description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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BACKGROUND OF THE INVENTION
1. Field of the Invention.
This invention relates to mechanisms in which a vibratory system is used to impart an impulse in one direction. This system may be used wherever such vibration is needed.
2. Description of Related Art.
U.S. Pat. No. 3,998,107 discloses a device for converting rotary motion into unidirectional linear motion. It involves a crank-like axle about which are connected a series of weights which are caused to rotate by a rotating cylindrical supporting structure. This system is described as resembling rocket and jet engines in that the system can achieve propulsion without the involvement of an external reactive medium.
U.S. Pat. No. 3,404,854 discloses an apparatus for imparting a net translational motion to a vehicle on a support system, to a water vessel or to a lighter-than-air vessel. It involves the rotation of an unbalanced weight mounted in turn on a rotating frame.
U.S. Pat. No. 4,241,615 discloses a device for imparting vibrating force to a plow in which a weight on a arm is rotated within a housing. In one embodiment, teeth on the circumference of the housing imparts rotation to the weight.
U.S. Pat. No. 4,280,368 discloses an adjustable device for producing vibratory forces which involves intermeshed gears mounted on plates. The angle between the plates may be adjusted thereby changing the magnitude of the vibratory forces produced.
U.S. Pat. No. 4,579,011 discloses a propulsion apparatus in which a rotating cam activates pistons in fluid filled reservoirs thereby causing an unbalanced centrifugal force and movement of the apparatus in a preselected linear direction.
U.S. Pat. No. 5,123,292 discloses a motivational generator for shakers and vehicles in which unbalanced weights mounted on arms in chevron-shaped vibratory devices are caused to rotate by a frame which itself rotates.
U.S. Pat. No. 5,172,599 discloses a vibratory device for shakers and vehicles in which unbalanced weights on arms are driven by gears mounted on a rectangular platform. The platform rotates is mounted on a rectangular frame which also rotates. The gyroscope-like rotation of the frame damps unwanted vibrations resulting in defined back and forth vibratory motions in a single plane.
SUMMARY OF THE INVENTION
The rotating eccentric weights vibrator system of this invention is comprised of a base and a rotating rectangular frame having mounted upon it eccentric weights which rotate in synchrony. The base has two arms which extend upright, and a rotating rectangular frame is supported by the arms and rotates about an axis located at about the middle of the long axis of the rotating rectangular frame. Rotating gear axles are mounted from one long side of the rectangular frame to the other, and the gear axles are parallel to the short sides of the rotating rectangular frame.
Two large gears are mounted on the gear axles which are closest to the axis about which the rotating rectangular frame rotates. These large gears mesh with small gears mounted on gear axles and cause the small gears to rotate. Eccentric weights are also mounted on the gear axles, large eccentric weights on axles with large gears and small eccentric weights on axles with small gears.
A stationary gear is mounted on the base. Drive gears which drive the rotation of large gears mesh with the stationary gear either directly or via an intermediate gear so rotation of the rotating rectangular frame causes rotation of the large gears in opposite directions, and subsequently rotation of the small gears in opposite directions to those of the large gears.
Eccentric weights are mounted on the gear axles and rotate with the gears. Large eccentric weights are mounted on axles having large gears and small eccentric weights on axles having small gears. The mass of large eccentric weights is twice that of the small eccentric weights.
Rotation of the rotating rectangular frame causes rotation of the gears, gear axles, and eccentric weights associated with the rotating rectangular frame. The rotation of the large eccentric weights generate forces which are in part canceled by the rotation in the opposite direction of the small eccentric weights. The net result is a force expressed in one direction only which may be used to propel a vehicle such as a watercraft.
The system of this invention may be regarded formally as one unbalanced flywheel on a axle which is synchronized to another unbalanced flywheel on a axle (Vibration and Impact R. Burton, Addison-Wesley Pub. Co. Inc., Reading, Mass., 1958, pages 89-92). Periodic forces which result in vibration in such a motor result from the displacement of the center of mass of the flywheel from the axis of rotation, which is located in the center of the rotating axle.
The displacement of the center of mass from the axis of rotation is called the eccentricity and is given the symbol e. When m is the mass of the flywheel, o is the angular velocity, and F is the force generated, for following relation holds:
F=meo.sup.2
The objective of this invention is to provide a simple means for motivating a vehicle such as a watercraft.
Another objective is to provide means for converting rotatory motion to a unidirectional force.
Another objective is to provide efficient conversion of energy by avoiding lost motion.
Another objective is to provide a motor which is reliable, economical in operation, and may be manufactured at low cost.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side view of the system including the drive unit.
FIG. 2 is a diagrammatic cross section of FIG. 1 along the plane 2--2.
FIG. 3 is a diagrammatic side view of the vibrator unit consisting of a rotating frame with associated gears and eccentric weights.
FIGS. 4 and 5 are diagrams depicting the forces generated by the vibrator unit.
FIGS. 6A, 6B, 6C and 6D are diagrams depicting the relative rotation of the gears and eccentric weights showing the direction of generated forces.
FIG. 7 is a diagram depicting the arrangement of the stationary gear, intermediate gear, and drive gears.
FIG. 8 is a second embodiment of the system in which two vibrator units are mounted on a single base and rotated by a single drive motor.
FIG. 9 is a diagram of the drive gears and pullys of the second embodiment system.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a side view of the rotating eccentric weights vibrator system. The rotating frame 71 is supported by the base 91. An electric motor 100 drives the system via a belt 102. The belt drives a pulley 194 and attached axle 70. Axle 70 causes rotating rectangular frame 71 to rotate. Two large gears 77 and 78 are mounted to the rotating frame by gear axles 73 and 74, respectively. Two small gears 76 and 79 are mounted to the rotating frame by gear axles 72 and 75, respectively. In operation, the rotating frame rotates about axle 70 and associated gears cause rotation of large and small gears and associated eccentric weights. The rotating frame and attached gears, axles, and eccentric weights is called a vibrator unit.
FIG. 2 is a cross section view of the invention. The system is supported by the base frame 91. The base frame is u-shaped and is comprised of two arms, 91a and 91b, and a frame support member 91c. A drive axle 70 or shaft is supported by and rotates in a bearing 92 which is mounted on base frame arm 91a. Immobile axle 84 or shaft is fixedly mounted in a collet 93 which is attached to base frame arm 91b.
The rotating rectangular frame 71 is a rectangular structure comprised of two long members 71a and 71b and two short members 71c and 71d, forming an area enclosed by and inside the rectangular frame.
At approximately the middle of the length of long member 71a a collet 90 is used to fixedly attach one end of drive axle 70 to the frame. A pulley 194 is attached to the other end of drive axle 70. Pulley 194 is attached via a belt or chain to a source of rotative motion such as an electrical motor. Drive axle 70 both partially supports the frame 71 and causes it to rotate.
At approximately the middle of the length of long member 71b the member is pierced by a bearing 94 into which is mounted an immobile axle 84. The frame 71 rotates about and is partially supported by immobile axle 84.
The long members of the rectangular frame are divided into first and second halves by the collet 90 and drive axle 74 and by the bearing 94.
A stationary gear 86 which does not rotate is mounted on the immobile axle 84. Drive gear 85 meshes with stationary gear 86. Drive gear 85 is mounted on gear axle 73 on the outside of the frame 71. Axle 73 extends through bearing 101 mounted in frame member 71b and through bearing 96 mounted in frame member 71a. Gear axle 73 is free to rotate. Large gear 77 is fixedly mounted on gear axle 73. Also fixedly mounted on gear axle 73 is eccentric weight 81. A crescent-shaped weight 81a is mounted on eccentric weight 81. Thus rotation of gear 85 causes rotation of large gear 77 and eccentric weight 81.
Small gear 76 and eccentric weight 80 are fixedly mounted on gear axle 72. Crescent-shaped weight 80a is mounted on eccentric weight 80. Gear axle 72 extends between bearing 102 mounted in frame member 71b and bearing 95 mounted in frame member 71a. Gear axle 72 is free to rotate. Small gear 76 meshes with and is caused to rotate by large gear 77.
Intermediate gear 103 is rotatively mounted on axle 104 which is attached by member 105 to immobile axle 84. Intermediate gear 103 meshes with stationary gear 86 and with drive gear 87. The role of intermediate gear 103 is to cause drive gears 85 and 87 to rotate in opposite directions.
Drive gear 87 meshes with intermediate gear 103. Drive gear 87 is mounted on gear axle 74 on the outside of the frame 71. Gear axle 74 extends through bearing 140 mounted on frame member 71b and bearing 97 mounted on frame member 71a. Gear axle 74 is free to rotate. Large gear 78 is fixedly mounted on gear axle 74. Also fixedly mounted on gear axle 74 is eccentric weight 82. Crescent-shaped weight 82a is mounted on eccentric weight 82. Thus rotation of gear 87 causes rotation of large gear 78 and eccentric weight 82.
Stationary gear 86, drive gears 85 and 87, and intermediate gear 103 have the same diameter.
