally takes about 0.3 to less than 1 minute. Where the magnetic field is deployed, this is under the automatic control of the instrument and is determined by an embedded algorithm that controls the test cycle. Once this step is complete, the instrument deploys a magnetic field which holds the magnetic particles to the side of the extraction chamber. Wash fluid from the wash fluid chamber 122 is then pneumatically forced into the extraction chamber and flushes the contents into the wash fluid waste chamber 123 . Note that the wash fluid waste chamber has a vent 146 and that during this step the instrument seals the ingress 118 to the amplification chamber, thus waste fluid is directed into the waste chamber rather than entering conduit 106 . This step takes about 30 seconds. The wash fluid in the preferred embodiment is deionized water and the volume of wash fluid that passes through the extraction chamber is 20 to 30 uL. Note also that the silicon chip that forms one wall of the amplification chamber also forms one wall of the extraction chamber, as shown in FIG. 23 , thus the extraction process can be performed at a controlled temperature. In the preferred embodiment nucleic acid extraction from blood occurs at room temperature.
[0195] In the next step, the instrument opens the ingress seal 118 and releases the magnetic particles from the wall of the extraction chamber and draws them through the wax layer at the boundary of the extraction chamber and conduit leading to the amplification chamber. The instrument ensures that the temperature of the extraction chamber is sufficient for the wax to be in liquid form and permit the magnetic particles to pass through. In the preferred embodiment the wax is paraffin and the controlled temperature is at between 45 to 700 C. As discussed previously passage of the particles through the wax minimizes interferents of PCR amplification, which can include hemoglobin. The particles are then drawn into the amplification chamber. In the preferred embodiment the amplification chamber has a volume 10 of 10 to 20 uL. As shown in FIG. 23 the chamber 606 is “U” shaped having a total length of 8 mm, width of 8 mm and height of 0.25 mm. Other features of the element 609 shown in FIG. 23 are chambers 600 and 602 , ports 603 , 604 and 607 , conduits 601 and 608 , and heater 605 .
[0196] The next step of the process involves the instrument pneumatically displacing the PCR amplification reagent from its chamber into the amplification chamber. The PCR amplification reagents comprise DNA polymerase, a buffer and a modified primer. The primer comprises a sequence of bases complimentary to a first region of the target nucleic acid, a polymerase blocking region, a single stranded hybridization region attached to the polymerase blocking region with an attached detectable moiety, which is biotin. In the preferred embodiment the buffer consists of 22 U/ml Thermococcus species KOD, thermostable polymerase complexed with anti-KOD antibodies, 66 mM Tris-S04 (pH 8.4), 30.8 mM (NH4)2S04, 11 mM KCI, 1.1 mM MgSO4, 330 uM dNTPs, as well as proteins and stabilizers (Invitrogen Life Technologies AccuPrime Pfx SuperMix manual, Cat. No. 12344040), but alternatively could be 20 mM Tris-HCL (pH 8.8), 2 mM MgS04, 10 mM KCI, 10 25 mM (NH4)2S04, 0.1% Triton-X-100, 0.1 mg/ml nuclease-free BSA as described in the Stratagen Pfu DNA polymerase Instruction Manual Cat#600135 Revision$ 064003d).
[0197] In the next step the instrument seals the two sealing elements in the device, 118 and 119 , to retain the beads and reagent in the amplification chamber and the cycles the temperature thirty times between 95° C. and 99° C., and a hybridization step at 68 C with durations at each temperature of 2 seconds and 12 seconds respectively. The overall amplification time is about 12 minutes. Once this step is completed, the amplified target is then transferred from the amplification chamber and into the conduit that leads to the detection region of the device. In one embodiment, at the end of the PCR reaction gaskets sealing the PCR chip entry and exit ports are lifted off of both the entry and exit ports. An air bladder is depressed in the cartridge, creating a positive air pressure in the entry port gasket, forcing the liquid out of the exit port gasket, moving the liquid towards the final detection region of the chip. Here, a set of conductivity bars are used for monitoring the movement of liquid to the detection region.
[0198] In the preferred embodiment the clam-like primers are used, thus in the unheated conduit that leads to the detection region, these primers re-anneal to themselves and are effectively removed from the assay as interferents. In an alternative embodiment, where electrophoresis is used to separate out unwanted primer the elements described in FIG. 12 and FIG. 13 are combined into the single-use device as shown in FIG. 24 . This separation process is described above. In the single-use device with electrophoretic separation, the instrument makes electrical connection to the electrophoresis electrodes 74 , 75 and 76 (see FIG. 13 ), and 652 , 653 and 654 (see FIG. 24 ). In the device the time for this step is typically less than 1 to 2 minutes, depending on the sizes of primer and amplicon. In another alternative embodiment where enzymatic removal of unused primer is employed, the enzymatic mixture is applied to a portion of the wall 150 of the conduit leading from the amplification chamber to the detection region. This material dissolves onto the liquid containing the amplicon and converts the primer to a non-interfering form as described above. The dry reagent mixture on the wall is preferably the enzyme in a support matrix comprising trehalose or ficoll, which promotes rapid dissolution. The time taken for the enzymatic step is typically about six minutes and is dependent on the amount of enzyme, temperature, type of primer being removed. In another embodiment, post-hybridization of the amplicons with a first capture oligonucleotide, which removes the detection region of the amplicons, followed by a wash step to remove any unbound unincorporated oligonucleotides which would be involved in the final capture step can be used. The amplicons and primers bound in the first capture step are then un-bound using heat or alkaline conditions, then allowed to move to the final detection region, where the capture oligonucleotides capture fully created amplicons.
[0199] In the next step the amplicon arrives in the detection region and the dissolution of the reagent on the wall of the detection chamber 151 occurs. In the preferred embodiment this reagent is streptavidin-labeled alkaline phosphatase which binds to the moiety on the amplicon which is preferably biotin to form a complex of amplicon and the enzyme. This complex can then bind to the capture oligonucleotide on the sensor. Depending on the kinetics the amplicon may also bind first to the capture oligonucleotide and then the labeled enzyme. In the device the time for this step is typically about 5 to 15 minutes.
[0200] In the final step detection reagent is displaced from the detection reagent chamber into the sensing region, thereby displacing any unbound amplicon and labeled enzyme to the waste chamber. Elements 152 and 153 which are constriction that cause turbulence in the region of the sensor may optionally be included to enhance the efficiency of the hybridization step, thus reducing the hybridization time and the amount of wash fluid that is required. In the device the time for this step is typically less than 70 seconds and the amount of wash fluid that is used is about 10 to 50 uL. As stated previously the wash fluid also contains a reagent that enables detection. A trailing portion of the fluid is retained over the sensor, thus enabling the captured alkaline phosphatase to convert the reagent p-aminophenol phosphate to p-aminophenol which is then oxidized at the electrode to give rise to a measurable current. In the device the time for this step is typically less than 1 minute. Positioning of the trailing edge with respect to the. sensor may be achieved using a pair of electrodes 155 and 156 forming a conductivity sensor as described above.
[0201] The measured current is used by the instrument to determine the presence or absence of the suspected target nucleic acid in the original sample. This may be a qualitative result, or where the target is present, a quantitative determination of the amount of target in the sample. An algorithm for a particular target factors the original sample volume entering the extraction chamber, the number and efficiency of amplification cycles and the efficiency of the capture reaction along with any other necessary factors to determine the original concentration of the target in the sample. Such factors are independently determined using known samples from a reference method. These methods are well known in the art.
[0202] In a related embodiment, a second sensor 154 is provided in the detection region to account for any non-specific binding of the streptavidin-labeled alkaline phosphatase to the first sensor. The second sensor is the same as the first but. has a capture oligonucleotide that does not bind to the amplicon. Any signal at the second sensor is subtracted from the signal at the first by the algorithm. The overall time for the assay, from sample entry into the single-use device and insertion into the instrument, takes between about 10 and 20 minutes and generally depends on the specific target and the required number of amplification cycles. When the genetic test is complete and result is displayed by the instrument, the actuation mechanism within the instrument then releases the device and it can be removed and discarded by the user. The instrument is then ready to receive a new single-use device. A significant advantage of the disclosed device and instrument combination is that once the sample has entered the device, all other steps are controlled by the instrument, thus eliminating possible human-error in the test cycle. This means the system can be used reliably by those not specifically skilled in analytical laboratory measurement. For example a physician may use the system at the bedside or during a patient's office visit. The system may also be used at remote locations, for example in environmental monitoring and hazard assessment. An added benefit of the design is that it also retains sample residue and amplified material within the device for safer disposal.
[0203] In an alternative embodiment of housing 100 , the extraction chamber 102 contains a filter material 157 and 421 , impregnated with extraction reagents comprising a chelating agent and a chaotropic agent. One wall of the extraction chamber is also composed of heating element with a thermistor for controlling temperature. The filter material is preferably composed of 3MM Whatman paper and has a carboxylated surface which preferentially binds nucleic acid. When the sample, e.g. blood, enters the extraction chamber, it dissolves the extraction reagent and nucleic acid from the cellular material binds to the filter. This step of the extraction process takes about 0.5 to 2 minutes. A bolus of wash fluid from the wash fluid chamber 122 is then pushed through the extraction chamber and exits into the wash fluid waste chamber 123 , carrying away lysed cellular debris from the sample, while leaving the extracted nucleic acid adsorbed onto the filter. Multiple boluses of wash fluid may be used to ensure a complete wash. A further bolus of wash fluid is then pushed into the chamber and the instrument activates the heating element and controls the temperature of the bolus of fluid to 90° C., by means of the thermistor. This caused the nucleic acid absorbed onto the filter to desorb from the filter and dissolve in the fluid. The fluid containing the nucleic acid material is then pneumatically transferred to the amplification chamber. In this embodiment the wash fluid is preferably deionized water.
[0000]
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 1
<211> LENGTH: 31
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-31
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 1
ACTTCATACA CAACTCCCGC GTTGCATAAC T
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 2
<211> LENGTH: 20
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-20
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 2
TGGCAAGGG TAAACAGATC
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 3
<211> LENGTH: 22
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-22
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 3
AACAATACCA CCGTAGCGAT CA
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 4
<211> LENGTH: 22
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-22
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 4
AACAATACCACCGTAGCGATCA
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 5
<211> LENGTH: 59
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-59
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 5
ACTCATACA CAACTCCCGC GTTGCATAAC TAAAAACTGG
CAAGGGTAAA CAGATCCCC
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 6
<211> LENGTH: 75
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-75
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 6
TTGCCAGACT TCATACACAA CTCCCGCGT GCATAACTAA
AAAGTATGAA GTCTGGCAAG GGTAAACAGA TCCCC
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 7
<211> LENGTH: 79
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-79
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 7
ACCCTTGCCA GACTTCATAC ACAACTCCCG CGTTGCATAA
CTAAAAAGTA TGAAGTCTGG CAAGGGTAAA CAGATCCCC
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 8
<211> LENGTH: 38
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-38
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 8
TTGCCAGACTTCATACACAACTCCCGCGTrGCATAACT
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 9
<211> LENGTH: 33
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-33
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 9
GTATGAAGTCTGGCAAGGGTAAACAGATCCCC
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 10
<211> LENGTH: 35
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-35
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 10
ACCCTGCCAGACTTCATACCCGCGTTGCATAACT
<200> SEQUENCE CHARACTERISTICS:
<210> SEQ ID NO: 11
<211> LENGTH: 32
<212> TYPE: DNA
<213> ORGANISM: Artificial
<220> FEATURE:
<221> NAME/KEY: Misc_feature
<222> LOCATION: 1-32
<223> OTHER INFORMATION: sequence is synthesized
<400> SEQUENCE: 11
GTATGAAGTCTGGCAAGGGTAAACAGATCCCC
[0204] The above-described exemplary embodiments are intended to be illustrative in all respects, rather than restrictive, of the present invention. Thus, the present invention is capable of implementation in many variations and modifications that can be derived from the description herein by a person skilled in the art. All such variations and modifications are considered to be within the scope and spirit of the present invention as defined by the following claims. | The present invention relates to automated devices and methods for the extraction of nucleic acids from cells, the amplification of segments of nucleic acid and the detection of nucleic acids, all in a convenient and portable manner. The invention is particularly suited for use in point-of-care medical diagnostics testing. | 2 |
This application is a continuation of Ser. No. 485,728, filed Apr. 15, 1983, now abandoned.
This invention relates to pharmaceutical compositions and preparations thereof. More particularly this invention relates to pharmaceutical compositions containing oleanolic acid and/or a physiologically acceptable salt thereof.
BACKGROUND OF THE INVENTION
Anti-ulcer properties have been reported for a number of compounds having the oleanane-type of triterpenoid structure. Amongst these compounds glycyrrhetinic acid(1)(3β-hydroxy-11-oxo-18β-olean-12-en-30-oic acid) esters, amides and salts thereof are particularly known for their usefull anti-ulcer activities and some of these compounds have also been used in the treatment of ulcers. One specific derivative of glycyrrhetinic acid that received widespread attention is carbenoxolone sodium (U.S. Pat. No. 3,070,623) which is the disodium salt of the hemisuccinate of glycyrrhetinic acid. It is reported to prevent the formation and to effect the healing of gastric ulcers in animals and humans. U.S. Pat. Nos. 3,766,206, 3,934,027 and 3,859,328 report 18β-glycyrrhetinic acid amides to be effective for the treatment of and for prevention of gastric and duodenal ulcers when administrered orally or intraperitoneally. In Belgian Pat. No. 628,444 the anti-ulcer properties of a number of metal salts of glycyrrhetinic acid and its hemi-esters are reported. In European Pat. No. 0,009,801 (18β and 18α)-2α-cyano-3,11-dioxo-olean-12-en-29-oic acid and lower alkyl derivatives thereof are reported to be effective in the treatment and/or prevention of gastric and duodenal ulcers when administered orally.
Glycyrrhizinic acid, the β,β'-glucoronic acid ester of glycyrrhetinic acid, is present in liquorice, which is known to be effective in the treatment of gastric and duodenal ulcers. In British Pat. No. 1,445,831 it is claimed that the aluminium or iron salts of glycyrrhizinic acid are effective anti-ulcer compounds with hardly any or none of the undesirable side effects known for the parent acid.