Small gear 79 and eccentric weight 83 are fixedly mounted on gear axle 75. Crescent-shaped weight 83a is mounted on eccentric weight 83. Gear axle 75 extends between bearing 99 mounted on frame member 71B and bearing 98 mounted on frame member 71A. Gear axle 75 is free to rotate. Small gear 79 meshes with and is caused to rotate by large gear 78.
Other means, such as individual electric motors, may be used to cause rotation in opposite directions of gear axles 73 and 74.
The eccentric weights are illustrated in FIG. 4 as disks in side view. They may be constructed as hemicircles or as weights mounted on a disk asymmetrically with respect to the center of the disk.
The diameter and mass of small gear 76 are equal to that of small gear 79. The diameter and mass of large gear 77 are equal to that of large gear 78. The diameter of large gears 77 and 78 is twice that of small gears 76 and 79. The mass of large eccentric weight 81 is equal to that of large eccentric weight 82. The mass of small eccentric weight 80 is equal to that of small eccentric weight 83. The mass of each of the large eccentric weights is twice that of each of the small eccentric weights. The mass of the vibrator unit comprised of rectangular frame, intermediate gear, drive gear, large and small gears, large and small eccentric weights, associated gear axles and gears is substantially symmetrically distributed about the axis of symmetry formed by immobile axle 84 and drive axle 70.
The motor may be constructed of any suitable strong and durable material, such as steel, iron, polymers.
FIG. 3 is a side view of the rotating rectangular frame with associated gears, axles, and weights, also called a vibrator unit, of the motor depicted without the base frame for clarity. In this Fig., a long frame side 71a supports gears 76, 77, 78, and 79 and eccentric weights 80, 81, 82, and 83. The frame rotates about axle 70 fixedly attached by collet 90 to long frame side 71a and located at about the middle of the length of the long frame side 71a. Large gear 77 is attached to gear axle 73. Gear axle 73 is mounted by bearing 96 to long frame side 71a adjacent to axle 70. Small gear 76 is mounted on gear axle 72. Gear axle 72 is mounted by bearing 95 to long frame side 71a adjacent to gear axle 73. Small gear 76 meshes with and is rotated by large gear 77. Large gear 78 is attached to gear axle 74. Gear axle 74 is mounted by bearing 97 to long frame side 71a adjacent to axle 70. Small gear 79 is mounted on gear axle 75. Gear axle 75 is mounted by bearing 98 to long frame side 71a adjacent to gear axle 74. Small gear 76 meshes with and is rotated by large gear 78. Large gears 77 and 78 do not mesh.
Disk-shaped eccentric weights 80a, 81a, 82a, and 83a are attached to gear axles 72, 73, 74, and 75, respectively. Crescent-shaped weights 80A, 81A, 82A, and 83A are attached to eccentric weights 80, 81, 82, and 83, respectively.
The means for rotating the gear, axles are not shown in FIG. 3.
In operation, pulley 194, drive axle 70, and rectangular frame 71 are caused to rotate by an external source of power such as an electrical motor. Rotation of rectangular frame 71 about the axis formed by immobile axle 84 and drive axle 70 causes rotation of drive gear 85 which meshes with stationary gear 86. Rotation of drive gear 85 causes rotation of large gear 77 and large eccentric weight 81. In addition, rotation of large gear 77 causes rotation of small gear 76 and small eccentric weight 80. Rotation of rectangular frame 71 about the axis formed by immobile axle 84 and drive axle 70 causes rotation of intermediate gear 103 which meshes with stationary gear 86. Rotation of intermediate gear 103 causes rotation of drive gear 87. Rotation of drive gear 87 causes rotation of large gear 78 and large eccentric weight 82. In addition, rotation of large gear 78 causes rotation of small gear 79 and small eccentric weight 83.
FIGS. 4 and 5 show the cancellation and reinforcement of forces generated by the rotation of eccentric weights. FIG. 4 shows a clockwise rotating eccentric weight on a motor and FIG. 5 shows a counterclockwise rotating eccentric weight on the same motor. In both FIGS. 4 and 5, sector 6d preceeds sector 6a in rotation. Forces generated in sectors 6d of FIG. 5 cancel the forces of 6d of FIG. 4. The forces of 6a of FIG. 4 add to the forces of 6a of FIG. 5.
FIGS. 6a-6d depict the centrifugal forces generated by the rotation of the eccentric weights during one revolution of the rotating rectangular frame.
FIG. 6a shows the beginning of a revolution when all eccentric weights are oriented on the same side and there is a net impulse in the direction of the arrows.
FIG. 6b shows the forces after 1/4 revolution where the net impulse is in part canceled by the rotation of the large eccentric weights through a 1/4 revolution and by the rotation of the small eccentric weights through a 1/2 revolution.
FIG. 6c shows the net forces again in a reduced condition due to a further 1/4 revolution of the large gears and due to opposed forces generated by a 1/2 revolution of the small gears.
Finally, FIG. 6D shows the last quarter of the revolution where a minor net force in the direction of the arrows is generated by a further 1/4 rotation of the large eccentric weights and by the 1/2 revolution of the small eccentric weights.
FIG. 8. is a side view of a second embodiment of the invention. This embodiment is supported by a base 120 upon which is mounted the drive motor 100 and a u-shaped base frame 191 mounted perpendicular to the base. Lower vibrator unit 122 and upper vibrator 123 are rotatively mounted between the arms of base frame 191 by axle 130. A pulley 121 is fixedly attached to axle 130 so that rotation of pulley 121 causes vibratory unit 122 to rotate. Pulley 121 is connected by belt 102 to motor 100. Rotation of pulley 121 causes rotation of vibrator unit and associated gears, axles, and weights in the same manner that rotation of pulley 94 in FIG. 2 causes rotation of the vibrator unit and associated gears, axles, and weights. Dotted line 116 shows the circular movement of vibrator unit 122 and arrow 119 shows the counterclockwise movement of vibrator unit 122.
Pulley 134 is also attached to axle 130 so that rotation of vibratory unit 122 causes rotation of pulley 134.
Vibratory unit 123 is mounted at the upper end of base frame 191 by axle 132. A pulley 136 is fixedly attached to axle 132 so that rotation of pulley 136 causes vibratory unit 123 to rotate. Pulley 136 is connected by belt 112 to pulley 111. Rotation of pulley 136 causes rotation of vibrator unit and associated gears, axles, and weights in the same manner that rotation of pulley 194 in FIG. 2 causes rotation of the vibrator unit and associated gears, axles, and weights. Dotted line 117 shows the circular movement of vibrator unit 123 and arrow 118 shows the clockwise movement of vibrator unit 123.
Axle 131 is mounted near the middle of the length of base frame 191. Intermediate gear 115 and pulley 110 are attached to axle 131. Axle 133 is mounted near the middle of the length of base frame 191. Intermediate gear 114 and pulley 111 are attached to axle 133. Axle 133 is close enough to axle 131 that intermediate gear 115 meshes with intermediate gear 114.
Belt 113 attaches pulley 110 to pulley 134. Belt 112 attaches pulley 111 to pulley 136.
FIG. 9 shows the details of the relation between intermediate gears 115 and 114 and pulleys 110 and 111.
In operation, motor 100 causes rotation of pulley 121, axle 130, vibratory unit 122, and pulley 134. Rotation of pulley 134 is conveyed by belt 113 to pulley 110. Rotation of pulley 110 causes rotation of axle 131 and intermediate gear 115. Intermediate gear 115 meshes with intermediate gear 114. Rotation of intermediate gear 115 causes rotation of intermediate gear 114, axle 133, and pulley 111. Rotation of pulley 111 is conveyed by belt 112 to pulley 136. Rotation of pulley 136 causes rotation of vibrator unit 123.
There therefore is an unbalance between the generation of forces depicted in FIGS. 6a-6d, with the strongest forces generated as shown in FIG. 6a. This unbalanced forces results in the generation of mobility in a single direction and may be used to propel a watervessel.
There has been described a novel rotating eccentric weights vibrator system which fulfills all the objects and advantages sought. Many changes, modifications, variations and other uses and applications of the subject invention will, however, become apparent to those skilled in the art. All such changes, modifications, variations and other uses and applications of the present invention which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow. | The vibrator system of this invention provides conversion of rotary motion to an unidirectional motion and may be used to propel watervessels. The vibrator system involves a rotating vibrator unit which bears large and small rotating eccentric weights. A gear arrangement provides synchronized rotation of the weights which results in a net unidirectional force. In a second embodiment, two vibrator units are mounted on a single frame and are rotated in synchrony. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a HIGH DEFINITION MULTIMEDIA INTERFACE (HDMI) connector, and more specifically to a small connector utilized in digital TV, DVD player, deck-top box (video signal converter), and other digital Audio/Video (AV) product.
[0003] 2. Description of the Related Art
[0004] LCD in nowadays has become a most popular output device for Audio/Video (AV) product. Since it plays an important role in the products of modern PC monitor and TV display, and in the light of connector for digital signal transmission has become a mainstream product in LCD industries, the HDMI connector of the invention is thus created to serve this purpose.
[0005] The HDMI (High Definition Multimedia Interface) is a transmission interface utilized for the transmission of a high definition multimedia digital signal including high fidelity image and multi-channel audio signal. The earliest specification of the HDMI was established by several Audio/Video industries, such as HITACHI, Panasonic, Philips, Sony, Silicon Image, Thomson and Toshiba. It established the most frequently used standard specification based on DVI (Digital Visual Interface) for digital image signal transmission. The object of the invention is to transmit a digital screen signal between PC and LCD and display a live scene on LCD with high fidelity. Furthermore, the digital image signal transmitted by DVI also provides the effect of unauthorized copy proof, and its signal may be encoded at the transmitting end and decoded at receiving end that will provide the effect of preventing unauthorized reproduction of the image signal being transmitted. Although DVI improved the resolution and quality of picture on a LCD screen, however, DVI is not absolutely perfect, because it didn take the transmission of digital audio signal into account so far, therefore users need to connect additional line or use traditional AV terminal for signal transmission. This may not raise the question of compatibility among the signal transmissions in the application of personal computer, but it does cause chaos when used in the family theater set which is getting more and more popular among the consumers. Furthermore, as the digital products such as digital video camera and digital electronic camera are prevailed, it may become bothersome that if LCD TV requires a plurality connection lines. This may also increase the number of installation components for family theater set, and further increase the price of product. Therefore, the HDMI of the present invention is thus created for family theater set to eliminate the flaws of DVI mentioned above.
[0006] The HDMI of the present invention is not only in compliance with the standard specification of DVI but also take digital audio signal into account in the design of HDMI connector, which is not only fully compatible with DVI but also capable of transmitting uncompressed data of digital AV signal without distortion. Furthermore, the HDMI also has advantages, such as, it complies with all kinds of video format specification used in the market, thus, it is capable of communicating with all kinds of product by all kinds of video transmission formats. Therefore, the HDMI provides the best quality and high fidelity video signal for consumer AV products, and because it supports all kinds of transmission format of digital video signal, resulted in less cable and smaller connector for the transmission of uncompressed data. Furthermore, the HDMI also succeeded the feature of unauthorized copy proof of DVI. It will alleviate the burden of movie filmmakers worrying that the export of the highest quality video products will come across with unauthorized reproduction by piracy. The HDMI connector also provides two-way communication for digital TV, DVD player, deck top box (signal converter) and other small connectors of digital AV products. The advantage is that the player provides the best image quality through determining which format is suitable for the received signal automatically. The HDMI connector is more convenient to install inside different AV products, because it is designed to reduce the volume of interface connector significantly.
[0007] It is known from the mentioned above that the HDMI will be a mainstream connector for AV product in the future. The HDMI will be the first AV standard specification supported throughout the software supplier and system provider to CE (Consumer Electronics) makers in a chain link. Therefore, the HDMI connector needs to be built with a strong construction to comply with the demand of high speed transmission. The object of the invention is to provide such new type of connector construction for the newly developed system.
[0008] The metallic housing of current general connector has several connection types to adapt the structure of the PCB (printed circuit board). The metallic housing has two major types an insertion type and a SMT (surface mount technology) type. The connectors are usually mounted at the edge of printed circuit board to adapt the requirements of the housing structure of product and provide interface function for the connection of external and internal circuit of the product. Current connector has a flange with screw holes for engagement with the housing by screws to reinforce the fixity of connection. Furthermore, current contact terminal units also utilize the insertion type and the SMT type, and produce various types of connector through combination of accessories. However, miscellaneous types of connector will cause a great confusion in the procurement of accessories due to lack of interchangeability of the accessories, and thus increase the cost of accessory stock.
SUMMARY OF THE INVENTION
[0009] The main object of the present invention is to provide a connector for high definition multimedia digital transmission interface which utilizes modular components in compliance with standard specification to assemble various types of connectors through combination of various modular components, therefore, minimize the number of components stock and thus reduce the cost of material.
[0010] Another object of the present invention is to provide a connector for high definition multimedia digital transmission interface, which utilizes an uniform insulated housing to combine with the different metallic housing and the contact terminal assemblies to establish a standard and swift assembly works.
[0011] To achieve the above objects, the HDMI connector in accordance with the present invention comprises an insulated housing, a metallic housing, and a contact terminal unit, characterized in that the insulated housing is an uniform standard design, whereas the metallic housing and the contact terminal unit are modular design. The structure of the metallic housing utilizes a standard design, and the solder pin and flange utilize modular design, wherein the solder pin is categorized in the vertical insertion type and the horizontal SMT type, and the flange is an optional selection according to the requirements of the products. The interior design of the metallic housing adapted to the engagement with the insulated housing utilizes the standard design, whereas the contact terminal unit is categorized in the vertical insertion type and the horizontal SMT type.
[0012] The present invention will be readily apparent to those skilled in the art upon reading the following description of a preferred embodiment of the present invention and upon reference to the accompanying drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] With reference to FIG. 1 and FIG.2 , A HDMI connector of the present invention comprises an insulated housing 1 , a metallic housing 2 , and a contact terminal unit 3 , wherein the insulating housing 1 is an standard design, whereas the metallic housing 2 and the contact terminal unit 3 are modular design. The structure of the metallic housing 2 utilizes an standard design, and the solder pin 21 and flange 22 utilize modular design, wherein the solder pin 21 is categorized in the vertical insertion type 211 and the horizontal SMT type 212 , and the flange 22 is an optional selection according to the requirements of the products. The interior design of the metallic housing 2 adapted to the engagement with the insulated housing 1 utilizes the standard design, whereas the solder pin of the contact terminal unit 3 is categorized in the vertical insertion type 31 and the horizontal SMT type 32 .
[0014] Because the embodiments of the invention present various types utilizing a combination of different module types, for purpose of convenient explanation the inventor designates the metallic housing 2 with flange 22 as and without flange 22 as and the metallic housing 2 with the solder pin 21 utilizes the vertical insertion type 211 is designated as and the horizontal SMT type 212 as and the contact terminal unit 3 with the solder pin 21 utilizes the vertical insertion type 211 of is designated as and the horizontal SMT type 212 as.
[0015] The embodiment of ABC type connector structure will be described hereinafter. Referring to FIG. 1 and FIG. 2 , the insulated housing 1 has a rectangular main block 10 , and a flat terminal block 102 is projected from the front surface 101 of the main block 10 , there is a plurality of guide slots 103 furnished on the top and bottom side of the terminal block 102 for insertion of the terminal of contact terminal unit 3 , and the guide slots 103 is fed through the main body 10 to the hollow portion 15 at the rear part of the main body 10 . When the insulated housing 1 is inserted into the metallic housing 2 , the front surface 101 may thrust against the rear end of insertion slot at the bottom of the metallic housing 2 and retain the metallic housing 2 in place. The dented slots 111 are furnished at the two sides of the top surface 11 of the main body 10 hollowed at rear part; the function of the slots 111 is to latch with the resilient fold piece 201 on the top surface 26 to secure the fixity of the insulated housing 10 when moved into the metallic housing 2 . The slot 131 and the projection 132 are furnished on the both side surfaces 13 of the main body 10 whereby the slots 131 are mated with the inward projected stop wedge 231 of the metallic housing 2 , and the stop block 1311 is furnished at the end of the inner slots 131 may thrust with the stop wedge 231 to secure the insulated housing 1 inside the metallic housing 2 without further backward displacement, and the projection 132 mated with the slide slot 232 of the metallic housing 2 to secure the insulated housing 1 inside the metallic housing 2 without further forward displacement. The positioning paths 121 dented inward at rear part of the bottom surface 12 of the main body 10 provide an equal number of guide slots 103 for insertion of the terminals of the terminal block 102 to secure the solder pin at the insertion spot. And the bottom plate 122 extended from the front end of bottom surface 12 of the main body 10 with inclined end section of both sidewalls form a carrier to be integrated with the bottom surface 24 of the metallic housing 2 and firmly fixed with each other. The recess 123 furnished on the bottom plate 122 with position aligned with the clamp 241 on the bottom surface 24 of the metallic housing 2 to keep the clamp 241 remained available after the integration with the insulated housing 1 , furthermore, the positioning posts are also provided at the bottom of the insulated housing 1 to secure the connector firmly positioned on the printed circuit board.
[0016] The interior structure design complies with the uniform standard adopted by the insulated housing 1 . The insertion opening 25 in the front end of the metallic housing 2 is furnished with error proof on both sides, this standard specification known in the industry will not be described herein. A feature of the invention is the integration structure of the insulated housing 1 and the rear part of the metallic housing 2 . The integration consists of the fold piece on the top surface 26 , the fold plate 202 extended to rear end, the inward projected stop wedge 231 , and the slide slot 232 , wherein the fold piece 201 , the inward projected stop wedge 231 and the slide slot 232 are interacted with the corresponding integration structure of the insulated housing 1 when inserted in the metallic housing 2 , wherein the fold piece 201 , the inward projected stop wedge 231 and the slide slot 232 are mated with the slot 111 , notch 131 and protrusion 132 respectively. Furthermore, the fold plate 202 is foldable to accommodate the whole insulated housing 1 inside the metallic housing 2 when the insulated housing 1 is inserted in, and there is a plurality of clamps 241 furnished on the top and bottom surfaces of the metallic housing 2 to latch the plug connector accordingly.