Derivatives of ursolic acid are also known to possess anti-ulcer properties. In British Pat. No. 1,251,977, for instance, the preparation and anti-ulcer properties of esters of ursolic acid of the type 2 (R and R' not equal to hydrogen) are described.
In British Pat. No. 1,205,012 the isolation of liquiritic acid (3) from and extract of Glycyrrhiza glabra is described. Liquiritic acid, which is a stereo-isomer of glycyrrhetinic acid (1), has been found to possess cicatrisant, anti-inflammatory and anti-ulcer properties.
Derivatives of oleanolic acid (oleanolic acid: 4, R and R'=H) have also been acclaimed for their anti-ulcer properties. In British Pat. No. 1,251,976 esters of the type 4 ##STR1##
(with R and R' not equal to hydrogen) of oleanolic acid are reported to be active anti-ulcer compounds. In Example 10 of the latter patent the glucose induced anti-ulcer activity of three of the esters and oleanolic acid are given. Oleanolic acid was included in this test apparently for purposes of reference or comparison.
While the three esters showed marked reduction (21 to 60%) in ulceration, a non-significant reduction of 8% in ulceration was observed for oleanolic acid. This test suggests that the chemically induced ulceration is not significantly reduced by oral administration of oleanolic acid. In another report the anti-ulcer activities of glycyrrhetinic acid and related compounds, including oleanolic acid, were evaluated (S. Shibata in Proc. Asian Symp. Med. Plants Spices, K. Kusamran (Ed), vol. 1, pp. 59-78, 1981). Firstly, the inhibiting activities against stress-induced ulceration in mice are given (p. 65). Two of the test compounds (glycyrrhetinic acid and olean-12-en-3β, 30-diol) were reported to exhibit promising inhibiting activity. By contrast, the results obtained in the latter test suggest non-significant, if any, inhibiting activity against stress-induced ulceration for oleanolic acid. The paper also describes (p. 66) the effect of the glycyrrhetinic acid type of compounds against aspirin-induced ulceration, but only two compounds (glycyrrhetinic acid and olean-12-en-3β, 30-diol) which showed positive reduction of the stress-induced ulceration, were included.
It is therefore seen that although oleanolic acid has been included in tests together with other oleanane-type of triterpenoid compounds, the results reported showed no substantial, if any, preventative effect for oleanolic acid against stress-induced and chemically-induced ulceration.
The inescapable conclusion from the prior art data is therefore that oleanolic acid is not suitable for the prevention of stress-induced and chemically-induced ulceration. Furthermore, no mention can be found in the prior apt of any healing effects of oleanolic acid in respect of ulcers.
SUMMARY OF THE INVENTION
Surprisingly, therefore, it has now been found by the present applications that oleanolic acid (or salts thereof) is effective for the prevention and the healing of ulcers.
It has been found that chemically induced ulceration, i.e. produced by analgesic and/or anti-inflammatory drugs, such as aspirin and indomethacin, or other chemical agents, is significantly reduced when these drugs are administered in conjunction with oleanolic acid (or the aforesaid salts). Furthermore, it has been found that the toxicity of the organic acids, e.g. salicylic acid and other analgesic and/or anti-inflammatory drugs is reduced to a significant extent when administered in conjunction with oleanolic acid. The fact that the intrinsic beneficial activity of the analgesic and/or anti-inflammatory drugs is not detrimentally influenced by their use in conjunction with oleanolic acid, very much enhances the value of this invention. It has also been found that oleanolic acid itself possesses some analgesic activity and also that the combined use of oleanolic acid (or its aforesaid salts) with analgesic drugs results in an additive analgesic effect.
It has furthermore been found that pharmaceutical preparations comprising oleanolic acid or the salts thereof are also significantly effective in the prevention or reduction of stress induced gastro-intestinal ulcerations.
It has furthermore been found that oleanolic acid (or its aforesaid salts) is also effective in the healing of ulcers. It will also be understood that whenever oleanolic acid is used for the treatment of ulcers the aforesaid analgesic activity of oleanolic acid may in addition be beneficial in relieving the pain associated with ulcers.
The acute toxicity of oleanolic acid, which is present in edible fruit, such as grapes, is very low. Toxic doses are considerably higher than the therapeutic doses contemplated in accordance with the present invention.
Also in accordance with the present invention there are provided pharmaceutical compositions comprising an effective amount of oleanolic acid and/or a physiologically acceptable salt thereof optionally in combination with a pharmaceutical diluent or adjuvant.
Further in accordance with the present invention, there are provided pharmaceutical compositions comprising an effective amount of oleanolic acid and/or a physiologically acceptable salt thereof in combination with one or more analgesic and/or anti-inflammatory compound(s) in an effective and tolerated amount and concentration.
Further in accordance with the present invention there are provided pharmaceutical compositions comprising an effective amount of oleanolic acid and/or a physiologically acceptable salt thereof in combination with one or more compatible compound(s) effective in the treatment of stress conditions.
It is therefore feasible that such compositions can be usefully employed for the healing of ulcers, and to reduce the formation of gastro-intestinal ulcers whether chemically or stress-induced.
The analgesic and/or anti-inflammatory compounds or drugs contemplated may include the following substances:
Aspirin and aspirin derivatives, such as benorylate; salicylic acid, salicylates and derivatives, such as flufenisal; indoleacetic acids, such as indomethacin; phenylacetic acids such as ibuprofen; N-arylanthranilic acids, such as mefenamic acid; and any other acidic or other substances used in the treatment of pain and inflammatory conditions which substances cause or promote gastro-intestinal damage.
Physiologically acceptable salts of oleanolic acid which may be employed may include one or more of the following:
Sodium oleanolate;
Ammonium oleanolate;
Calcium oleanolate;
Magnesium oleanolate;
Aluminum oleanolate; or the like.
Further in accordance with the present invention there are provided pharmaceutical formulations of oral dosage forms comprising an effective amount of oleanolic acid and/or a physiologically acceptable salt thereof for release of the active ingredient at a desired site in the gastro-intestinal tract, for instance either in the stomach and/or duodenum according to known formulation techniques, e.g. slow releasing tablets.
Still further in accordance with the invention, there are provided pharmaceutical compositions comprising an effective tolerated amount of oleanolic acid and/or a physiologically acceptable salt thereof and a known compound effective in preventing ulcer formation and/or a known compound effective in thereapeutically treating ulcers and/or a known compound(s) effective in relieving the symptoms associated with ulcers, such as an antacid, e.g. aluminum hydroxide.
Due to its low toxicity, high dosages of oleanolic acid or salts thereof, can therefore be employed to produce useful results, depending upon the particular effect which is required.
Oleanolic acid is particularly suitable for oral administration and for that reason the preparations of oleanolic acid, or salts thereof, are preferably of a kind intended for oral use, namely: tablets, coated tablets, dragees, capsules, powders, granulates and soluble tablets, and liquid forms, e.g. suspensions, dispersions or solutions, optionally together with an additional active ingredient, such as one or more analgesic and/or anti-inflammatory compound(s), as discussed above.
The invention extends to a method of preparing such pharmaceutical compositions as described hereinbefore and compositions when so prepared. The compositions may be manufactured by a method which comprises mixing oleanolic acid and/or a salt thereof as above defined with a pharmaceutically acceptable carrier or auxiliary, and optionally with an analgesic and/or anti-inflammatory substance and/or another compound(s) as aforesaid.
Oleanolic acid is a known compound occurring naturally in plants, and may be prepared by any of the extraction methods known in the art.
The salts of oleanolic acid may be prepared according to methods known in the art of preparation of salts of lipophylic carboxylic acids. Alternatively, the salts of oleanolic acid can be prepared directly from plant material containing oleanolic acid in any known manner. The salts of oleanolic acid may be purified by methods known in the art, preferably by, recrystallisation from aqueous organic solvents such as aqueous alcohols.
According to a still further feature of the present invention, there is provided a method of treatment of patients suffering from, or susceptible to, ulcerogenic type disorders of the stomach and intestines, particularly acute and chronic gastric and duodenal ulcers and related conditions, which comprise administering to the said patient an effective amount of oleanolic acid and/or a physiologically acceptable salt thereof, optionally together with additional active ingredients as discussed above.
DETAILED DESCRIPTION OF THE INVENTION
The invention and its various aspects will now be described hereunder. Examples 1 and 2 are not to be regarded as part of the invention but are intended rather for information and background.
EXAMPLE 1
Preparation of Oleanolic Acid
Suitable plant material, for example grape husks (preferably dried and milled), is exhaustively extracted with such solvents in which oleanolic acid is soluble.
These include:
aromatic solvents, such as benzene;
esters, such as ethyl acetate;
ketones, such as acetone;
halogenated hydrocarbons, such as chloroform and dichloromethane;
alcohols, such as methanol and ethanol;
ethers, such as diethyl ether or dioxane;
and mixtures thereof.
Preferably the extractions are performed with chloroform, dichloromethane, ethanol, or methanol, or mixtures thereof.
From these extracts, the oleanolic acid can be separated by any method known in the art.
Preferably the extracts are treated with sufficient aqueous base to effect conversion into a water soluble salt of oleanolic acid. Preferably a diluted sodium hydroxide solution is used for this purpose.
The aqueous solution of this salt is now treated with a suitable water immiscible solvent (such as dichloromethane or diethyl ether) to remove the bulk of the non-acidic components from the aqueous phase.
The purified aqueous solution containing the salt of oleanolic acid is now acidified with a suitable acid (preferably hydrochloric or sulphuric acid), to reconvert the salt to oleanolic acid.
The crude oleanolic acid can now be recovered by filtration or sedimentation, but preferably by extraction with a solvent which is not water miscible but which is a good solvent for oleanolic acid (preferably dichloromethane or diethyl ether), and subsequent evaporation of that extract.
Purification of the crude oleanolic acid can be achieved by recrystallisation or chromatography.
EXAMPLE 2
Preparation of Sodium Oleanolate
A 10% aqueous solution of sodium hydroxide is added to an almost saturated solution of oleanolic acid in a water immiscible solvent, for example dichloromethane or diethyl ether. The volume of the sodium hydroxide solution is controlled by the amount of oleanolic acid taken; the final mixture should contain at least one, preferably 1,5 to 3, mole sodium hydroxide per mole oleanolic acid--a large excess of the sodium hydroxide solution may lower the yield. The mixture is mixed well (vigorous stirring or shaking) and the precipitated sodium oleanolate is separated. The sodium oleanolate can be recrystallised from aqueous organic solvents, preferably aqueous methanol or aqueous ethanol.
PHARMACOLOGICAL TESTS
Test 1
Analgesic Activity of Oleanolic Acid
The analgesic effect of the compound was tested in oral application to rats. 45 Minutes after application of the compound, the rats received an intraperitoneal injection of 1.0 ml 1% acetic acid. This causes a series of characteristic spasms in the untreated control animals. Analgesic effects are indicated by the reduction of the frequency of these spasms. The following results were obtained with the compound:
______________________________________ Average No. of spasms %Dose (mg/kg) (25 mins) Inhibition______________________________________Untreated (control) 43.75 -- 10 40.0 8.6 31.6 22.12 49.4100 15.10 65.7______________________________________
Test 2
Activity of Oleanolic Acid against Stress Induced Ulcers
Stress induced ulcers are experimentally caused in rats by encasing the animals in plaster of Paris bandages for 24 hours. The effect of compounds on this formation of stress ulcers is assessed by applying the drugs 1 hour before encasing the animals in the bandage and again 6 hours after encasing the animals. After 24 hours, the bandage is removed and gastric damage is assessed compared to that of untreated animals.
Treating the animals with the compound at a dose of 100 mg/kg resulted in an 83.5% inhibition of the mean total ulceration score.
Test 3
Influence of Oleanolic Acid and Sodium Oleanolate on Gastric damage caused by Administration of Analgesic/Anti-Inflammatory Drugs in Rats
Gastric damage caused by irritant substances (e.g. aspirin, indomethacin or other acidic analgesic/anti-inflammatory drugs) is assessed by applying a suitable dose of the protective compound followed later by a relatively high dose of the irritant (in the case of aspirin, approximately 550 mg/kg). After a further 5 hours, the extent of gastric damage is determined.
A. Effect on gastric damage cuased by Aspirin
Dose related reductions of the gastric damage were found as follows:
______________________________________(i) Dose of oleanolic Percentage inhibition of acid (mg/kg) Aspirin induced gastric damage______________________________________ 30 28 100 49 300 69______________________________________(ii) Dose of sodium Percentage inhibition of oleanolate (mg/kg) Aspirin induced gastric damage______________________________________ 30 1 100 30 300 47______________________________________
B. Effect on Gastric Damage Caused by Indomethacin
A dose related inhibition of the gastric damage was found as follows:
______________________________________ Percentage inhibition ofDose of oleanolic Indomethacin inducedacid (mg/kg) gastric damage______________________________________ 10 61 30 66100 80300 86______________________________________
Test 4
Acute toxicity of Oleanolic Acid
The low acute toxicity of oleanolic acid is illustrated by the fact that doses up to 4000 mg/kg did not cause any deaths in mice when administered by oral route.
Test 5
Influence of Oleanolic Acid on Gastric Damage caused by Administration of Resperine in Rats
The animals were treated with oleanolic acid (per os; tragacanth vehicle) and directly thereafter with reserpine (6 mg/kg; subcutaneous injection). After 16 hours the extent of gastic damage was determined.
Treating the animals with oleanolic acid at a dose of 100 mg/kg resulted in a 25% inhibition of reserpine induced gastric damage compared with an untreated control group.
Test 6
Influence of Oleanolic Acid on Gastric damage (HCl - Gastrin ulcer) caused by Administration of Tetragastrin in Rats
Each animal was treated with hydrochloric acid (0,2 ml of a 20% solution; per os) on day zero. From day one onwards to day 14 the animals were treated once daily with tetragastrin (100 μg/kg/day; intraperitoneal injection) and twice daily with the protective compound (100 mg/kg/treatment; per os in tragacanth). On day 15 the extent of gastric damage was determined.