[0017] From the above description, it is understood that the metallic housing 2 and the insulated housing 1 of the HDMI connector of the present invention are thus fabricated and assembled through a multiple locking mechanism to form a rigid and compact structure in compliance with the strict requirements of high definition multimedia interface device. The specification of fold piece 201 , fold plate 202 , inward projected stop wedge 231 and slide slot 232 are all standardized to form standard modules of the metallic housing 2 . The other feature of the invention is the design of the solder pin 21 and the flange 22 , wherein the flange 22 furnished with lock hole is foldable in an upward vertical direction to fulfill the requirements of the print circuit board and the housing structure. The invention utilizes a basic standard structure to incorporate with the variations of the solder pin 21 and flange 22 to form a standard mode of the metallic housing. There are four types of metallic housing 2 of the embodiment, AB type metallic housing module utilizes the flange 22 and the solder pin 21 with a vertical insertion type solder pin 211 , also referring to FIG. 3 , Ab type metallic housing module utilizes the flange 22 and the solder pin 21 with the horizontal SMT type solder pin 211 , aB type metallic housing utilizes without the flange 22 and the solder pin 21 with a vertical SMT type solder pin 212 , and ab type metallic housing utilizes the flange 22 and the solder pin 21 with a vertical SMT type solder pin 212 .
[0018] With reference to FIG. 1 and FIG. 2 , the front end terminal contact portion of the contact terminal unit 3 of the embodiment 1 in FIG. 1 and FIG. 2 is of standard specification, and the spike 33 for fixing terminal is furnished at the rear end of the contact portion, wherein the rear end of the spike 33 is folded to form the solder pin, and the terminal solder pin in the embodiment is the horizontal SMT type terminal solder pin 32 . There are two types of the contact terminal unit, one is the horizontal SMT type terminal solder pin 32 designated C type, and the other is the vertical insertion type terminal solder pin 31 designated c type (as shown in FIG.4 ).
[0019] The assembly method of the invention is first to place the terminals of the contact terminal unit 3 into the guide slots 103 of the terminal block 102 of the insulated housing 1 , followed by placing the terminal solder pin into the positioning path 121 on the bottom surface of the main body 10 , and the front surface 101 of the insulated housing 1 will thrust against the rear end of the bottom insertion slot of the metallic housing 2 when the whole insulated housing 1 inserted in the metallic housing 2 , wherein the notches 131 of the both side surfaces 13 being mated with the inward projected stop plate 231 of the metallic housing 2 thrust the stop block 1311 of the inner end of the notches 131 against the inward projected stop plate 231 to secure the insulated housing 1 in the inner part of the metallic housing 2 without further backward displacement. The projection 132 of the side surface 13 also cooperates with the slide slot 232 of the metallic housing 2 to secure the insulated housing 1 in the inner part of the metallic housing 2 without frontward displacement. Finally, the fold piece 201 on the top surface 20 of the metallic housing 2 is folded to mate with the slot 111 on the top surface 11 of the insulated housing I to reinforce the fixity of the insulated housing 1 , and the fold plate 202 of the metallic housing 2 is folded to accommodate the insulated housing 1 into the metallic housing 2 . As shown in the FIG. 5 , a type of the invention presented by one of the module combinations designated as ABC type connector, wherein the solder pin 21 utilizes the vertical insertion type solder pin 211 , the terminal utilizes the horizontal SMT type terminal solder pin 32 and with the flange 22 on the metallic housing 2 .
[0020] There is plurality of module types adopted for the invention. In FIG. 6 , the embodiment No. 2 is an ABc type, which is composed of the solder pin 21 utilizing the vertical insertion type solder pin 211 , the vertical insertion type terminal solder pin 31 and the flange 22 on the metallic housing 2 . Referring to FIG. 7 , the embodiment No. 3 is an AbC type which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the horizontal SMT type terminal solder pin 32 and the flange 22 on the metallic housing 2 . In FIG. 8 , the embodiment No. 4 is an Abc type, which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the vertical insertion type terminal solder pin 31 and the flange 22 on the metallic housing 2 . In FIG. 9 , the embodiment No. 5 is an aBC type which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the horizontal SMT type terminal solder pin 32 and without the flange 22 on the metallic housing 2 . In FIG. 10 , the embodiment No. 6 is an aBc type which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the vertical insertion type terminal solder pin 31 and without the flange 22 on the metallic housing 2 . In FIG. 11 , the embodiment No. 7 is an abC type which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the horizontal SMT type terminal solder pin 32 and without the flange 22 on the metallic housing 2 . In FIG. 12 , the embodiment No. 8 is an abc type which is composed of the solder pin 21 utilizing the horizontal SMT type solder pin 212 , the vertical insertion type terminal solder pin 31 and without the flange 22 on the metallic housing 2 .
[0021] From the above description it is understood that the HDMI connector in accordance with the present invention utilizes modular design to standardize the specification of the connectors. It provides four types of the metallic housing 2 and two types of the contact terminal unit 3 to compose eight types of the HDMI connector providing more flexibility and swiftness in assembly, and also simplifies material stocks and promotes mobility of the product variation in the assembly line.
[0022] Although the present invention has been described with reference to a preferred embodiment thereof, it is apparent to those skilled in the art that there are a variety of modifications and changes that may be made without departing from the scope of the present invention which is intended to be defined by the appended claims. | The present invention provides a high definition multimedia interface (HDMI) connector with various types through combinations of the outer metallic shells and the inner terminal modules of the HDMI connector. The outer metallic shell may exhibit various types including with or without the presence of flange on the front edge of said outer metallic shell and with or without the application of the surface mount technology (SMT) to the solder pins. Therefore, the HDMI of the present invention is applicable to provide different types of connector to fulfill market requirements through the combinations of different types of module. | 7 |
BACKGROUND OF THE INVENTION
A. Field of the Invention
The present invention relates to tools and implements for making elongated circular cross-section bore holes such as post holes into soil beneath the surface of the ground. More particularly, the invention relates to a hole digger tool and apparatus which uses a vacuum pump to remove soils severed by cutting teeth and has a rotating unclogger bar to break up mud or clay clogs which could impede removal of dislodged soil.
B. Description of Background Art
There are a variety of situations which require making elongated, relatively deep holes into the ground. These include digging generally cylindrically-shaped holes for receiving fence posts, sign posts and the like. Such holes have a typical diameter range of from about 4 inches to about 12 inches, and a depth of 3 to 6 feet or more.
Digging relatively deep, elongated holes such as post holes in the ground tends to be a tedious, slow, labor intensive task, when using conventional manually operated, manually powered digging implements. A widely used manually powered, “clam-shell” post hole digger includes a pair of shovels, each of which has a generally semi-circularly curved blade. The shovel blades are fixed to the lower ends of upwardly protruding handles which are pivotably mounted to one another at a location between the shovel blades and the upper ends of the handles, and arranged so that the concave surfaces of the shovel blades confront one another to define therebetween a generally cylindrically-shaped space corresponding to a hole to be dug.
Clam-shell post hole diggers are used by pivoting the upper ends of the handles towards one another to place the handles in generally parallel alignment with one another, thus also orienting the shovel blades at the lower ends of the handles in generally parallel alignment. The handles are then grasped by an operator to orient them vertically, i.e., perpendicularly to a ground surface into which a post hole is to be dug. The operator then brings his arms down forcefully towards the surface of the ground, thus causing pointed tips of the shovel blades to penetrate the ground soil, and the handles are rocked back and forth in a horizontal direction, to thus impart a twisting cutting motion to the shovel blades.
Next, the upper ends of the handles are drawn apart to thus pivot the shovel blades towards one another, underneath soil which has been loosened by downward and twisting cutting actions of the shovel blades. The claim-shell digger tool is then raised above the ground to thus withdraw the shovel blades from the ground and thereby remove the severed soil, which may then be dumped at any convenient location. This is done by pushing the upper ends of the handles together, thus causing the inner facing concave surfaces of the shovel blades to pivot away from one another, allowing soil supported on those surfaces to fall away from the blades.
The handles are once again put into parallel alignment, and claim-shell digger tool is again thrust downward to thus drive the shovel blades downward into the hole being dug to thereby begin a new cycle of soil excavating. These cycles are repeated as often as required to dig a hole of a desired depth. As can be well appreciated, digging post holes with a clam-shell digging tool of this type is a very laborious, slow task.
Another method of forming post holes which is in common use employs a large diameter auger that is rotated by an electric, hydraulic or air-driven motor. Boring post holes with a powered auger of this type is much quicker and easier than using a claim-shell type digger tool, but the cost of such devices, and the requirement of providing electric, hydraulic or compressed air power to them, limits the extent of their use.