In this test oleanolic acid brought about 49% inhibition of gastric damage and cimetidine a 41% reduction of gastric damage compared with an untreated control group.
Test 7
Healing effect of Oleanolic Acid on thermally Induced Ulceration in Rats
Thermal stomach ulceration was induced on day zero by means of a heated (75° C.) stainless steel stamp (5 mm in diameter). From day one onwards to day 13 the animals were treated twice daily with oleanolic acid (100 mg/kg; per os in tragacanth). On day 14 the animals were examined for the extent of gastric damage.
Oleanolic acid brought about a 59% reduction of gastric damage in this test compared with an untreated control group.
Test 8
Healing effect of Oleanolic Acid on chemically Induced Ulceration in Rats
Ulceration was induced by injecting 30% acetic acid into the stomach of the animals on day zero. From day one onwards to day 10 the animals were treated twice daily with the protective compound (100 mg/kg; per os). On day 11 the extent of gastric damage was determined.
Treating the animals with oleanolic acid resulted in a 73% reduction of gastric damage, compared with an untreated control group, while carbenoxolone sodium gave a 42% reduction in the same test.
Test 9
Reduction of Acute Toxicity of Aspirin when administered in Conjunction with Oleanolic Acid
Oral administration of aspirin and of a mixture of aspirin and oleanolic acid (in a 1:1 mass ratio) to mice gave the following results:
______________________________________ LD 50 (mg/kg)Treatment Males Females Combined______________________________________Aspirin alone 1110 2100 1800Aspirin and Greater than 4100 in all casesoleanolic acid______________________________________
Test 10
Lack of Interference of Oleanolic Acid with the anti-Inflammatory effect of Aspirin
The lack of interference of oleanolic acid with the anti-inflammatory effect of aspirin was demonstrated by comparing the inhibition of swelling (in a carrageenan induced rat paw oedema) by aspirin alone to that of aspirin at the same dose in the presence of various quantities of oleanolic acid. The compounds (aspirin and oleanolic acid) were administered orally.
______________________________________ % inhibition at time (hrs)Dose of oleanolic Dose of Aspirin geenan injectionacid (mg/kg) (mg/kg) 1.5 3 4.5 6______________________________________-- 25 12 17 11 18-- 50 18 32 17 16-- 100 30 42 32 23-- 200 45 52 34 30 25 25 23 19 22 6 50 50 25 23 13 14100 100 33 40 32 22200 200 44 36 29 25______________________________________
The differences recorded in the above test between aspirin alone and aspirin plus oleanolic acid are not significant, illustrating the lack of significant interference by oleanolic acid.
Test 11 The analgesic effect of Aspirin in the presence of Oleanolic Acid
Measurement of the analgesic effect of the test compounds was done as set out in Test 1. The ED 50 was computed for the various treatments as follows:
______________________________________Treatment ED50 (mg/kg)______________________________________Aspirin 22.3Oleanolic Acid 55.8Aspirin & oleanolic 16.0 (expressed in termsacid (mass ratio 1:1) of aspirin)______________________________________
These figures illustrate that not only does oleanolic acid not inhibit the analgesic effect of aspirin but in fact that there is an additive analgesic effect apparently due to the intrinsic analgesic activity of oleanolic acid.
Test 12
The antithrombotic effect of Aspirin in the presence of Oleanolic Acid
Aspirin inhibits the occurrence of pulmonary thrombo-embolism in animals treated with arachnidoic acid. Oleanolic acid has no effect in this regard. Addition of oleanolic acid to aspirin in a mass ratio of 1:1 causes a non-significant change in ED 50 (expressed in terms of aspirin) from 41 mg/kg for aspirin alone to 48 mg/kg for the mixture. This shows that oleanolic acid does not significantly inhibit the antithrombotic effect of aspirin.
PREPARATION OF PHARMACEUTICAL COMPOSITIONS
Oleanolic acid or one of its salts may be incorporated in pharmaceutical compositions for administration to a patient. The method of preparing such compositions includes the steps of ensuring that the compound(s) are free of undesirable impurities--this may require repeated recrystallisation or washing; comminuting the compound(s) to a required particle size; and incorporating the compound(s) for example oleanolic acid either alone or in combination with at least one analgesic and/or anti-inflammatory drug or other compound mentioned above, for example aspirin, into a desired form for administration to a patient, for example in a solid (powder, tablet or capsule form with a pharmaceutically-acceptable carrier or adjuvant) or in a liquid form (suspension or solution) for oral ingestion.
The method may include treating the compound(s) or composition(s) to any other step(s) conventionally applied in preparing pharmaceutical compositions.
EXAMPLE OF FORMULATION OF TABLETS
Tablets, each weighing 500mg and containing 100 mg of oleanolic acid were manufactured as follows:
______________________________________Composition (for 10 000 tablets)______________________________________Oleanolic acid 500 gAvicel PH102 1700 gKollidon CL 6.25 gAerosil Plain 200 25 gDried Starch (maize) 25 gMagnesium Stearate 187.5 g______________________________________
PROCEDURE
Oleanolic acid, Avicel PH102 and Kollidon CL were mixed and the mixture was then forced through a sieve of 0.5 mm openings. Aerosil Plain 200 and dried maize starch were mixed and the mixture forced through a sieve of 0.3 mm openings. The two sieved mixtures and magnesium stearate of partical size less than 0.3 mm were combined and mixed well. The total mixture was then granulated by means of mechanical granulation. The granules were finally processed into tablets using punches of 13 mm diameter. | The invention provides oleanolic acid and/or a physiologically acceptable salt thereof for use in treating a patient prophylactically and/or therapeutically for ulcerogenic-type disorders of the stomach and/or intestines. The ulcerogenic disorders can be of the type chemically induced and/or stress-induced.
The invention also provides a pharmaceutical composition comprising an active amount of oleanolic acid and/or a physiologically acceptable salt thereof in combination with an analgesic compound and/or an anti-inflammatory compound. The invention further provides for use of oleanolic acid in preventing and/or significantly reducing and/or therapeutically treating ulcerogenic-type disorders of the stomach and/or intestines. | 8 |
RELATED APPLICATION
This application claims the priority of U.S. Provisional Application No. 60/420,964 filed on Oct. 24, 2002, the disclosure of which is incorporated herein in its entirety by reference.
FIELD OF THE INVENTION
This invention relates to the processing of a message to determine a tag value according to a message authentication code.
BACKGROUND OF THE INVENTION
Data integrity and authenticity may be fundamental expectations in any secure data communications system, and they comprise an assurance that information has not been modified by someone who is not authorized to do so. In wireless communications scenarios there is a particularly high risk of an adversary intercepting and possibly modifying the communicated data and, thus, a particular need for integrity protection and authentication.
Data integrity may be provided by a Message Authentication Code (MAC). MACs are used for the integrity protection of data communications payload, since they provide a computationally efficient way of protecting even large amounts of data.
MACs are based on a symmetric shared secret between the sender and the receiver. The secret value is called the key. The secret key is one input variable to the MAC calculation and the message to be protected is another input. The MAC calculation results in an integrity check value which is referred to as a tag value. Only somebody who possesses the correct secret key is able to calculate the tag value for any given message. In conventional automatic integrity protection scenarios, the calculated tag value is appended to the message before transmitting the message and the tag value over the communications channel to the recipient. Upon receiving a message protected by a MAC, the receiver calculates a corresponding tag value on the basis of the received data and the shared secret key. If the calculated tag value is equal to the received tag value, the message is accepted as authentic. Examples of known MACs include the so-called Keyed-Hashing for Message Authentication (HMAC) algorithm which is based on cryptographic one-way hash functions such as the secure hash algorithm SHA-1 and the message-digest algorithm MD5.
In manual authentication schemes the calculated tag value is not necessarily appended to the transmitted message. In such a scheme, the tag value may be calculated by the device sending the message and by the device receiving the message. Subsequently, a user compares the calculated tag values or manually transfers a calculated tag value from one device to the other for comparison by that device. Similarly, in some applications, a MAC may be used to perform an integrity check of a data item which was generated by two different devices separately. Hence, in this scenario the data item is not transmitted from a sender to a receiver and, thus, the tag value need not be appended to the data before transmission.
The article “Enhancements to Bluetooth baseband security” by C. Gehrmann and K. Nyberg, Proceedings of Nordsec 2001, Copenhagen, November 2001, describes an example of such a manual authentication scheme of a Diffie-Hellman shared secret that was previously generated by two devices without ever communicating the shared secret via a communications link. The method is based on the assumption that, if a man-in-the-middle is present in the Diffie-Hellman key exchange, the established Diffie-Hellman keys will be different in the legitimate devices. According to this method the generated shared secret is authenticated by manually exchanging a secret key, calculating a tag value of a message authentication code from the generated shared secret and the secret key, and by manually comparing the generated tag values.
In such scenarios involving a user interaction it is desirable to keep the length of the tag value short, in order to make a comparison or a transfer of the tag value by a user feasible, i.e. in order to reduce the time necessary for such a manual comparison and to reduce the risk of errors.
G. Kabatianskii, B. Smeets and T Johansson, “On the cardinality of systematic A-codes via error correcting codes”, IEEE Transaction on Information theory, vol. IT-42, pp. 566-578, 1996, describe the relation between message authentication codes and error correcting codes and disclose a MAC construction based on an error correcting code where the code is partitioned into equivalence classes such that all codewords that differ by a constant are replaced by a singular codeword, thereby generating a new code, the so-called factor code. The tag value is then calculated from a symbol of that factor code on the basis of two keys.
SUMMARY OF THE INVENTION
Some embodiments of the present invention provide a tag value of a message authentication code that provides a high level of forgery protection for small tag sizes and small key sizes.
Some embodiments include a method of processing a message to determine a tag value from the message and from a key according to a message authentication code. The method includes:
selecting one of a plurality of symbols, the plurality of symbols forming a codeword encoding a data item derived from the message, the codeword encoding the data item according to an error correcting code, wherein said key determines which one of said plurality of symbols is selected; and determining the tag value to be the selected symbol.
This method may provide a high level of forgery security even for small tag sizes and small key sizes. A computationally efficient MAC construction may also be provided by directly selecting the tag value as a symbol of a codeword of an error correcting code.
In some embodiments, the data item derived from the message is the message itself. Hence, the message is directly used as an input to the error correcting code.
In some other embodiments, the data item derived from the message is a hash value of a one-way hash function calculated from the message, thereby reducing the message size and allowing a further reduction of the size of the key and/or the tag value while maintaining the same level of security.
Security may thereby be based on an unconditional security of the MAC function rather than relying on computational security as is the case when hash functions with long hash codes are used as MAC functions.
The MAC construction described above and in the following may provide sufficiently low forgery probabilities even for short tag values and short keys, i.e. tags and keys having a length of less than 10-15 digits and/or characters and/or other symbols, e.g. 4-6 hexadecimal characters, so as to allow a user to communicate and/or compare the tag values.
As used herein, the term message is intended to comprise any digital data item the integrity and/or authenticity of which is to be verified. Examples of messages include data items sent from a sender to a receiver, e.g. via a wireless communications link, data items generated separately or in cooperation by different devices, and the like.
In some embodiments, at least a contribution to the message is communicated from a sender to a receiver via a first communications channel; and the tag value and, optionally, the key are communicated via a second communications channel separate from the first channel. In one embodiment, the second communications channel involves a user interaction.
For example, the entire message may be communicated or, in some embodiments, each device participating in the communication may generate a contribution to the final message and send the contribution to the respective other device. Both devices then generate the final message. In this case, one or more of the transmitted contributions and/or the final message may be verified by the method described above and in the following.
Further preferred embodiments are disclosed in the dependant claims.
It is noted that the features of the method described above and in the following may be implemented in software and carried out in a data processing system or other processing means caused by the execution of computer-executable instructions. The instructions may be program code means loaded in a memory, such as a RAM, from a storage medium or from another computer via a computer network. Alternatively, the described features may be implemented by hardwired circuitry instead of software or in combination with software.
Embodiments of the present invention can be implemented in various ways including the method described above and in the following, a communications device, and further product means, each yielding one or more of the benefits and advantages described in connection with the first-mentioned method, and each having one or more embodiments corresponding to the embodiments described in connection with the first-mentioned method and disclosed in the dependant claims.
Some embodiments of the present invention also relate to a communications device for communicating data messages, the communications device comprising processing means adapted to determine a tag value from a message and from a key according to a message authentication code, the processing means being adapted to:
select one of a plurality of symbols, the plurality of symbols forming a codeword encoding a data item derived from the message, the codeword encoding the data item according to an error correcting code, wherein said key determines which one of said plurality of symbols is selected; and determine the tag value to be the selected symbol.
The term communications device comprises any device comprising suitable circuitry for receiving and/or transmitting communications signals, e.g. radio communications signals, to facilitate data communication. Examples of such devices include portable radio communications equipment and other handheld or portable devices. The term portable radio communications equipment includes all equipment such as mobile telephones, pagers, communicators, i.e. electronic organisers, smart phones, personal digital assistants (PDAs), handheld computers, or the like.
Further examples of communications devices include stationary communications equipment, for example stationary computers or other electronic equipment including a wireless communications interface. In one embodiment, one of the devices may be a network device, e.g. an access point of a computer network providing wireless access to that computer network, e.g. a LAN.
The term processing means comprises any circuit and/or device suitably adapted to perform the above functions. In particular, the above term comprises general or special purpose programmable microprocessors, Digital Signal Processors (DSP), Application Specific Integrated Circuits (ASIC), Programmable Logic Arrays (PLA), Field Programmable Gate Arrays (FPGA), special purpose electronic circuits, etc., or a combination thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a flow diagram of an example of a message authentication scenario involving user interaction.
FIG. 2 shows a flow diagram of another example of a message authentication scenario involving user interaction.
FIG. 3 illustrates a flow diagram of a method of calculating a message authentication code based on an error correcting code.
FIGS. 4 a - b illustrate flow diagrams of examples of a method of calculating a message authentication code based on a Reed-Solomon code.
FIG. 5 shows a table illustrating the probabilities of a successful substitution attack-for a number of construction examples of the MAC construction of FIGS. 4 a - b.
FIG. 6 shows a block diagram of two communications devices.