In apparent recognition of certain limitations of clam-shell or auger-type post hole diggers, U.S. Pat. No. 7,185,720 disclosed a hole digger which includes an elongated, skeletonized cylinder that has circumferentially spaced apart, elongated bars which are fastened at the upper ends thereof to the periphery of an upper mounting ring, and near the lower ends of the bars to a lower, mounting ring. The bars extend below the lower mounting ring and terminate in wedge-shaped, pointed cutting teeth.
The digging tool disclosed in U.S. Pat. No. 7,185,720 includes a straight, hollow vacuum tube which fits coaxially down through the bore of the skeletonized frame and is longitudinally movable therewithin. The upper end of the vacuum tube is connected through a flexible vacuum hose to a vacuum source, such as a wet-or-dry shop vacuum unit. The tool is used by pressing the pointed edges of the cutting teeth into a soil surface, twisting the unit back and forth with respect to its longitudinal axis to thus cause the teeth to exert a rotary cutting action on the soil surface, and oscillating the vacuum tube up and down to thus vacuum up severed soil.
While the hole digger implement disclosed in U.S. Pat. No. 7,185,720 appears to be an improvement over certain prior art hole diggers such as clam-shell type hole diggers, the present inventor has found that diggers of the type disclosed in the '720 patent have certain limitations. For example, the requirement that the vacuum tube in the '720 digger be oscillated up and down can become burdensome. Also, the present inventor has found that using vacuum assisted hole diggers of the type described in U.S. Pat. No. 7,185,720 in wet, muddy or clay soil can be problematic, because the mud or clay tends to lodge within the vacuum tube, thus clogging the bore of the vacuum tube and preventing soil from being drawn upwardly through the tube.
The foregoing considerations in part prompted the present invention, which is described in detail below.
OBJECTS OF THE INVENTION
An object of the present invention is to provide a vacuum assisted post hole digger apparatus for boring post holes in soil which includes a vacuum assisted post hole boring tool and a vacuum source.
Another object of the invention is to provide a vacuum assisted post hole digger tool which includes an elongated hollow tubular housing that has a vacuum inlet fitting at an upper end thereof and a plurality of circumferentially spaced apart soil cutting blades or teeth which are attached to the outer circumferential surface of a cylindrical sleeve located at the lower end of the tubular housing, the cutting teeth extending below the lower transverse annular end wall of the sleeve.
Another object of the invention is to provide a vacuum assisted post hole digger tool which includes an elongated zig-zag shaped mud and clay unclogger bar that is attached at an upper end thereof to an elongated drive shaft coaxially positioned within the bore of an elongated hollow tubular housing which has at an upper end thereof a laterally outwardly angled vacuum inlet tube, the drive shaft protruding upwards through a rotatable vacuum-sealing type bearing located in an upper wall of the vacuum inlet tube to thus enable the shaft to be coupled to a rotary power tool such as an electric drill.
Another object of the invention is to provide a vacuum assisted post hole digger tool which includes an elongated zig-zag shaped mud and clay unclogger bar that is attached at an upper end thereof to an elongated drive shaft coaxially positioned within the bore of an elongated hollow tubular housing which has at an upper end thereof a laterally outwardly angled vacuum inlet tube, the drive shaft being coupled to an electric motor mounted on the vacuum inlet tube.
Various other objects and advantages of the present invention, and its most novel features, will become apparent to those skilled in the art by perusing the accompanying specification, drawings and claims.
It is to be understood that although the invention disclosed herein is fully capable of achieving the objects and providing the advantages described, the characteristics of the invention described herein are merely illustrative of the preferred embodiments. Accordingly, I do not intend that the scope of my exclusive rights and privileges in the invention be limited to details of the embodiments described. I do intend that equivalents, adaptations and modifications of the invention reasonably inferable from the description contained herein be included within the scope of the invention as defined by the appended claims.
SUMMARY OF THE INVENTION
Briefly stated the present invention comprehends a vacuum assisted post hole digger tool and apparatus for boring relatively deep, longitudinally elongated holes such as post holes into soil.
The vacuum assisted post hole digger apparatus according to the present invention utilizes a novel post hole digger tool which includes an elongated hollow tubular housing that has at the; upper end thereof a laterally outwardly curved vacuum inlet coupling tube. The apparatus includes a vacuum source such as a wet-or-dry shop vacuum powered by an electric motor which is connectable through a flexible vacuum hose to the vacuum inlet coupling tube of the tool.
The post hole digger tool according to the present invention includes a cylindrical ring-shaped bore head which is attached to the lower transverse end of the tubular housing. The bore head includes a cylindrical sleeve which is coaxially aligned within the tubular housing, and is of approximately the same diameter as the housing. The bore head has protruding downwards of the lower transverse annular edge wall thereof a plurality, typically four, of circumferentially spaced apart cutting blades or teeth. In a preferred embodiment, the teeth are attached to the outer circumferential surface of the cylindrically shaped sleeve which comprises the body of the bore head.
The vacuum assisted post hole digger tool according to the present invention includes a longitudinally elongated, zig-zag shaped mud and clay unclogger bar which is attached at an upper end thereof to an elongated drive shaft that extends upwardly through the center of the elongated bore through the tubular housing of the tool. The upper end of the drive shaft protrudes through the center of a vacuum-tight bearing fitted in an upper wall of the vacuum inlet tube, in coaxial alignment with the bore through the cylindrical housing.
The post hole digger tool according to the present invention includes a pair of transversely aligned cylindrically-shaped turnstile-type handles which protrude perpendicularly outwards form opposite sides of the tubular housing. The handles are located in a horizontal plane a short distance below the upper transverse end of the housing below the vacuum inlet coupler tube.
The vacuum assisted post hole digger tool according to the present invention is used by first connecting the outer, inlet end of the vacuum inlet coupler tube through a flexible hose to a vacuum source, such as an electrically powered wet-or-dry shop vacuum unit which includes a blower that has a vacuum inlet port and a cannister for collecting debris discharged from the output port of the blower. Next, the handles of the tool are grasped, and the tool lifted to position it vertically above a ground surface in which a hole is to be bored. The tool is then lowered to place the bore head teeth in contact with a ground surface. The tool handles are then toggled cyclically in clockwise and counterclockwise directions, e.g., plus and minus 90 degrees, to thus cause the bore head cutting teeth to penetrate the ground, assisted by downward force exerted by the weight of the housing.
The vacuum source is then turned on, and maintained on while the tool handles are rocked back and forth. Earth loosened by the cutting teeth is drawn up through the hollow bore of the tool housing by the vacuum source, facilitating boring action of the teeth.
When the vacuum assisted post hole digger tool is used in wet, muddy soil or in clay, the upper end of the drive shaft of the mud unclogger bar which protrudes upwards form the vacuum inlet tube is coupled to a rotary power source, such as by being clamped in the chuck of an electric drill. The rotary power source is then energized while the tool is in use, causing the mud unclogger bar to rotate, pulverize and break up mud or clay clogs which could otherwise form and prevent vacuum removal of severed soil material.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a vacuum assisted post hole digger apparatus with a rotary clog breaker according to the present invention.
FIG. 2 is a perspective view of the vacuum assisted post hole digger tool part of the apparatus of FIG. 1 .
FIG. 3 is a longitudinal medial sectional view of the tool of FIG. 2 .
FIG. 4 is an upper plan view of the tool of FIG. 3 .
FIG. 5 is a fragmentary side elevation view of the post hole digger of FIG. 1 on an enlarged scale, showing a bore head component thereof.
FIG. 6 is a lower plan view of the bore head component of FIG. 5 .
FIG. 7 is a partly exploded perspective view of an upper part of the post hole digger tool of FIG. 1 , showing a mud and clay unclogger bar of the tool removed from the tool housing.
FIG. 7A is a fragmentary perspective view of the post hole digger tool of FIG. 7 , on an enlarged scale, and showing an upper end of the housing modified to include alternating grooves and flanges.
FIG. 8 is a fragmentary perspective view of a lower part of the tool of FIG. 2 , showing the mud and clay unclogger bar thereof extended from the bore head thereof.
FIG. 9 is a perspective view of the post hole digger tool of FIG. 1 , showing the tool connected to a vacuum source and positioned above a ground surface preparatory to using the tool to dig a hole in the ground.
FIG. 10 is a view similar to that of FIG. 9 , showing the post hole digger tool of FIG. 1 being readied to dig a hole in muddy soil.
FIG. 11 is a longitudinal sectional view of the arrangement of FIG. 9 , showing how the tool of FIG. 1 is used to severe soil.
FIG. 12 is a view similar to that of FIG. 11 , showing severed soil being drawn up through the bore of the tool by vacuum.
FIG. 13 is a longitudinal sectional view of the tool of FIG. 10 , showing a mud and clay unclogger bar of the tool being rotated to break up mud clogs.