FIG. 7 illustrates an embodiment of a secure key exchange mechanism where a contribution to the generated shared secret is communicated via a wireless communications link and authenticated by the message authentication described in connection with FIGS. 3 and 4 a - b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a flow diagram of an example of a message authentication scenario involving user interaction. The message authentication scenario involves two devices, generally designated A and B, respectively. The steps on the left side of the flow diagram, generally designated by reference numeral 101 , are performed by device A, while the steps on the right side of the flow diagram, generally designated by reference numeral 102 , are performed by device B.
In the example of FIG. 1 , both devices have stored a message d as illustrated by boxes 103 and 109 , respectively. For example, the message d may have been generated by one of the devices and sent to the other device; alternatively, both devices may have received the message d from one or more other devices, or they may have generated the message in cooperation with each other and/or with a third device.
In order to verify that both devices have stored the same message, in an initial step 104 , device A generates a key k, e.g. a secret string of a suitable length and selected from a suitable key space. In step 105 , device A sends the generated key to device B, e.g. via a wireless communications link or another suitable data connection between the two devices. In step 110 , device B receives the key. In the following, the key received by device B will be referred to as k′.
In step 106 , device A calculates a tag value t of a MAC function using the message d stored by device A and the key k generated by device A as inputs. Similarly, in step 111 , device B calculates a corresponding tag value t′ of the same MAC function as device A, using the received key k and the message d stored by device B as inputs.
In step 107 device A displays the calculated tag value t and the generated key k to the user of device A. Similarly, in step 112 , device B displays the tag value t′ calculated by device B and the received key k′ to the user of device B. The user(s) compare the displayed values in order to determine whether they are equal, i.e. whether t=t′. For example, if the devices are in the vicinity of each other, a user may directly compare the displayed values. If the devices are located remotely from each other, a user of device A may read out the tag value t and the key k from device A, communicate the tag value and the key to a user of device B, e.g. by telephone or other communications means, such that the user of device B may perform the comparison with the tag value t′ and the key k′ displayed by device B.
In steps 108 and 114 , the user(s) of devices A and B, respectively, enter the result of the above comparison, e.g. by pressing an OK-button, if the tag values and keys were equal, and a CANCEL button, if the values were not equal.
It is understood that various alternative embodiments of a user input of the result of the authentication may be implemented. For example, the user may only be required to enter the result into one of the devices. In yet another embodiment, the devices may assume that the authentication was not successful, if the user does not press the OK button within a predetermined time period.
If the tag values and keys are equal, the message d stored in the two devices is successfully authenticated, and devices A and B may continue their respective processing of the message. Hence, the authentication scenario of FIG. 1 involves a user interaction as indicated by the dashed arrow 114 , since the user compares the displayed values and indicates the result of the comparison to the devices.
FIG. 2 shows a flow diagram of another example of a message authentication scenario involving user interaction. Again, the message authentication scenario involves two devices A and B, respectively, and the steps on the left side of the flow diagram, generally designated by reference numeral 201 , are performed by device A, while the steps on the right side of the flow diagram, generally designated by reference numeral 202 , are performed by device B.
As in the above example, both devices have stored a message d as illustrated by boxes 103 and 109 , respectively. In order to verify that both devices have stored the same message, in an initial step 104 device A generates a key k.
In step 205 , device A calculates a tag value t of a MAC function using the message d stored by device A and the key k generated by device A as inputs.
In step 206 , device A displays the generated key k and the calculated tag value t to the user of device A. For example, the values may be displayed as two separate values or concatenated into a single string.
The user of device A reads out the displayed value(s) and enters it into device B (step 208 ). For example, the user may enter the values via a keyboard or keypad of device B, or via any other suitable input device. It is understood that, e.g. if the devices are located remotely from each other, the user of device A may communicate the value(s) to a user of device B, e.g. by telephone or other communications means, such that the user of device B may enter the values into device B.
In subsequent step 209 , device B calculates the tag value t′ of the same MAC function as device A, using the entered key k and the message d stored by device B as inputs.
In step 210 , device B compares the calculated tag value t′ with the tag value t entered by the user of device B. If the tag values are equal, the message d is authenticated successfully (step 211 ); otherwise the message d is rejected as corrupted (step 212 ). In one embodiment, the device B may display a corresponding message to the user of device, indicating the result of the authentication. Alternatively or additionally, device B may send a corresponding message to device A.
Again, the authentication scenario of FIG. 2 involves a user interaction as indicated by the dashed arrow 213 .
Hence, in the above, two examples of authentication scenarios that involve a user interaction are described. In the above scenarios, at least one of the key k input to the MAC function and the tag value t calculated by the MAC function are read out and/or entered by a user. The user may even be required to communicate the values to another user, e.g. via telephone. Hence, in the above and similar scenarios, it is desirable to keep the size of the tag value and the key short without reducing the security provided by the authentication scheme.
It is further understood that the scenarios described above merely serve as examples, and that there are numerous other authentication schemes involving user interaction. For example, in one embodiment, the key k may be generated by a third device and communicated to the devices A and B, or the key may be generated by the user, e.g. as a PIN number, and input into both devices, or the key may be hard-coded into the two devices, or the like. Furthermore, the key and, possibly, the tag value may be calculated by device A long in advance of the actual authentication. For example, device A may generate the key and the tag value in connection with the generation of the message d by device A. In yet another embodiment, the communicated parameters, i.e. the key k in FIG. 1 or the key and the tag in FIG. 2 , may be communicated from device A to a third device from which it may be accessed by device B. For example, if B is a network device of a computer network, the above parameters may be communicated to another computer of the computer network where they may be stored and subsequently retrieved by device B.
FIG. 3 illustrates a flow diagram of a method of calculating a message authentication code based on an error correcting code. In the example of FIG. 3 , it is assumed that a data item d from a data space D is to be authenticated using a message authentication code (MAC), e.g. as in the steps 106 and 111 of FIG. 1 or in steps 205 and 209 of FIG. 2 . For the purpose of this example, the data item d will also be referred to as message. e
In general, a MAC is a mapping f from a data space D and a key space K to a tag space C, i.e. f: D×K→C where a message dεD and a key kεK is mapped to a tag tεC, i.e. (d,k)→t.
A MAC is used to protect the integrity of the message, i.e. to ensure that the data has not been altered, e.g. during transmission from a sender to a receiver of the message. In manual authentication, short MAC values are used, i.e. tags having a length of less than 10-15 digits and/or characters and/or other symbols, thereby allowing a user to communicate and/or compare the tag values. In such a manual authentication scheme, the security is based on an unconditional security of the MAC function rather than on computational security. For example, if hash functions with long hash codes are used as MAC functions, the security is based on computational security.
The unconditional security of a MAC function may be determined by considering different types of possible attacks. Two main types of attacks that are typically considered are the impersonation attack and the substitution attack. In order to ease the understanding of the following description, these types of attacks will be briefly described here. For a more detailed description reference is made to e.g. G. Kabatianskii, B. Smeets and T Johansson, “On the cardinality of systematic A-codes via error correcting codes”, IEEE Transaction on Information theory, vol. IT-42, pp. 566-578,1996, which is incorporated herein in its entirety by reference.
In an impersonation attack, the attacker tries to convince a receiver that some data is sent from a legitimate sender without observing any prior data exchange between the legitimate sender and the receiver. In a substitution attack, on the other hand, the attacker first observes some data d and then replaces the observed data with some other data d′≠d. The probabilities for the attacker to succeed in an impersonation attack and a substitution attack are denoted P I and P S , respectively, and they may be expressed as
P
I
=
max
c
∈
C
P
(
c
is
valid
)
,
P
S
=
max
c
,
c
′
∈
C
c
≠
c
′
P
(
c
′
is
valid
|
c
is
observed
)
.
For example, in the context of the key exchange protocol described in connection with FIG. 7 below, the probability for an attacker to replace the observed data d with some other data d′ is a relevant measure of the security of the key exchange method, i.e. the probability to replace a public key transmitted during the key exchange with another public key. In this scenario, the attacker succeeds, if d′ is accepted by the receiver as valid data. In a short-range wireless communications scenario, such as Bluetooth, both devices are physically close to each other and may be restricted to only accept data, if both devices have signalled that they are ready. Hence, as in such a scenario the impersonation attack can easily be avoided, the probability of a substitution attack may be regarded as the more relevant measure of security. Furthermore, in many manual authentication scenarios, the tag value calculated by the MAC function is communicated over a separate communications channel different from the communications link over which the data is sent. This is in contrast to a standard MAC scenario, where both the data and the tag value are transmitted together and may be observed by an attacker. With these assumptions, the probability of a successful substitution attack may be expressed as
P
S
=
max
d
,
d
′
∈
D
d
≠
d
′
P
(
f
(
d
,
k
)
=
f
(
d
′
,
k
)
|
d
is
observed
)
.
Thus, assuming that the key is chosen uniformly at random from the key space K, the above probability may be expressed as
P
S
=
max
d
,
d
′
∈
D
d
≠
d
′
{
k
∈
K
:
f
(
d
,
k
)
=
f
(
d
′
,
k
)
}
K
,
where |·| the cardinality of a set, i.e. |K| is the cardinality of K and the numerator in the above equation is the cardinality of the set of all keys in the key space K yielding the same MAC function for both d and d′. Hence, it follows from the above equation that, in order to provide high security, the collision probability of the MAC function f should be low.
The following examples of MAC constructions are based on error correcting codes. For the purpose of this description error correcting codes over a finite field F q will be considered. In particular, a q-ary code over F q with codewords of length n will be considered and denoted by V. In general, the code is a mapping from messages to codewords, such that each message corresponds to a unique codeword and each codeword comprises a number of symbols. Hence, the code V consists of all vectors vεV={V (d) :dεD}, where v (d) =(v 1 (d) , v 2 (d) , . . . , v n (d) ), i.e. the v i (d) εF q are the symbols of the codeword v (d) .
The Hamming distance d H (x,y) between two q-ary n-tuples x and y is the number of components of the n-tuples that are not the same, i.e. d H (x,y)=|{iε{1, . . . , n}:x i ≠y i }|. The minimum distance of a code V is
d H ( V ) = min x , y ∈ V x ≠ y d H ( x , y ) ,
i.e. the minimum distance between all codewords of the code V.
With reference to FIG. 3 , an embodiment of a MAC construction based on error correcting codes will be described, i.e. FIG. 3 is a flow diagram of an embodiment of any of the sub-processes 106 , 111 , 205 , 209 , 714 , of FIGS. 1 , 2 , and 7 , respectively.
In an initial step 301 , the input data to the MAC construction is provided, i.e. the message d to be authenticated and the key k to be used as input to the MAC function. In one embodiment, the key may be a string of symbols, digits, characters, or the like. Preferably, the key comprises less than 10-15 symbols, more preferably less than 7 symbols, e.g. 4-6 hexadecimal characters.
In step 302 , an index iε{1, . . . , n} is selected as a function g of the key k, i.e. i=g(k). In particular, if the key space K has n elements, i.e. |K|=n, each k may uniquely be mapped to one of the symbol indices and each index corresponds to one key. In one embodiment, the key is directly used as an index, i.e. i=k.
In step 303 , the tag value t is determined as the i-th symbol of the codeword v (d) of the code V that correspond to the message d, i.e.
t=f ( d,k )= v i (d) =v g(k) (d) .
Hence, the tag value is determined to be a selected symbol of the codeword of an error correcting code, where the codeword is the codeword corresponding to the message and the symbol is specified by the key. Consequently, in the above example, a MAC is obtained with a key space size equal to n and with a message space size equal to the coding space size. Furthermore, the above probability P S for a substitution attack is given by
P S =1 −d H ( V )/ n.
FIGS. 4 a - b illustrate flow diagrams of examples of a method of calculating a message authentication code based on a Reed-Solomon code.
The term Reed-Solomon (RS) codes refers to a type of error correcting codes where the code words are defined via a polynomial division with a generator polynomial, see I. S. Reed and G. Solomon, “Polynomial Codes over Certain Finite Fields”, journal of Soc. Ind. Appl. Math., vol. 8, pp. 300-304,1960, which is incorporated herein in its entirety by reference. The term Reed-Solomon code is further intended to comprise variants of the Reed-Solomon code, e.g. so-called generalised Reed-Solomon codes.
In the construction of FIG. 4 a , in an initial step 401 , the input data to the MAC construction is provided, i.e. the message d to be authenticated and the key k to be used as input to the MAC function, as described in connection with FIG. 3 above.
In step 402 , the message is expressed as a q-ary τ-tuple over F q , i.e. d=d 0 , d 1 , . . . , d τ−1 , where d i εF q . Hence, the Reed-Solomon (RS) encoding polynomial corresponding to the message is defined as
p (d) ( x )= d 0 +d 1 x+d 2 x 2 + . . . +d τ−1 x τ−1 .
In step 403 , the tag value of the MAC is calculated by evaluating the polynomial at a point specified by the key k, i.e.
t=f ( d,k )= v k (d) =p (d) ( k )= d 0 +d 1 k+d 2 k 2 + . . . +d τ−1 k τ−1 .
Hence, the key k specifies a symbol of the Reed-Solomon code that is used as a tag value. It is understood that, as described above, the symbol may be specified by any suitable function of the key.
It is further noted that, in this construction, the key is selected from the finite field F q , i.e. kεF q . Consequently, this construction has the following properties: n=q=|K| and |D|=q τ =n τ . The minimum distance of the above code is d H (V)=n−τ+1 and, thus, the probability of a successful substitution attack is P S =(τ−1)/n. It is an advantage of Reed-Solomon codes that they are long codes with a high minimum distance, thereby providing high security.
The above further implies that the probability P S increases with the size of the message space D.
FIG. 4 b shows a flow diagram of another embodiment of a MAC construction based on a Reed-Solomon code.
Again, according to this construction, in an initial step 404 , the input data to the MAC construction is provided, i.e. the message d to be authenticated and the key k to be used as input to the MAC function.