FIG. 14 is an elevation view of a modification of the tool of FIG. 2 , which has a larger diameter bore head.
FIG. 15 is a fragmentary view of the tool of FIG. 14 , showing a bore head thereof.
FIG. 16 is a lower plan view of the bore head of FIG. 15 .
FIG. 17 is a perspective view of another modification of the tool of FIG. 2 , which has an integral drive motor for rotating the mud and clay unclogger bar of the tool.
FIG. 18 is an elevation view of a modified bore head for the tools of FIGS. 1-14 .
FIG. 19 is a lower plan view of the bore head of FIG. 18 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1-8 illustrate a basic embodiment of a vacuum assisted post hole digger tool and apparatus with rotary clog breaker according to the present invention. FIGS. 9-13 illustrate operation of the post hole digger tool and apparatus according to the present invention. FIGS. 14-16 illustrate a modification of the tool of FIGS. 1-8 , which is useable for making larger diameter holes. FIG. 17 illustrates a modification of the tool of FIGS. 1-8 which includes an integral drive motor for rotating a mud and clay unclogger bar of the tool.
FIGS. 18 and 19 illustrate a modified bore head for use with tools shown in FIGS. 1-17 , for use in making large holes.
Referring first to FIG. 1 , a vacuum assisted post hole digger apparatus 20 may be seen to include a novel post hole digger tool 21 according to the invention, a vacuum source such as an electrically powered wet-or-dry shop vacuum unit 22 , and a flexible vacuum hose 23 which interconnects the tool 21 and the vacuum source 22 .
As shown in FIGS. 1-3 , vacuum assisted post hole digger tool 21 includes a straight, longitudinally elongated, circular cross-section cylindrical housing 24 , which is made of heavy gauge steel or cast iron. Although the dimensions of housing 24 are not critical, example embodiments of the invention which were tested by the present inventor had outer diameters ranging between about 4 inches to 7 inches, and lengths of about six feet.
As shown in FIG. 7 , housing 24 of tool 21 has located a short distance below upper transverse annular end wall 25 thereof a pair of straight, horizontally oriented left and right handle bars 26 L, 26 R, which are attached to and protrude perpendicularly outwards from diametrically opposed sides of the outer circumferential wall surface 27 of housing 24 . Preferably, as shown in the figures, handlebars 26 L, 26 R have fitted over them insulating tubular rubber handle grips 26 LG, 26 RG.
As shown in FIGS. 3 , 7 and 8 , housing 24 of tool 21 has disposed through its length a uniform diameter, circular cross-section bore 28 which has an upper opening 29 and a lower opening 30 .
Referring to FIGS. 1 , 3 and 7 , it may be seen that post hole digger tool 21 includes a vacuum inlet tube 31 , which preferably has the shape of a tubular right-angle elbow, that has a lower vertical section 32 , and an upper horizontal section 33 which protrudes laterally outwards from the upper end of the vertical section.
As shown in FIGS. 3 and 7 , tool 21 includes a coupler 34 for coaxially coupling the inner, vertical section of vacuum inlet coupler elbow 31 in a vacuum-light connection to the upper open end of tubular housing 24 , thus forming a smooth, hermetically sealed passageway between the elongated straight bore 24 of the housing and the curved bore 35 of the vacuum inlet elbow.
FIGS. 3 , 4 and 7 show a preferred construction of coupler 34 which includes a lower flange section 36 of vertical section 32 of vacuum inlet coupler 31 that has an enlarged diameter bore 37 that insertably receives the upper end of tubular housing 24 . In a most preferred embodiment, coupler 34 is a rotary union-type which enables the lateral arm 33 of vacuum inlet tube elbow 31 to be rotated in a horizontal plane relative to the longitudinal axis of tubular housing 24 . Preferably, as shown in FIG. 7A , the upper end of tubular housing 24 has formed in outer cylindrical wall surface 27 thereof a series of alternating, longitudinally spaced apart circular grooves 27 G and flange barbs 27 F, for frictionally securing against relative longitudinal movement a vacuum hose or vacuum inlet tube 31 connected to tubular housing 24 .
Referring still to FIGS. 3 and 7 , it may be seen that post hole digger tool 21 includes a bore head assembly 38 which is attached to a lower end 39 of tubular housing 24 . As may be seen best by referring to FIGS. 6 and 7 , bore head assembly 38 includes a cylindrical isolation collar 40 which fits coaxially over the outer circumferential wall 27 of tubular housing 24 , and protrudes below the lower transverse end wall 41 of the housing. Isolation collar 40 is made of an electrically insulating material such as heavy rubber, and provides electrical isolation between housing 24 and a toothed bore head 42 . The function of isolation collar 40 is to prevent an operator of tool 21 from receiving an electrical shock should bore head 42 inadvertently contact a live buried electrical cable, as will be explained below.
As shown in FIGS. 5 , 6 , 7 and 8 , bore head 42 of bore head assembly 38 includes a cylindrically-shaped base ring 43 that has attached to the outer cylindrical wall surface thereof a plurality of wedge-shaped cutting teeth 45 . As shown in FIG. 5 , each cutting tooth 45 includes an upper rectangular bar-shaped upper root section 46 , a longer vertical edge 47 which protrudes downward below the lower transverse annular edge 48 of the base ring 43 , a shorter vertical edge 49 , and a lower straight edge 50 which angles obliquely downwards from the shorter vertical edge 49 to intersect at an acute angle the longer vertical edge 47 and form therewith a triangular vertex 51 which forms the cutting point of tooth 45 .
Although the number and spacing of cutting teeth 45 may be varied, in an example embodiment of tool 21 which was tested by the present inventor and depicted in FIGS. 5-8 , bore head 42 had four cutting teeth 45 - 1 , 45 - 2 , 45 - 3 and 45 - 4 , spaced circumferentially apart at 90-degree intervals.
Referring to FIG. 7 , it may be seen that tool 21 may optionally include an inner, connector sleeve 52 which is fastened coaxially within base ring 43 , as by circumferentially spaced apart bolts 53 disposed radially through aligned holes 54 and 55 through the cylindrical walls of 56 , 57 , respectively of the base ring 43 and connector sleeve 52 with the lower transverse annular edge wall 59 of the connector sleeve aligned with lower transverse edge wall 59 of the bore head sleeve. Similarly, connector sleeve 52 is fastened at an upper end thereof within bore 40 A of isolation collar 40 by bolts 60 disposed radially through aligned holes 61 , 62 through the cylindrical wall 40 B of isolation collar 40 , and aligned holes through connector sleeve 52 , located near the upper annular edge wall 63 of the connector sleeve.
As shown in FIGS. 3 , 7 and 8 , isolation collar 40 is attached to an inner connector sleeve 52 and the lower end of tubular housing 24 in a manner which creates an annular ring-shaped air gap 52 U between the upper transverse annular end wall of the sleeve 52 and the lower transverse annular end wall 41 of tubular housing 24 . Air gap 52 U electrically isolates bore head 42 from tubular housing 24 .
As may be understood by referring to FIGS. 3 , 6 , and 7 , bore head 42 has longitudinally through its length a central coaxial bore 42 B which preferably has a diameter at least as large as the diameter of bore 28 through housing 24 , bore 42 B communicating at an upper end with bore 28 , and having a lower entrance opening 42 D.
FIGS. 3 , 7 and 8 illustrate the construction of a novel mud and clay unclogger component 64 of the tool 21 .
As shown in FIGS. 3 , 7 and 8 , mud and clay unclogger 64 includes an elongated longitudinally disposed rectangular cross-section, zig-zag shaped unclogger bar 65 which end is joined at upper end thereof by a coupler collar 66 to an elongated drive shaft 67 . Drive shaft 67 , which preferably has a round cross-section, is disposed longitudinally upwards through the center of bore 28 through housing 24 . As shown in FIGS. 1-4 , the upper end of drive shaft 67 is rotatably mounted in the center of bearing 68 that is fitted into the upper wall 70 of vacuum inlet coupler elbow 31 . Bearing 68 is coaxially aligned with the longitudinal center line of housing 24 and forms a vacuum-tight seal with upper wall 69 of elbow 31 , so that air cannot leak from the exterior of elbow into the bore 35 through the elbow, when the air pressure in the bore is reduced below ambient atmospheric pressure by coupling the elbow to a vacuum source, such as a shop vacuum 22 shown in FIG. 1 .
As may be seen best by referring to FIGS. 7 and 8 , mud and clay unclogger bar 65 has a zig-zag shape formed by a series of flat sections which angle outwardly and inwardly with respect to the common longitudinal center lines of mud and clay unclogger bar coupler 66 and drive shaft 67 , to form a zig-zag shape. Thus, as shown in FIG. 8 , mud and clay unclogger bar 65 has a first upper straight vertical segment 70 coaxially aligned with coupler 66 and drive shaft 67 , and a first, upper straight angled section 71 that angles radially outwardly and downwardly from the lower end of the upper straight section 70 . Mud and clay unclogger bar 65 also has a second straight vertical section 72 which extends downwardly from parallel to the longitudinal center line of housing 24 and drive shaft 67 , but is located on a first, e.g., right side of the common longitudinal center lines.