In step 405 , a one-way hash function h is applied to the message. For the purpose of this description, the term one-way hash function refers to an algorithm that takes a data item, e.g. a string, as the input and produces a fixed-length binary value (hash) as the output. In particular, this process is irreversible, i.e. finding a data item that has produced a given hash value should be computationally unfeasible. Similarly it should further be computationally unfeasible to find two arbitrary data items that produce the same hash value. An example of a suitable hash function is the standard Secure Hash Algorithm SHA-1. The SHA-1 algorithm takes a message of less than 264 bits in length and produces a 160-bit message digest. Other examples of one-way hash functions include MD4, MD5, and the like. The output of the hash function δ=h(d) is then used as an input to the Reed-Solomon code. In one embodiment, the output of the hash function is truncated to further reduce the effective message size.
Hence, in step 406 , the hash value 6 expressed as a q-ary τ-tuple over F q , i.e. δ=δ 0 , δ 1 , . . . , δ τ−1 , where δ i εF q .
In step 407 , the tag value t of the MAC is calculated by evaluating the corresponding Reed-Solomon encoding polynomial at a point specified by the key k, i.e.
t=f (δ, k )= v k (δ) =p (δ) ( k )=δ 0 +δ 1 k+δ 2 k 2 + . . . +δ τ−1 k τ−1 .
Hence, by first applying a one-way hash function like SHA-1 to the message, the size of the message space is reduced, thereby reducing the probability P S of a successful substitution attack without considerably increasing the key length or the length of the output of the MAC, i.e. the length of the tag. Consequently, a secure authentication is provided even for short keys and short message tags, thereby allowing the communication of the key and the message tags via a human interaction.
FIG. 5 shows a table illustrating the probabilities of a successful substitution attack for a number of construction examples of the MAC construction of FIGS. 4 a - b . The first column designated log 2 |D| comprises the size of the message as number of bits, the second column designated log 2 (n) shows the key size in terms of the number of bits, while the last column shows the corresponding probability of a successful substitution attack. For example, a code having a code length of four hexadecimal digits and a key size of four digits (n=q=16 4 , i.e. log 2 (n)=16) yields a forgery probability of around 2 −13 to 2 −16 for messages that are 128 bits long. Hence, a SHA-1 output truncated to 128 bits and a key size and code size of 4 hexadecimal bits yields a sufficiently high security. If the key size is increased to 5 digits (log 2 (n)=20), the probability decreases further to around 2 −17 or less.
FIG. 6 shows a block diagram of a communications system including two communications devices generally designated A and B. The communications device A and the communications device B communicate with each other via a communications link 605 .
The communications device A comprises a processing unit 602 , a radio communications unit 603 connected to the processing unit, a storage medium 604 connected to the processing unit, and a user interface 606 connected to the processing unit.
The radio communications unit 603 transmits the data received from the processing unit 602 via the radio link 605 to the communications device 607 , and it receives data from the radio link and forwards them to the processing unit. For example, the radio communications unit 603 may be based on the Bluetooth technology and transmit/receive in the ISM band at 2.45 GHz.
The processing unit 602 , e.g. a suitably programmed microprocessor, processes the data received from other devices and the data to be sent to other devices according to the functionality implemented by the communications device A. In particular, the processing unit 602 is suitably programmed to perform the security functions described above, in particular the generation of a key and corresponding tag value of a MAC function as described above.
The storage medium 604 , e.g. an EPROM, EEPROM, flash memory, or the like, is adapted to store the key k as well as the necessary parameters for the message authentication described above.
The user interface 606 comprises a display for displaying the generated key K and the corresponding tag value t, such that a user may read out the generated values and transfer them to the communications device B. Additionally, the user interface 606 may comprise data input means, such as a keyboard, a keypad, a pointing device, a touch screen, or the like.
The communications device B comprises a processing unit 609 , a radio communications unit 608 connected to the processing unit, a storage medium 610 connected to the processing unit, and a user interface 611 connected to the processing unit.
The radio communications unit 609 corresponds to the radio communications unit 603 of communications device A, thereby allowing radio communication between the radio communications devices A and B.
The processing unit 609 processes the data received other devices and the data to be sent to other devices according to the functionality implemented by the communications device. In particular, the processing unit is suitably programmed to perform the security functions described above, in particular the authentication method described above and corresponding to the authentication mechanism implemented by device A.
Likewise, the storage medium 604 , e.g. an EPROM, EEPROM, flash memory, or the like, is adapted to store the key k and the tag value t.
The user interface 611 comprises an input device, e.g. a keypad, a keyboard, a touch screen, or the like allowing a user to enter the key k and the corresponding tag value t generated by communications device A. Additionally, the user interface may comprise a display, a pointing device, and/or the like.
Hence, the communications system of FIG. 6 comprises two communications devices, e.g. two portable communications devices such as mobile telephones, a mobile telephone and a portable computer, two portable computers, or any combination of similar electronic equipment that are adapted to perform a message authentication according to the method described above.
In one embodiment, the processing units and/or the storage media may be removably inserted in the corresponding communications device, thereby allowing, the security association to be established independent of the actual device. For example the storage medium and/or processing unit may be constituted by a smart card, e.g. a SIM card.
It is further noted that the communications devices may comprise further components which have been omitted in the schematic block diagram of FIG. 6 . For example, depending on the actual implementation of the authentication scheme, the devices may comprise further input and/or output means for inputting and/or outputting the parameters of the authentication method. For example, one of the devices may comprise a further communications interface, e.g. a network card, for retrieving the key and or tag value from a network server, or the like.
FIG. 7 illustrates an embodiment of a secure key exchange mechanism where a contribution to the generated shared secret is communicated via a wireless communications link and authenticated by the message authentication described above. Hence, in this embodiment, the message is a contribution to a shared secret. When two devices, generally designated A and B, respectively, are intended to perform a secure key exchange in order to establish a shared secret key, they perform the following steps, where the steps on the left side of the flow diagram, generally designated by reference numeral 701 , are performed by device A, while the steps on the right side of the flow diagram, generally designated by reference numeral 702 , are performed by device B.
The following key exchange is based on the so-called “Diffie-Hellman” method for key agreement. In order to ease understanding of the following description, the Diffie-Hellman key agreement will be briefly described. For a more detailed description reference is made to U.S. Pat. No. 4,200,770, which is included herein in its entirety by reference.
When two devices A and B wish to establish a shared secret key, they agree on a prime number p>2 and a base g, which is a primitive mod p. The parameters p and g may be hard-coded into both devices, they may be generated by one of the devices and communicated to the other device, they may be retrieved from a third party, or the like. For example, in order to generate p and g, a value of p may be selected, for example as a large random number, e.g. comprising 1000 bits or more, and a known prime test may be performed in order to test whether p is a prime number. If not, a new p may be selected and tested until a prime number is found. Subsequently, a random number g is selected and it is tested whether g is a generator; if not, a new g is selected and tested until a generator is found.
Each device generates a secret number which is less than p−1. In the following, the secret number generated by device A will be called x, and the secret number generated by device B will be called y. Each device then generates a public key based on the secret value and the above parameters: Device A generates X=g x mod p, where mod designates the modulus function, i.e. the remainder of an integer division. Similarly, device B generates Y=g y mod p.
The devices exchange their public keys, and each device calculates a common secret value S according to:
Device A: S=(Y) x mod p, Device B: S=(X) y mod p.
Hence, as a result, the devices A and B have established a common secret key S without having communicated the secret values x and y, since (g y mod p) x mod p=(g x mod p) y mod p.
Now referring to FIG. 7 , in an initial step 703 of the key exchange, device A generates a random number x, a corresponding Diffie-Hellman public key X, and a short secret string K. The Diffie-Hellman public key X is calculated as described above based on corresponding parameters g and p, which have been agreed upon by the devices A and B. Preferably, the secret string K is determined randomly from a suitable key space, e.g. as a string of 4-6 hexadecimal digits.
In subsequent step 704 , device A uses a message authentication code (MAC) as described above to calculate a tag value t from the public key X using the secret string K as a key. It is understood that, in some embodiments, where additional data is communicated during the key establishment, the tag value may be calculated from a message including the public key X and the additional data, thereby providing integrity protection for the additional data as well.
In step 705 , the generated secret string K and the calculated tag value t are communicated to device B via a suitable communications channel, as indicated by the dashed arrow 706 in FIG. 7 . For example, the values of K and t may be transferred from device A to device B by a user interaction, e.g. by reading out the values from a display of device A and by keying in the values into device B. In another embodiment, the values may be transferred by some other means, e.g. via a telecommunications network, by sending the values as an encrypted message, e.g. an e-mail, an SMS, or the like, or via any other suitable communications channel, preferably a communications channel different from the communications channel for which the secure communications is to be established. It is an advantage that the devices A and B do not have to have a communications link established with each other; they do not even have to be in the proximity of each other. For example, the user of device A may communicate the secret string and the tag value to the user of device B by phone, mail, or any other suitable means. Furthermore, the communication of the generated values of K and t may be performed in advance of the time at which the shared secret key is actually to be established between the devices, e.g. as part of a registration procedure. In one embodiment, an identifier ID is communicated together with K and t in order to facilitate subsequent retrieval of K and t.
In step 707 , device B receives the values of K and t and, in step 710 , stores them in a storage medium 711 of device B, e.g. an EPROM or EEPROM of a portable device, on a smart card, on a hard disk or any other suitable data storage device. If the values K and t are related to an identifier ID, the values K and t are stored in relation to that identifier, e.g. using the identifier as an index.
Similarly, in step 708 device A stores the secret string K, optionally in relation to the identifier ID, in a storage medium 709 of device A. Furthermore, device A stores the secret value x, upon which the calculation of the public key X was based.
This concludes the initial registration process. The following steps including the actual key exchange are performed when the devices A and B are actually connected via a communications link. This may be immediately after the above initial registration or at a later point in time, as indicated by the lines 727 in FIG. 7 .
In step 712 , device A initiates the actual key exchange by transmitting the public key X to device B via a wireless communications link. In an embodiment where the secret string K was related to an identifier ID, device A also transmits that identifier. Likewise, if, in step 704 , the tag value t was calculated for the public key and some additional data, that additional data is also send from device A to device B.
When device B receives the public key X from device A (step 713 ), in step 714 device B retrieves the secret string K from the storage medium 711 , in one embodiment based on the identifier ID. Device B calculates the MAC tag value t′ of the received public key X and based on the secret string K.
In step 715 , device B compares the calculated tag value t′ with the previously stored tag value t. If the tag values are different, the received public key is rejected (step 716 ). For example, device B may abort the key exchange by sending a corresponding message to device A and/or by informing the user about the rejection, e.g. by providing a visual or audible indication. Otherwise, i.e. if the tag values are equal, the public key X is accepted and the process continues at step 717 .
In step 717 , device B generates a secret value y and a corresponding Diffie-Hellman public key Y, as described above.
In step 718 , device B generates the corresponding Diffie-Hellman shared secret key S=(X) y mod p.
In step 719 , device B encrypts the secret string K retrieved from the storage medium 711 using the generated shared secret key S resulting in an encrypted secret string K*. The encryption may be based on any suitable encryption method based on a symmetric secret key.
In step 720 , device B sends the encrypted string K* and the Diffie-Hellman public key Y to device A. Again, in one embodiment device B further sends the corresponding identifier ID.
In step 721 , device A receives the encrypted string K* and the Diffie-Hellman public key Y.
In step 722 , device A generates the Diffie-Hellman shared secret key s=(Y) x mod p using the secret value x stored in storage medium 709 .
In step 723 , device A uses the generated shared secret key S to decrypt the received encrypted secret string K* to obtain the decrypted secret string K′.
In step 724 , device A compares the received and decrypted secret string K′ with the secret string K originally generated by device A and stored in storage medium 709 . If the secret strings are not equal, the received public key Y is rejected, i.e. the generated shared secret key S is discarded (step 725 ). Otherwise the process continues at step 726 .
In step 726 , the received public key Y is accepted, i.e. the calculated shared secret key S is accepted as a shared secret. In one embodiment, a corresponding message is sent to device, thereby completing the key exchange. The generated shared secret key may now be used to protect the subsequent communication between the devices A and B, e.g. by encrypting and/or integrity protecting the messages sent between the devices.
It is understood that, in an alternative embodiment, the public key Y communicated from device B to device A may be authenticated by a different method, e.g. by calculating a MAC according to the method described above.
It is understood that the authentication method described herein may also be used to authenticate a previously established shared secret, e.g. a shared secret generated by an anonymous Diffie-Hellman key agreement. Hence, in this embodiment, the message is a shared secret, cooperatively generated by two devices.
It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
Although preferred embodiments of the present invention have been described and shown, the invention is not restricted to them, but may also be embodied in other ways within the scope of the subject matter defined in the following claims.
The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. | A method of processing a message to determine a tag value from the message and from a key according to a message authentication code. The method including the steps of selecting one of a plurality of symbols, the plurality of symbols forming a codeword encoding a data item derived from the message, the codeword encoding the data item according to an error correcting code, wherein said key determines which one of said plurality of symbols is selected; and determining the tag value to be the selected symbol. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This patent application claims priority to co-pending German Patent Application No. DE 10 2007 032 395.8, filed Jul. 10, 2007 which is hereby expressly incorporated by reference in its entirety as part of the present disclosure.
BACKGROUND OF THE INVENTION
The present invention relates to a rotating actuator with a variable latching behavior according to the preamble of the patent claim 1 .
BRIEF DESCRIPTION OF RELATED ART
In the case of rotating actuators, in particular in motor vehicles, it is desirable to provide the operator with a haptic feedback concerning the rotation of the rotating actuator by a certain amount, in order to indicate the completion of an operating step, for example. For this purpose, rotating actuators comprising a latching behavior are known in which a latching element latches into a latching contour. This, however, is disadvantageous in that such a rotating actuator has an invariable latching behavior and is thus suitable only in a limited extent for operating a plurality of functions, for example, of an on-board computer.
An electronically controlled fluid rotary knob as a haptic control element is known from the published patent application DE 100 29 191 A1, wherein the rotary knob of the rotating actuator moves in a magnetorheological fluid, the viscosity of which can be controlled by means of a magnetic field. By controlling the magnetic field it is possible to generate different latching behaviors. Such a rotating actuator has a complex structure, is expensive to manufacture and requires a complicated control system.
BRIEF SUMMARY OF THE INVENTION
It is the object of the present invention to provide a rotating actuator with a variable latching behavior that does not exhibit the drawbacks of the prior art.
The object is achieved by a rotating actuator in accordance with patent claims 1 and 2 . Advantageous embodiments are apparent from the dependent patent claims.
A rotating actuator with a variable latching behavior according to patent claim 1 comprises a housing, a rotary knob, a rotary shaft non-rotatably connected to the rotary knob and at least two latching contours non-rotatably connected to the rotary shaft. Furthermore, the rotating actuator comprises one support per latching contour, whereon at least one latching element is disposed which latches into the latching contour associated with the support, and which is mounted so as to be rotatable about the rotary shaft. The number of the supports matches the number of the latching contours. In addition, the rotating actuator comprises at least one locking device per support, by means of which the support can be locked relative to the housing.
In an alternative embodiment according to patent claim 2 , the rotating actuator comprises a housing, a rotary knob, a rotary shaft non-rotatably connected to the rotary knob and at least two latching elements non-rotatably connected to the rotary shaft. Upon rotation of the rotary knob, the latching elements thus move together with the rotary shaft. Furthermore, the rotating actuator has one support per latching element, with a latching contour being disposed on the support, into which the latching element associated with the support latches, and wherein the support is mounted so as to be rotatable about the rotary shaft. In addition, the rotating actuator comprises at least one locking device per support, by means of which the support can be locked relative to the housing. The number of the supports preferably matches the number of the latching elements. Optionally, the number of the latching elements is greater than the number of the supports if two latching elements latch into the latching contour of the same support.
The latching elements establish a connection in a positive fit between the latching contours, and thus the rotary knob, and the supports. If all the locking devices are deactivated, that is, the supports are not locked, then a rotation of the rotary knob causes a rotation of the supports. The supports rotate with the same angular speed as the rotary knob.
If the locking device is activated, then the associated support is fixed relative to the housing of the rotating actuator. A rotation of the rotary knob is opposed by a force generated in a known manner by the latching element and the latching contour. If the operator overcomes this force, the rotary knob and the rotary shaft rotate relative to the locked support. The latching element moves over the latching contour and the operator receives a haptic feedback concerning the rotation of the rotary knob in the form of a latching stop. The behavior of the latching stop over the angle of rotation of the rotary knob in this case substantially depends on the design of the latching contour.
If the locking device of the other support is activated, then this other support is fixed relative to the housing of the rotating actuator. When the rotary knob is rotated, the result is a latching behavior which substantially depends on the latching contour into which the latching element disposed on the fixed other support latches. Thus, the latching behavior can be varied by selecting the locked support. For this purpose, the latching contour and/or the latching elements preferably are configured in different ways. Optionally, several supports can be locked simultaneously, so that the latching behavior is a result of the superposition of the individual latching stops.
The latching contour is a successive arrangement of depressions and elevations, so that the result is, for example, a saw-tooth profile or an undulating profile. Preferably, the latching contour forms a closed circle. Depending on the configuration of the rotating actuator, the latching contour is located on the inside or the outside of the support. The number of latching positions per complete revolution of the rotary knob depends upon the number of depressions of the latching contour. The force for overcoming a latching stop is dependent, among other things, upon the height of the elevations relative to the depressions. The force curve of the latching stop depends on the shape of the flanks of the latching profile. The latching element preferably is a spring-mounted ball or a latch spring.
The locking device is preferably disposed stationary in the housing. It has, for example, a locking bar which is introduced into a recession of the support associated with the locking device or withdrawn from the recession by means of, for example, a feed mechanism. In another embodiment, the locking device comprises a magnetic ball latching device as it is described below.
A magnetic ball latching device comprises at least one permanent magnet, an electromagnet on a ferromagnetic core, and a ball which can be brought into engagement with a latching profile in a support. In this case, the permanent magnet is movably disposed in the device and can be moved between at least two end positions.
The permanent magnet is disposed between the open end of the ferromagnetic core and the ball. The ball consists of a magnetic or magnetizable material so that a force is exerted on the ball by a magnetic field. In each of its end positions, the permanent magnet is located in the area of the end of a leg of the ferromagnetic core. The magnetic field of the permanent magnet extends into the legs of the ferromagnetic core and thus retains the permanent magnet in its position.
A change of position of the permanent magnet is achieved by applying current to the electromagnet, so that a magnetic field forms in the ferromagnetic core as a consequence. The direction of the current through the electromagnet, and thus the direction of the magnetic field in the ferromagnetic core, is selected such that the magnetic pole corresponding to the pole of the permanent magnet facing the ferromagnetic core forms at that leg in the area of which the permanent magnet is located. This causes a repulsion of the permanent magnet from its current position into the other end position. Preferably, the movable permanent magnet is configured such that the permanent magnet is prevented from tipping over. In this context, tipping over means that the permanent magnet rotates in such a way that the other magnetic pole faces the ferromagnetic core.
The ball located in the area of the magnetic field of the permanent magnet follows the movement of the permanent magnet and can thus also be moved, for example, between two end positions. In one end position, the ball is in engagement with the latching profile in the support and thus blocks the movement of the support at least in one direction. In another end position, the ball is not in engagement with the latching profile. Due to the relatively small distance between the ball and the permanent magnet, a comparatively weak permanent magnet already leads to a strong magnetic force on the ball, and thus to a high resistance to vibration.
Preferably, the ferromagnetic core, which for example consists of iron, is substantially formed to be U-shaped. However, any other, in particular asymmetric, shape of the ferromagnetic core is possible without limiting the locking functionality.
The electromagnet disposed on the ferromagnetic core and the movable permanent magnet form a mechanical bistable flip-flop, with the ball following the position of the permanent magnet. Even if the ball is jammed in the latching profile, the permanent magnet is movable. If the ball is not jammed anymore at a later point in time, it follows the permanent magnet and withdraws from the engagement with the latching profile.
BRIEF DESCRIPTION DRAWINGS
The present invention is now to be explained in more detail with reference to four exemplary embodiments. In the drawings:
FIG. 1 shows a first embodiment of the rotating actuator according to the invention comprising three latching contours,
FIG. 2 shows a second embodiment of the rotating actuator according to the invention comprising two latching contours,
FIG. 3 shows a third embodiment of the rotating actuator according to the invention comprising two latching contours,
FIG. 4 shows a fourth embodiment of the rotating actuator according to the invention comprising three latching contours,
FIG. 5 shows a detailed view of a magnetic ball latching device, and
FIG. 6 shows a detailed view of a magnetic ball latching device in engagement with a latching profile.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 to 4 show schematic sectional views of different embodiments of the rotating actuator 1 according to the invention comprising a rotary knob 2 and a rotary shaft 3 non-rotatably connected with the rotary knob. For providing a better overview, the housing was omitted in FIGS. 1 , 3 and 4 . Recurring identical elements are provided with identical reference numerals.
The rotating actuator 1 according to FIG. 1 comprises three latching contours 5 , 11 and 17 , which are respectively incorporated in one of the latching discs 4 , 10 and 16 . The latching discs 4 , 10 and 16 are non-rotatably connected with the rotary shaft 3 or formed integrally with the rotary shaft 3 . Three disc-like supports 6 , 12 and 18 are mounted so as to be rotatable about the rotary shaft 3 . A ball 7 latching into the latching contour 5 of the latching disc 4 is mounted on the support 6 by means of a spring 8 . A ball 13 latching into the latching contour 11 of the latching disc 10 is mounted on the support 12 by means of a spring 14 . A ball 19 latching into the latching contour 17 of the latching disc 16 is mounted on the support 18 by means of a spring 20 .
Three magnetic ball latching devices 9 , 15 and 21 , which respectively include a movable ball, are disposed stationary in the housing of the rotating actuator 1 . As will be described with reference to FIGS. 5 and 6 , the balls can be brought into engagement with the latching profiles in the outer circumference of the supports 6 , 12 and 18 . If a ball latches into a latching profile, the corresponding support is locked. This means that the support is incapable of rotating in the housing of the rotating actuator 1 .
If none of the ball latching devices 9 , 15 and 21 is activated, then all three supports 6 , 12 and 18 can be rotated about the rotary shaft 3 . If the rotary knob 2 is rotated, the balls 7 , 13 and 19 exert forces on the supports 6 , 12 and 18 , so that they rotate at the same angular speed as the rotary knob 2 .
In FIG. 1 , the position of the balls of the ball latching devices is indicated by circles. In the present case, the latching device 15 is activated, that is, the ball of the latching device 15 is in engagement with the latching profile on the circumference of the support 12 . The rotation of the support 12 is thus disabled and the ball 13 runs through the latching contour 11 in the latching disc 10 upon rotation of the rotary knob 2 . For overcoming a latching stop, a flank of the latching contour 11 urges the ball 13 against the force of the spring 14 in the direction of the support 12 . This can be haptically perceived by the operator of the rotating actuator 1 as a latching stop.
The latching contours 5 , 11 and 17 are configured in different ways, as is indicated in FIG. 1 . Due to the different configuration of the latching contours, the force curve changes when a latching stop is being overcome, and/or the number of latching stops per rotation of the rotary knob 2 . By selecting which ball latching device is activated and thus, which of the supports is locked, the latching behavior of the rotating actuator 1 , that is, its haptic characteristic curve, can be varied. Depending on the desired latching behavior, one or more of the supports is locked.
In a second embodiment according to FIG. 2 , the rotary shaft 3 is rotatably mounted in a housing 22 by means of ball bearings 23 . The rotary shaft 3 comprises two cylindrical latching discs 24 and 31 spaced in the direction of the axis of the rotary shaft 3 and formed concentrically with the rotary shaft 3 . Latching contours 25 and 32 , respectively, which are configured differently, are incorporated in the end faces of the latching discs 24 and 31 that face each other.
Between the latching discs 24 and 31 , the supports 26 and 33 are disposed so as to be rotatable about the rotary axis 3 . The support 26 retains a ball 28 which is movable against the force of a spring 29 in the direction of the axis of the rotary shaft 3 . An annular saw-tooth latching profile 27 is disposed on the outer edge of the disc-like support 26 . The support 33 retains a ball 35 which is movable against the force of a spring 36 in the direction of the axis of the rotary shaft 3 . An annular saw-tooth latching profile 34 is disposed on the outer edge of the disc-like support 33 .
A ball of a ball latching device 30 can be introduced into the latching profile 27 , a ball of a ball latching device 37 can be introduced into the latching profile 34 . If a ball latching device is activated, that is, if a ball has been introduced into a latching profile, then the associated support is locked, that is, its rotation relative to the housing 22 is blocked.
In analogy to the first exemplary embodiment, the rotary knob 2 can be freely rotated when the ball latching devices 30 and 37 are deactivated. For example, if the ball latching device 30 is activated, its ball latches into the latching profile 27 and locks the support 26 . If the rotary knob 2 is now rotated, the ball 28 moves over the latching contour 25 and is displaced against the force of the spring 29 in the process. The operator of the rotating actuator 1 perceives this haptically as a latching behavior. A latching behavior results in an analogous manner if the ball latching device 37 is activated and if the ball 35 moves over the latching contour 32 . If the latching contours 25 and 32 are configured differently, then different latching behaviors result. If both ball latching devices 30 and 37 are activated, the result is a superposed latching behavior.
FIG. 3 shows another exemplary embodiment in which the rotating actuator 1 comprises a cup-shaped rotary knob 2 . Two supports 38 and 43 are also configured cup-shaped and are disposed concentrically relative to each other and to the rotary knob 2 so as to be rotatable about the rotary shaft 3 . The support 38 is mounted in the rotary knob 2 by means of a ball bearing 42 , the support 43 is mounted in the support 38 by means of a ball bearing 47 . A circular retaining disc 49 , which extends perpendicularly to the rotary shaft 3 , and through the center of which the rotary shaft 3 extends, retains the support 43 , and thus also the support 38 , by means of a ball bearing 48 .
Two latching balls 40 and 45 are non-rotatably connected with the rotary shaft 3 , they thus rotate with the same angular speed as the rotary knob 2 . The latching balls 40 and 45 are mounted by means of springs 41 and 46 , respectively, so that, relative to the rotary shaft 3 , they are movable in the radial direction. The ball 40 latches into a latching contour 39 in the support 38 , the ball 45 latches into a latching contour 44 in the support 43 . The latching contours 39 and 44 extend along the circumference of circular recesses in the bottom surfaces of the supports 38 and 43 , respectively.
A latching profile 53 , which cooperates with a ball latching device 52 , is incorporated in the annular edge of the support 38 . A latching profile 51 , which cooperates with a ball latching device 50 , is incorporated in the annular edge of the support 43 . Just as in the preceding exemplary embodiments, the supports 38 and 43 are freely rotatable about the rotary shaft 3 when the ball latching devices 50 and 52 are deactivated. If the rotary knob 2 is rotated, the balls 40 and 45 entrain the supports 38 and 43 , respectively.
If a ball latching device 50 or 52 is activated, a ball latches into the associated latching profile 51 or 53 , respectively, whereby the support 43 or 38 , respectively, is locked. If the ball latching device 50 is activated, then the ball 45 moves over the latching contour 44 when the rotary knob 2 is rotated and generates a latching behavior which can be perceived as a rotary haptic feedback by the operator of the rotating actuator 1 . If the ball latching device 52 is activated, then the ball 40 moves over the latching contour 39 when the rotary knob 2 is rotated and generates a latching behavior which preferably deviates from the latching behavior generated by the ball 45 in conjunction with the latching contour 44 .
Another embodiment of the rotating actuator 1 according to FIG. 4 differs from the rotating actuator according to FIG. 3 in that three cup-shaped supports 54 , 55 and 56 are disposed concentrically relative to one another and to the rotary knob 2 . The supports 54 , 55 and 56 are rotatable about the rotary axis 3 and can be locked separately by means of ball latching devices that are not shown. An unlocked support is rotated by an associated latching ball when the rotary knob 2 is rotated, in the case of a locked support, the latching ball moves over a latching contour on or in the support 54 , 55 or 56 and generates a corresponding latching behavior. The rotating actuators 1 according to the FIGS. 3 and 4 are particularly compact.