Referring still to FIG. 8 , it may be seen that mud and clay unclogger bar 65 also has a second straight angled section 73 which extends radially inwardly and at a slight downward angle from the lower edge of second straight vertical section 72 , and extends radially beyond the longitudinal center line of stirrer collar 66 to the left side of the center line. A third, left straight vertical mud and clay unclogger bar segment 74 extends downwardly from the lower left end of second angled mud and clay unclogger bar segment 73 , and is joined at a lower end thereof by third right-wardly and downwardly angled straight section 75 . The lower end of section 75 is terminated by a terminal downwardly and radially inwardly angled, bottom angled straight segment 76 , which forms with segment 75 a V-shaped lower end section. As shown in FIGS. 1 and 2 , the lower end 77 of lowest mud and clay unclogger bar segment 76 is approximately aligned with the lower transverse edges of cutting teeth 45 .
FIGS. 9-13 show how vacuum assisted post hole digger apparatus 20 according to the present invention is used. As shown in FIG. 9 , left and right handles 26 L, 26 R of post hole digger tool 21 are grasped in the left and right hands, respectively, of an operator A. The tool 21 is then positioned vertically above a location in which a hole is to be dug, and the points of the cutting teeth 45 inserted into the soil, using a downward force exerted on the teeth by the weight of tool housing 24 , and, if necessary, additional downward force exerted on handles 26 L, 26 R by the operator.
Next, as shown in FIGS. 1 and 9 , a vacuum hose 23 is connected at one end to elbow 31 , and at the other end to a vacuum source such as a wet-or-dry shop vacuum 22 .
Then, as shown in FIGS. 9 and 11 , handles 26 L, 26 R are used to oscillate, toggle or rock housing 24 alternately in clockwise and counterclockwise directions relative to the longitudinal axis of the housing, in angular excursions of approximately 90-180 degrees clockwise and 90-180 degrees counterclockwise. This action causes cutting teeth 45 of severed soil, as shown in FIG. 11 . Negative pressure within bore 28 of tubular housing 24 and bore 42 B of bore head 42 causes severed soil to be drawn up through the bore 28 of tool housing 24 , as shown in FIGS. 12 , thus facilitating rapid downward vertical digging motion, as shown in FIGS. 11 and 12 .
As shown in FIGS. 1 , 2 , 5 and 6 , the location of cutting teeth 45 on the outer cylindrical wall surface of base ring 43 forms a longitudinally disposed, annular arc-shaped gap between circumferentially spaced apart longitudinal edges of each pair of adjacent teeth. These gaps enable free flow of severed soil from the bore hole into the bore 28 of housing 24 , thus minimizing the possibility of forming a vacuum blockage of bore 28 , which would require withdrawing the housing vertically upwards in a bore hole being formed to clear the vacuum blockage.
FIGS. 10 and 13 illustrate how apparatus 20 is used to dig holes in wet or clay bearing soil. As shown in FIG. 9 , the positioning of tool 21 relative to a ground surface of wet soil in which a hole is to be dug is similar to that shown in FIG. 9 , in using the tool to dig a hole in dry soil. Moreover, the toggling or pivoting of the housing 24 of the tool 21 , and general procedure for using the tool, are similar for both dry and wet soil. However, as shown in FIG. 10 , when the bore 28 of tool housing 24 tends to become clogged because of wet, muddy or clay soil lodging within the bore, the upper end of stirrer rod drive shaft 67 that protrudes upwardly from vacuum inlet coupler elbow 31 is connected to a rotary power source, such as by clamping the end of the drive shaft in the chuck C of an electric drill B. The rotary power source is then energized, causing the zig-zag shaped mud and clay unclogger bar 65 located at the bottom end of rotating drive shaft 67 to slice through and pulverize mud clogs and clay, thus restoring efficient vacuuming of dirt and mud or clay through the bore 28 of tool housing 24 .
FIGS. 14-16 illustrate a modification 81 of the vacuum post hole digger tool shown in FIGS. 1-13 and described above. Modified post hole digger tool 81 has a bore head 102 of larger diameter than bore head 42 shown in FIGS. 1-8 , and includes a frusto-conically shaped tubular transition section 140 . Transition section 140 has an upper diameter approximately equal to that of tubular housing 84 of tool 81 , and a larger lower diameter equal to that of larger diameter bore head 102 .
FIG. 17 illustrates another modification 20 A of tool 20 shown in FIGS. 1-8 and described above. Modified tool 20 A has an integral drive motor 180 which replaces an external rotary power source such as the electric drill B shown in FIG. 10 . As shown in FIG. 17 , motor 180 is attached to a vacuum inlet tube elbow 31 by a bracket assembly 181 . Electrical power is supplied to drive motor 180 by a power cord 182 , which preferably is attached to the exterior of vacuum hose 23 . Preferably, power cord 182 includes a neutral conductor 183 which is connected directly to motor 180 , and a hot conductor 184 which is connected to the drive motor through an on/off switch 185 mounted on a handle bar grip 26 RG.
FIGS. 18-19 illustrate a modified bore head 242 for use with the vacuum assisted post hole digger tools 21 , 81 and 211 described above. As shown in FIGS. 18 and 19 , modified bore head 242 has a longitudinally elongated circular cross-section, hollow tubular teeth-anchor body 243 . Teeth anchor body 243 has an elongated upper elongated cylindrically-shaped connection tube section 230 , which at a lower transverse end thereof tapers radially inwardly to a smaller diameter, short neck section 231 .
The lower end of neck section 231 tapers radially outwardly to a longer teeth support section 232 of larger diameter than both upper connection tube section 230 and intermediate neck section 231 . As may, be seen best by referring to FIG. 19 , teeth support section 232 has a generally uniform wall thickness. Thus, a lower generally cylindrically-shaped section 233 of teeth support section 232 has a generally cylindrically-shaped bore 234 which at the upper end thereof tapers radially inwardly via an angled annular transition section 235 to join a cylindrical inner bore 236 which is disposed longitudinally through neck section 231 and upper connection tube section 230 .
As shown in FIGS. 18 and 19 , bore head 242 has attached to the outer cylindrical wall surface 244 of lower tooth support section 232 thereof a plurality of cutting teeth, including a first set of four axial cutting teeth 245 A, 245 B, 245 C, 245 D, which are spaced circumferentially apart at 90-degree intervals. As shown in FIGS. 18 and 19 , axial cutting teeth 245 are approximately parallel to the longitudinal axis of cutting tooth anchor body 243 . Each axial cutting tooth 245 has a short, rectangular bar-shaped, upper root section 246 , which is fastened to a flat 296 to the outer cylindrical wall surface 244 of the lower tooth support section 232 .
Referring still to FIGS. 18 and 19 , if may be seen that bore head 242 also has attached to outer cylindrical wall surface 244 of the bore head a second set of four angled cutting teeth 265 A, 265 B, 265 C, 265 D, which are located circumferentially midway between each pair of axial cutting teeth 245 , and hence are also spaced apart circumferentially at 90-degree intervals. As shown in FIG. 19 , each angled cutting tooth 265 has a relatively long, radially inwardly bent upper root section 266 , which is fastened to both a flat 296 of the lower part of outer cylindrical wall surface 244 of lower tooth support section 232 , at an intermediate longitudinal location of each tooth, and to an upper arcuately inwardly curved wall surface 297 of outer wall surface 298 of tooth support section 222 at an upper location of each tooth, each tooth having at an outer lateral edge thereof an acutely angled, wedge-shaped cutting point.
Referring to FIGS. 18 and 19 , it may be seen that each cutting tooth 245 , 265 has a similar symmetrical shape. Thus, as shown in FIG. 18 , each cutting tooth 245 , 246 has circumferentially spaced apart, longitudinally disposed straight, parallel left and right sides 247 , 249 which are coextensive with left and right sides of upper tooth section 246 of each tooth. As shown in FIG. 18 , each tooth 245 , 265 has a lower transverse edge 250 which is spaced longitudinally below the lower transverse annular end wall 248 of lower tooth support section 232 of bore head 242 . Lower transverse edge 250 has extending longitudinally upwards therein a symmetrically shaped notch 270 having the shape of an isosceles triangle, thus forming left 271 and right 272 cuspids of a bicuspid-shaped tooth, each having at an outer edge thereof an arcuately angled, wedge-shaped cutting point.