FIGS. 5 and 6 show, by way of example, the ball latching device 50 from FIG. 3 . The ball latching device 50 substantially consists of an electromagnet 58 on a ferromagnetic, U-shaped core 57 , a permanent magnet 59 and a magnetizable ball 60 . The permanent magnet 59 is mounted so as to be displaceable between two end positions, and disposed and guided in such a way that one of its magnetic poles permanently points in the direction of the ferromagnetic core 57 . In each of its end positions, the permanent magnet is located in the area of one of the legs at the open end of the ferromagnetic core 57 . Because of the magnetic force, the magnetizable ball 60 follows the movement of the permanent magnet 59 . In FIGS. 5 and 6 , the magnetic north pole is represented in a dotted way and the magnetic south pole in a hatched way.
In the state shown in FIG. 5 , the ball latching device 50 is deactivated. The permanent magnet 59 is in its first end position and the ball 60 is not in engagement with the latching profile 51 of the support 43 .
If the ball latching device 50 is activated, the electromagnet 58 reverses the magnetic field in the ferromagnetic core 57 . A magnetic force acts on the permanent magnet 59 which moves it into its second end position shown in FIG. 6 . The ball 60 follows the movement of the permanent magnet 59 and thus comes into engagement with the latching profile 51 of the support 50 . The support 43 is now locked.
The magnetic ball latching devices 9 , 15 , 21 , 30 , 37 and 52 substantially have the same structure as the magnetic ball latching device 50 . | Disclosed is a rotating actuator with a variable latching profile, the rotating actuator having a housing, a rotary knob and a rotary shaft connected in a rotationally fixed manner to the rotary knob, and also at least two latching contours connected in a rotationally fixed manner to the rotary shaft, one support per latching contour, on which support at least one latching element is arranged, the latching element engaging in the latching contour assigned to the support, and which support is mounted rotatably about the rotary shaft, and at least one locking device per support, by means of which the support can be locked relative to the housing. | 8 |
This application claims the benefit of U.S. Provisional application No. 60/006,266, filed Nov. 07, 1995.
BACKGROUND OF THE INVENTION
This invention relates to apparatus for holding a snowboard or the like in such a manner as to facilitate waxing and maintenance operations thereon.
The prior art has provided various forms of devices for holding skis on or above stationary support such as a workbench to allow for preparation of the ski base and edges. One such ski holding device is disclosed in U.S. Pat. No. 5,150,887 to Weissenbom et al issued Sep. 29, 1992.
Snowboards have become increasingly popular in recent years and, as is the case with skis, snowboards require frequent maintenance to ensure optimal performance and prolonged useful life. Maintenance procedures include cleaning, repair and waxing of the snowboard base materials as well as maintenance of the snowboard edges to remove roughness and the like. These procedures must be repeated throughout the life of the snowboard and hence it is desirable to provide apparatus for securing the snowboard in positions such that the maintenance work can readily be accomplished with, at the same time, a minimum of time and effort being required to mount and dismount the snowboard to and from the snowboard holder.
SUMMARY OF THE INVENTION
It is a general object of the invention to provide an improved apparatus for holding snowboards and the like at a work station during repair and maintenance operations.
A further object is to provide apparatus for holding a snowboard in a stable horizontal position during snowboard base preparation and maintenance which apparatus also employs means permitting the board to be swung around into a vertical orientation and held there in a stable manner for board edge maintenance procedures.
It is a further object of the invention to provide an improved three-point support arrangement which provides substantial support of the snowboard for base preparation and wherein an intermediate support can be quickly and readily swung out of the way to allow the board to be moved into a vertical orientation for edge maintenance.
It is a still further object of the invention to provide a snowboard holding apparatus of the type noted above which is provided with clamps for securely engaging the ends of the snowboard and holding it firmly in position during repair and maintenance procedures.
It is a further general object to provide apparatus for use in snowboard maintenance and repair procedures which is adaptable for use with a very wide variety of snowboards having different lengths, widths, board tip angles and board thicknesses.
Accordingly, the invention in one aspect provides a portable holder for use in spaced relation with a similar holder as a snowboard support for maintenance operations at a work station, each said holder being adapted to support one of the opposing end portions of the snowboard. The portable holder comprises a base section adapted to be fixed to the work station in a generally upright position and a snowboard support head mounted to said base section for movement between a position where said support head is generally horizontal for snowboard base maintenance to one where said support head is generally vertical. The base section further has a side clamp thereon for releasably clamping a snowboard in a generally vertical orientation for snowboard edge maintenance when the support head is in the generally vertical position, whereby said holder can be readily converted between snowboard base maintenance and snowboard edge maintenance operations.
The support head is preferably mounted to the base section for generally pivotal movement between said horizontal and vertical positions and means are provided for locking the support head in either said position.
The said side clamp preferably comprises a clamp leaf and a cam associated therewith to bias said clamp leaf against a snowboard located in said side clamp to fix the snowboard relative to said base section for edge maintenance thereof.
The snowboard support head typically has a resilient surface thereon to frictionally engage the snowboard when resting thereon in the generally horizontal snowboard base maintenance position.
In another embodiment of the invention each said holder includes an end clamp for gripping an end of the snowboard to secure same to said support head. Preferably said end clamp includes opposed jaws for gripping said snowboard end therebetween and a clamp jaw actuator handle for opening and closing the jaws. As a further feature said actuator handle has a pressure spring associated therewith to permit said jaws to resiliently engage a variety of snowboard end thicknesses.
The end clamp preferably includes a wing assembly detachably secured to said support head to hold the end clamp outboard of the base section, said wing assembly being flexible to accommodate a variety of snowboard tip angles.
Another aspect of the invention provides a center support for use with the portable holder described above and adapted to be attached to the work station intermediate a pair of said holders to provide additional support to the center of the snowboard during base maintenance. The center support has a board contacting center support head and means for adjusting the height of same relative to the work station.
The center support preferably includes a center support base to which said board contacting center support head is mounted. The center support base has upper and lower sections with the upper section being releasable from the lower section and pivotable and rotatable relative thereto outwardly and downwardly to provide clearance, when in use, to permit the snowboard to be moved into the vertical orientation and secured in the side clamps of the board holders for edge maintenance purposes.
In a preferred embodiment said center support head is mounted for movement inwardly or outwardly of the support base to provide the adjustment in height. A spring acts to bias the center support head outwardly, and means are provided to secure the center support head in the desired adjusted condition.
Further features of the invention will be apparent from the detailed description of preferred embodiments which follows hereinafter, reference being had to the appended drawings.
BRIEF DESCRIPTION OF VIEWS OF DRAWINGS
FIG. 1 is a perspective view illustrating a pair of snowboard holders clamped to a table or work bench in spaced relation with the snowboard shown in a raised position above these holders;
FIG. 2 is a further perspective view showing the snowboard positioned on the two holders for snowboard base preparation/maintenance;
FIG. 3 is a further perspective view showing the same two holders clamped to the work bench but with the snowboard having been moved into a vertical orientation and held by the clamps of the holders for snowboard edge maintenance;
FIG. 4 is a further perspective view showing the two holders in positions ready to be secured to an optional support rail, which support rail in turn is adapted to be fixed to a work bench or table;
FIG. 5 is a front elevation view of a holder in accordance with the invention with the snowboard supporting head portion being shown in the horizontal position;
FIG. 6 is a view similar to that of FIG. 5 except that the head portion has been rotated into a vertical orientation and the snowboard placed into position in the side clamp of the holder and secured in a vertical orientation;
FIG. 7 is a front elevation view of the base portion of the holder;
FIG. 8 is a top plan view of the holder base;
FIG. 8A is a further view showing the locking block in the base portion;
FIG. 9 is an elevation view of the board supporting head portion of the holder;
FIG. 10 is a perspective view of the portable kit of parts related to the embodiment of the invention shown in FIGS. 1-9;
FIG. 11 is a further perspective view showing a spaced pair of holders as in FIG. 1 for supporting opposing end portions of the snowboard, each such holder having a board end clamp for securing the board in position, there also being provided a center support assembly, all of the above being shown as clamped to a table or work bench;
FIG. 12 is a further perspective view showing the arrangement of FIG. 11 when in use with the snowboard being clamped in a horizontal position for base preparation;
FIG. 13 is a further perspective view showing the board oriented in a vertical position and held by the side clamps and the center support having been pivoted around and swung downwardly out of the way;
FIG. 14 illustrates the additional components over and above those in FIG. 1 needed to make up the holding system/assembly illustrated in FIG. 11;
FIG. 15 is a further perspective showing the holding system of FIGS. 11-14 in positions ready to be mounted by way of an optional support rail on a table or workbench;
FIG. 16 is a perspective view of the center support assembly.
FIG. 17 is a partially exploded view of the center support assembly;
FIG. 18 is a further perspective of the center assembly with the upper section of the center support base having been pulled upwardly and released from the lower base section;
FIG. 19 is a further perspective view of the center support showing the upper section thereof having been rotated 90° about a vertical axis relative to the lower section;
FIG. 20 is a further perspective of the center support showing the upper section of the support base having been lowered downwardly onto the lower section at right angles thereto;
FIG. 21 is a further perspective of the center support showing the entire upper section thereof having been pivoted 90° about the horizontal axis to move the center support out of the way as illustrated in FIG. 13;
FIG. 22 is a perspective view showing how the board end clamp assembly is mounted to the T-member of the board end holder;
FIG. 23 is a side elevation view, partly in section, of the board end clamp assembly with the jaws thereof in clamping engagement with the tip of a snowboard;
FIG. 24 is a side elevation view similar to that of FIG. 23 but with the clamp jaws shown separated or open;
FIG. 25 is an exploded perspective view of the board end clamp assembly and associated components;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring firstly to FIGS. 1-10, which illustrate an embodiment of the invention in its simplest form, there is shown a pair of portable holders 10 for use in spaced relation with one another as a snowboard support for maintenance operations being carried out at a work station. Each of these holders is adapted to support one of the opposing end portions of the snowboard 12.
Essentially, each holder comprises a base section 14 adapted to be fixed to the work station in a generally upright position. A snowboard support head 16 is mounted to the base section 14 for movement between a position where the support head 16 is generally horizontal for snowboard base maintenance (as seen in FIGS. 1 and 2) to a position wherein the support head 16 is generally vertically oriented (as in FIGS. 3 and 6). It will also be seen that the base sections 14 each further include a side clamp 18 thereon for releasably clamping the snowboard in the generally vertical orientation for snowboard edge maintenance (as seen in FIGS. 3 and 6). By virtue of this movably mounted support head 16 and by virtue of the side clamp 18 arrangement, the holders 10 can be readily converted between snowboard base maintenance and snowboard edge maintenance operations. Further details of the holder configuration and construction will be described hereinafter.
As clearly seen in FIGS. 1 and 2, the holders 10 are mounted to the work bench by means of C-clamps 20. The base sections of the holders are provided with convenient apertures 22 extending above and parallel to the base bottoms thereby to receive the upper legs of the C-clamps 20 to permit convenient clamping to the work bench.
As seen in FIG. 4, the holders are both mounted to an (optional) elongated support rail 26 having a multiplicity of ribs 28 on its upper surface which interface with spaced grooves 30 provided in the bottom of the holder base sections 14 thereby preventing unwanted rotation of the holders 10 about their vertical axes. Mounting knobs 32 sized to fit into the bottoms of the holder base sections 14 co-operate with headed adjustment screws 34 located within a center dove-tail groove 36 of the support rail 26 thereby to enable the holders 10 to be slid toward and away from one another and then tightened at the desired distance from each other thereby to accommodate the length of the snowboard to be worked on. The support rail 26 is, in turn, affixed to the work bench by means of suitable fasteners in a manner well known in the art.
Reference will now be had to FIGS. 5-9 which show the holder 10 in detail. The holder 10 itself is preferably made from a sturdy moulded plastics material preferably reinforced with glass fibres to provide the necessary strength and rigidity. The base section is preferably moulded as two almost identical halves about a plane of symmetry with the two halves being held together by threaded fasteners 40. These two halves of the base section, when assembled together, also interlock with and securely fix the side clamp assembly 18 to the base section 14.
The upper half of the base section 14 includes a spaced apart generally parallel pair of wide but relatively thin flanges 42. The previously mentioned support head includes a somewhat elongated head portion 44, to the central portion of which is affixed a support tongue 46. This support tongue is sized so as to fit between the two flanges 42 noted above of the base section. The lower corner of the support tongue is arcuately curved at 54. The support tongue has a large aperture 48 in it, which aperture has a pair of recesses 48a, 48b at right angles to one another and through which aperture 48 passes an adjustment bolt 50, which bolt passes through the two flanges 42 of the base section, through coil spring 51, through a locking block 53, and into adjustment knob 52 behind which is the spring-biased locking block 53. Locking block 53 is non-rotatably and slidably mounted for movement in frontal flange 42 and is shaped to complement the shape of the recesses 48a, 48b. Knob 52 can be tightened to move the locking block inwardly to lock the support head 16 in position or loosened to allow the block 53 to be pushed outwardly by the spring 55 to move it clear of the aperture in the tongue 46. Hence, by virtue of the two recesses 48a, 48b at right angles to one another with which locking block 53 can alternately engage, the support tongue 46 and support head 16 are provided with a pair of relatively stable locked positions, i.e. when the support head 16 is in the generally horizontal configuration shown in FIG. 5, the locking block 53 can enter into the first recess 48a when knob 52 is tightened (FIG. 8A). Conversely, after knob 52 is loosened to withdraw block 53 and the support head 16 is lifted upwardly, then the entire support head can be rotated around 90° and the support head then allowed to drop down vertically a short distance with knob 52 being tightened until block 53 enters into the second recess 48b (FIG. 8A) thus providing a locked second vertical position for the support head as shown in FIG. 6. This locked second (vertical) position is of importance in the second embodiment of FIGS. 11-25 as it enables two boards to be held in the vertical position at the same time for edge maintenance work.
The head portion 44 of the support head is provided with an elongated resilient rubber pad 56 to prevent damage to the snowboard upper surface during use and also to provide for good frictional engagement therewith. The upper surface of this pad 56 is preferably ribbed to increase the frictional holding forces. The head portion is also provided with reinforcing flanges 58 which are co-planar with and disposed in flanking relation to the support tongue 46. These flanges are each provided with a rectangular aperture 60 to permit mounting of a board end clamping assembly to be described hereinafter.
With reference to FIGS. 5 and 6 for example the side clamp 18 is fixed in a dove-tail-like recess between the two halves of the base section 14. With the exception of the pivoting lever cam, the side clamp is moulded as a one-piece formation. It includes a sturdy and rigid upright cam mounting arm 62, the upper end of which is bifurcated to receive the lever cam 64 which is pivoted to the upper end of the arm by a pivot pin 66. An elongated clamp leaf 68, which is integrally connected at its lower end with the base of the cam mounting arm 62, extends upwardly in spaced parallelism to the cam mounting arm 62, terminating slightly beyond the upper end of the latter. The clamp leaf 68 is provided with an elongated resilient rubber pad 70 to firmly frictionally grip the snowboard surface and at the same time preventing damage thereto. The lever cam 64 is provided with a cam section 72 which is shaped such that as the lever cam is rotated counterclockwise as seen in FIG. 5, the clamp leaf 68 is forced toward the side edge portions of the flanges 42 thereby securely engaging a snowboard which has been positioned between the base section flanges 42 and the clamp leaf 68. That portion of the clamp leaf 68 which makes contact with the cam section 72 may be provided with multiple serrations therein (not shown) to prevent unwanted release of the lever cam 64 during use.
The complete kit of parts required to provide the arrangement shown in FIG. 1 is illustrated in FIG. 10. The two holders 10 are shown along with the associated C-clamps 20. All of these parts may be easily fitted into a convenient carrying bag to provide ready portability. The kit can be assembled or fitted onto any convenient work bench or table top.
The snowboard holding system illustrated in FIGS. 11-24 includes a number of additional features over and above those described above in connection with the arrangement of FIGS. 1-10. FIG. 11 is a perspective view showing a spaced pair of holders 10 constructed as described above in connection with FIGS. 1-10. However, each such holder 10 is provided with a respective board end clamp assembly 80 for snugly securing the board in position on the two holders 10. In addition, there is also provided a center support 82 to provide increased stability under the board when working on the base. As shown in FIG. 11, the two holders 10 and the center support 82 are secured to the work bench by means of the C-clamps 20 illustrated. In place of the C-clamps, the support rail assembly 26 shown in FIG. 15 may be utilized. This support rail assembly makes use of the same adjustment knobs 32 and screws 34 as briefly described in connection with FIG. 4 whereby the two holders 10 and center support 82 may be adjusted back and forth along the support rail 26 and fixed in any desired positions relative to one another.
FIG. 12 shows the snowboard positioned on and supported by the two holders 10 and the center support 82. In addition the end clamp assemblies 80 have been moved into the holding or gripping positions whereby the snowboard is positively prevented from moving off the two holders 10 and center support 82.
In the configuration shown in FIG. 13 the snowboard has been rotated into the vertical position for edge repair or maintenance, the board being held in the side clamps 18 of the two holders 10 exactly as illustrated previously in connection with FIG. 3. The only difference here is that the center support 82 has been swung around and downwardly clear of the lower edge of the snowboard.
FIG. 14 is a perspective view depicting the additional components needed to make up the snowboard supporting and holding system shown in FIGS. 11 onward over and above those components needed to produce the system of FIGS. 1-10. In particular all that is needed is the center support 82, an additional C-clamp to hold it in place on the work bench, and two board end clamp assemblies 80, one for each of the previously described holders 10. This helps to illustrate the fact that a small repair shop may choose to start out with the simpler system illustrated in FIGS. 1-10 and then at a later point in time upgrade the system to the more sophisticated arrangement of FIGS. 11-25 simply by purchasing the additional components illustrated in FIG. 14.
The center support 82 is clearly shown in its several configurations in FIGS. 16-21. With reference to FIG. 16, the center support includes a center support head 84 which contacts the snowboard surface during use and applies upward pressure to it, the center support head 84 being mounted in the base upper section 86 with the latter, in turn, being mounted to the lower base section 88. These components, as with the holders 10 previously described, are preferably made of a tough fibre-filled plastics material to provide the necessary strength and rigidity. Each of the upper and lower base sections 86, 88 are preferably made by moulding as two halves secured together by suitable fasteners 90 in a manner which need not be described in detail.
Referring to FIG. 17, the center support head 84 includes a somewhat elongated rectangular head element 92 which is covered by a rubber pad 94 thereby to engage the snowboard surface without damaging same while providing a reasonable frictional grip therebetween. A support tongue 96 is formed integrally with the head element and extends downwardly from the central portion thereof, such tongue 96 having opposed generally parallel walls and having an elongated center slot 98 extending longitudinally thereof. The lower comers of the support tongue are recessed and are provided with short posts 100 which serve to retain thereon coil compression springs 102.
The support tongue 96 extends downwardly into a slot-like recess 104 provided in the upper base section 86. The upper base section 86 is provided with spaced pockets (not shown) each receiving a respective one of the coil springs 102 noted above so that when the support tongue 96 is properly positioned within the recess 104, the springs 102 tend to urge the entire center support head 84 upwardly. A height adjustment bolt 105 also extends through the upper part of the upper base section 86, this bolt being associated with an adjustment block 107 which is located in an elliptical hole (not shown) so that it cannot rotate on the rear face of the upper base section such that the adjustment block 107 can make direct contact with the rear face of the support tongue 96 (as seen in FIG. 17), such rear face being provided with shallow serrations (not shown) such that when the adjustment bolt 105 is tightened, as by rotating an adjustment knob 109, the center support head 84 can be effectively secured in any desired position height-wise relative to the base sections 86, 88. Accordingly, once the snowboard has been positioned on the holders 10 which support the opposing end portions of the snowboard, the effective supporting height of the center support head 84 can readily and quickly be adjusted to provide the desired degree of stability to the central portion of the board.
With reference to FIG. 18 it will be seen that the upper base section 86 has been lifted upwardly a predetermined distance relative to the lower base section 88. The lower part of the upper base section 86 is provided with a generally rectangular recess 108 which snugly receives therein an upstanding rectangular boss 110 formed on the upper or top surface of the lower base section 88. Hence, when the upper and lower base sections 86, 88 are in close communication with each other as shown in FIG. 16, the entire base acts as a single rigid unit and there is sufficient interference between the walls of the recess 108 and boss 110 that a small amount of force is required to pull them apart. It will also be noted that the upper base section 86 is provided with a flat-sided transverse pin 112 which extends lengthwise and within the above-noted recess 108 and is fixed for rotation with upper base section 86. This pin 112 is engaged with and passes through the enlarged eye 114 formed at the upper end of a vertical coupling pin 116 which is mounted in the lower base section 88. This coupling pin 116 is provided with a lower enlarged head 118 which limits the degree of upward movement of the coupling pin 116 relative to the lower base section 88. In other words, the head 118 of the coupling pin, which comes up into contact with the interior surface of the top wall of the lower base section 88, effectively limits the degree to which the upper base section 86 can be lifted, this upper limit being illustrated in FIG. 18 where it will be seen that the lower extremities of the upper base section 86 are just clear of and slightly above the upper extremities of the boss 110.
With reference to FIG. 19, it can be seen that the entire upper base section 86, together with the central support head 84, have been rotated through a 90° angle about the axis of pin 116 relative to the lower base section 88. It will be further observed from FIG. 19 that the aforementioned boss 110 is essentially of a hollow configuration, firstly to accept the transverse pin 112 when the upper base section 86 has been fitted downwardly over the boss 110 as in FIG. 16, and secondly, to provide transversely oriented opposed openings 120 defining trunnions into which the transverse pin 112 may enter once the upper base section 86 has again been lowered downwardly onto the lower base section 88 (such upper and lower base sections being at 90° angles to one another about a vertical axis, all as illustrated in FIG. 20). The distance between the flats of the transverse pin 112 is only marginally less than the widths of the entrances to openings 120 to allow entry when the upper base section 86 is vertical, but preventing escape of the transverse pin 112 from openings 120 after the upper base section has been rotated 90° to the horizontal as shown in FIG. 21.
By virtue of the structure just described the entire upper base section 86 together with the central support head 84 can be rotated around the axis defined by the transverse pin 112 to the orientation shown in FIG. 21 such that the entire upper base section 86 and center support head 84 have now been pivoted around, downwardly, and well clear of the snowboard, hence allowing the latter to be moved into the vertical position and secured by the side clamps of the two holders 10 in the configuration best illustrated in FIG. 13.
It was previously noted that in the arrangement shown in FIGS. 11-24, that the two holders 10 were each provided with an associated board end clamp assembly 80. One of these assemblies will now be described with reference to FIGS. 22-25.
It was previously noted that the reinforcing flanges 58 of the support head were provided with a spaced part pair of rectangular apertures 60 (FIGS. 9 and 22). Each end clamp assembly 80 includes a clamp wing 124, the inner proximal end of same bearing spaced anchor tips 126 (as best seen in the enlargement associated with FIG. 22), each such anchor tip comprising a bifurcated spear head 128 sized to fit into the rectangular aperture 60 tightly so that the halves of the bifurcated spear head 128 are sprung toward each other during insertion through the aperture 60 with the opposed recesses 130 behind the spear head permitting the two halves to thereafter spring outwardly whereby these tip portions of the clamp wing 124 are firmly anchored in position.
As best seen in FIGS. 23 and 24, the clamp wing 124 extends laterally outwardly away from the associated support head 16 of the holder 10. The distal end of this clamp wing is provided with a hinge connection 132 including a hinge pin 134 serving to mount to the distal end of the clamp wing a lower clamp jaw 136, an upper clamp jaw 138 an the upper clamp jaw actuator lever 140. The outer or distal extremity of the lower clamp jaw 136 is provided with a further hinge pin 142 which serves to pivotally mount the upper clamp jaw 138. Both the lower clamp jaw 136 and the upper clamp jaw 138 are provided with respective rubber jaw pads 144 and 146 which serve to grip the opposing snowboard end surfaces without causing damage thereto.
The upper clamp jaw actuator handle 140 is pivotally mounted to the lower clamp jaw 136 by way of a pivot axle 148 which is located generally intermediate the upper clamp jaw pivot axis 142 and the aforementioned hinge pin 134 which connects the entire lower clamp jaw 136 to the distal end of the clamp wing.
As best seen in FIGS. 23 and 24, the upper clamp jaw is provided with an arcuately curved clamp jaw arm 150. This curved clamp jaw arm 150 is provided with an outer shallow detent 152 positioned in an outboard position adjacent the upper clamp jaw pad 146. The inner or proximal end of the jaw arm has a short lip projecting outwardly in close proximity to the upper clamp jaw pivot pin 142. Both the detent 152 and lip 154 are adapted to cooperate with the arcuately curved end portion 156 of a pressure tongue 158 which is slidably mounted in the actuator handle 140. A coil compression spring 160 mounted within the actuator handle continually urges the pressure tongue 158 outwardly and into engagement with the arcuately curved surface of the clamp jaw arm 150 and, when appropriately positioned, into engagement with either detent 152 or lip 154 noted above.
With reference to FIG. 23, when the actuator handle 140 has been moved to the raised position as shown, the end of the pressure tongue 158 comes into engagement with the outer detent 152 thus exerting maximum pressure or force between the upper and lower clamping jaws 138, 136 (and the snowboard end portion engaged therebetween). As the actuator handle 140 is rotated in the opposite direction by the operator, this pressure tends to be reduced somewhat and as the actuator handle 140 is brought all the way downwardly toward and slightly beyond the position illustrated in FIG. 24, the pressure tongue 158 contacts lip 154 thus exerting a counterclockwise force which causes the upper clamp jaw 138 to open with a snap-action effect. In order to prevent over rotation of the actuator handle 140 in this counterclockwise direction there is provided a rearwardly extending tab 162 which is fixed to and forms a part of the lower clamp jaw 136 and onto which tab pressure may be applied by the fore finger of the operator when the actuator handle 140 is being rotated downwardly in the counterclockwise direction thereby to achieve the rapid snap action opening effect for the upper clamp jaw 138. The ease with which the board ends can be clamped and released by the above-described assembly will be apparent from the above.
It will be appreciated that the end clamp assembly 80 must be arranged to accommodate a fairly large range of board tip angles. In order to achieve this, and to provide the necessary resiliency and flexibility, the clamp wing 124 is pivotally connected to the upper and lower jaws via the hinge 132 and pin 134 referred to previously. However, this in itself is insufficient as it is desired that the upper and lower clamp jaws 138, 136 not be permitted to droop or hang downwardly and in order to prevent this, the clamp wing 124 and lower clamp jaw 136 are each provided with associated pairs of spring seating blocks 164 between each of which pairs extends a coil compression spring 166. These coil compression springs 166 keep the outer end of the entire end clamping assembly from drooping downwardly but yet provide sufficient resiliency so that when a snowboard is mounted as illustrated in FIG. 23, this resiliently biased hinge arrangement can be easily deflected sufficiently as to permit the tip of the snowboard to enter into a proper association between the upper and lower clamping jaws 138, 136 and to be firmly clamped therebetween.
The various ways in which the structures described above may be utilized will be readily apparent from the foregoing description and the accompanying drawings. Those skilled in this particular art will appreciate that the apparatus described above permits snowboard repair and maintenance work to be readily accomplished while, at the same time, a minimum amount of time and effort is required to mount and dismount the snowboard to and from the holding devices described above. | Apparatus for holding a snowboard in a stable horizontal position during snowboard base preparation and maintenance, which apparatus also employs mechanism permitting the board to be swung around into a vertical orientation and held there in a stable manner for board edge maintenance procedures. An improved three-point support arrangement which provides substantial support of the snowboard for base preparation and wherein an intermediate support can be quickly and readily swung out of the way to allow the board to be moved into a vertical orientation for edge maintenance. The apparatus may be provided with clamps for securely engaging the ends of the snowboard and holding it firmly in position during repair and maintenance procedures. The apparatus is adaptable for use with a very wide variety of snowboards having different lengths, widths, board tip angles and board thicknesses. | 0 |
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