As may be seen best by referring to FIG. 19 , each tooth 245 , 265 has in transverse section the shape of regular prism; including a central section having flat and parallel inner and outer longitudinally disposed rectangular sides 272 , 273 , and left and right triangular cross-section side section 274 , 275 , the outer longitudinally vertices 276 , 277 of which form longitudinally disposed, wedge-shaped knife edges. | A tool for boring holes in soil includes an elongated tubular housing which has disposed through its length a bore having an upper opening coupleable to a vacuum source and a lower opening coupled to the bore of a ring-shaped bore head having circumferentially spaced apart cutting teeth protruding downwards from the bore head. A zig-zag shaped unclogger bar disposed coaxially through the bore head and rotated by a drive shaft disposed coaxially through the tubular and housing and protruding through a bearing in an upper end of the housing and driven by a rotary power source such as an electric motor fixed to the housing fragments lumps of clay or wet soil lodged in the bore of the housing, facilitating removal of soil and clay, which are severed by twisting the tool around its longitudinal axis by manipulating handle bars protruding from the upper end of the housing. | 4 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to the field of post tension systems for strengthening concrete. More particularly, the invention relates to an improved anchor and method for reducing corrosion on the wire strands of a post-tension tendon.
[0002] Mono-strand tendons typically comprise a seven wire strand cable or tendon placed within a plastic or elastomeric sheath. A seven wire tendon is formed with six wires helically wrapped around a central core wire.
[0003] Wire cable corrosion is a significant concern in post tension systems. Such corrosion occurs when water, salt and other corrosive agents contact the metallic tendon materials. Tendon failure typically occurs due to water intrusion into the interstices between the tendon and is typically concentrated at tendon ends or anchors.
[0004] Such failure also occurs at portions of the tendon damaged segments caused during installation. The installation of tendons typically occurs in a rugged construction environment where the tendons can be damaged by equipment, careless handling and contact with various site hazards. When the elastomeric sheath is punctured, a water leak path contacting the wire tendon is established. The puncture must be patched to resist water intrusion between the sheath and tendon. The puncture and patch can create a discontinuity between the tendon and the sheath, and this discontinuity can impede proper installation and performance of the tendon.
[0005] One conventional technique for providing extra protection in corrosive environments is to increase the thickness of the plastic sheath covering the tendon. A plastic sheath at least forty mils thick can be formed around the tendon resist abrasion and puncture damage. Although this approach provides incremental protection against leakage, a thicker sheath does not provide redundant protection to the tendon steel.
[0006] Another technique for providing extra protection in corrosive environments uses seals and grease-filled pockets for blocking water intrusion into the central tendon core. Oil or grease is pumped into the exposed tendon end to fill the interstices at the tendon ends, however this procedure does not protect the internal wire strands forming the tendon.
[0007] Another technique for resisting high corrosion environments is to specially coat or otherwise treat the individual wire strand with an electrostatic fusion-bonded epoxy to a thickness between one and five mils thick. Similar wire coating techniques use galvanized wire and other corrosion resistant wires within the multiple wire cables to form a corrosion resistant tendon. Significant effort has been made to create improved corrosion resistant materials compatible with the exterior sheaths and resistant to corrosion. Corrosion resistant materials typically have an affinity to metal and are capable of displacing air and water. Additionally, such materials are relatively free from tendon attacking contaminants such as chlorides, sulfides and nitrates. However, such tendons are expensive and the effectiveness of such corrosion resistant materials may not resist corrosion after the tendon is damaged.
[0008] Tendon corrosion typically occurs near the post-tension anchors because the outer sheath is removed from the wire tendon at such locations. To protect the bare wire from corrosion, protective tubes are connected to the anchor and are filled with grease or other corrosion preventative material. This conventional practice is demonstrated by different post-tension systems. For example, U.S. Pat. No. 5,271,199 to Northern (1993) disclosed tubular members and connecting caps for attachment to an anchor. U.S. Pat. No. 5,749,185 to Sorkin (1998) disclosed split tubular members for attachment to and anchor and for installation over the tendon. U.S. Pat. No. 5,897,102 to Sorkin (1999) disclosed a tubular member having a locking surface for improving the connection to an anchor, and a cup member and extension for engagement on the other side of the anchor. U.S. Pat. No. 6,027,278 to Sorkin (2000) and U.S. Pat. No. 6,023,894 to Sorkin (2000) also disclosed a tubular member having a locking surface to improve the connection to an anchor. U.S. Pat. No. 6,098,356 to Sorkin (2000) disclosed attachable tubular members filled with corrosion resistant grease.
[0009] A need exists for an improved post-tension seal for preventing fluid intrusion into the inner part of a post-tension anchor. The system should be compatible with existing installation procedures and should resist the risk of water intrusion into contact with internal tendon wires.
SUMMARY OF THE INVENTION
[0010] The invention provides an anchor and pocketformer for engagement with a post-tension tendon. The apparatus comprises an anchor base having a shaped aperture for permitting insertion of the tendon therethrough, a sheath engaged with the anchor base wherein said sheath includes a cylindrical extension having a contact end distal from the anchor base for contacting the tendon as the tendon is inserted through the cylindrical extension and the anchor base aperture, and a pocketformer detachably engagable with the sheath.
[0011] In different embodiments of the invention, the pocketformer can comprise a spindle and a pocketformer body engagable with the spindle. Either the spindle or the pocketformer can be attachable to the sheath, and the spindle can extend through the anchor base to provide a continuous path for insertion of the tendon therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] [0012]FIG. 1 illustrates a mono-strand cable enclosed with a first sheath.
[0013] [0013]FIG. 2 illustrates a second sheath.
[0014] [0014]FIG. 3 illustrates a first sheath closely formed to the cable exterior surface.
[0015] [0015]FIG. 4 illustrates an exploded view of a base, spindle, pocketformer and retainer cap.
[0016] [0016]FIG. 5 illustrates a cap and spindle directly attachable to a base sheath.
[0017] [0017]FIG. 6 illustrates a pocketformer integrated with a spindle.
[0018] [0018]FIG. 7 illustrates a sheath cutter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0019] The invention provides a unique system for providing a post tension system resistant to corrosion. Each tendon typically comprises an exterior sheath surrounding at least two strands formed with a material such as carbon steel.
[0020] [0020]FIG. 1 illustrates a sectional view wherein mono-strand wire tendon 10 , formed with individual wire strands 12 about center wire 14 , is positioned within first sheath 16 . One or more wire strands 12 are helically wrapped about center wire strand 14 and form helical grooves on the exterior surface of cable 10 . Such helical grooves are cumulatively identified as shaped annulus 18 defining the space between tendon 10 and the interior cylindrical surface of first sheath 16 .
[0021] Because wire strands 12 are circular in cross-seciton, spaces between adjacent wire strands 12 and center wire 14 are cumulatively identified as cable interior interstices 20 . As shown in FIG. 1, annulus 18 and interstices 20 are filled with corrosion resistant material 22 . Grease or another suitable material can be used for corrosion resistant material 22 to eliminate air pockets and to resist water intrusion into contact with wire strands 22 . By filling annulus 18 with a lubricant or corrosion resistant material 22 , the interior surface of first sheath 16 can be substantially cylindrical in one embodiment of the invention.
[0022] [0022]FIGS. 2 and 3 illustrate second sheath 26 formed about first sheath 16 . Annulus 28 is formed between second sheath 26 and first sheath 16 and is filled with a lubricant 30 to facilitate sliding movement therebetween. Lubricant 30 can comprise a corrosion resistant material similar to material 22 . Grease or another lubricant is place on the outer surface of the seven strand wire tendon adjacent to the elastomeric sheath to resist corrosion created by air and water infiltration between the tendon and the sheath. In FIG. 2 annulus 28 is substantially cylindrical. In FIG. 3 first sheath 16 is tightly formed about the exterior surface of tendon 10 and helical grooves, filled with corrosion resistant material, are formed in the exterior surface of first sheath 16 . This feature preferably uses a material for first sheath 16 having a thickness less than ten mils. Conventional membranes are typically twenty-five mils thick for regular systems and forty mils thick for high corrosion resistant, encapsulated systems. By providing a slim first sheath 16 about tendon 10 which is capable of fitting tightly about tendon 10 to create grooves in the exterior surface of first sheath 16 , corrosion resistant material 30 can be stored in annulus 28 to resist intrusion by water of other contamination into contact with first sheath 16 or tendon 10 .
[0023] [0023]FIG. 4 illustrates post-tension anchor comprising base 30 having shaped aperture 32 . Base 30 is formed with a cast metal material suitable for handling large compressive loads. Sheath 34 is attached to base 30 and includes cylindrical extension 36 having a contact end 38 distal from base 30 . Contact end 38 is preferably at least four inches distal from base 30 , however shorter or longer lengths are possible within the usable scope of the invention. The inner surface of contact end 38 is preferably circular in cross-section for contacting the exterior surface of tendon 10 as tendon 10 is inserted through cylindrical extension 36 and base aperture 32 . Seal 40 can be positioned between contact end 38 and tendon 10 to restrict liquid intrusion into the inside of cylindrical extension 36 .
[0024] [0024]FIG. 4 illustrates one embodiment of the invention in expanded form wherein extension 36 includes threadform 42 proximate to base 30 . Spindle 44 is attachable to threadform 42 with threadform 48 formed on a first end of spindle 44 . By inserting spindle 44 completely through anchor base 30 , a continuous path is created for insertion of tendon 10 therethrough.
[0025] Spindle 44 can be substantially shaped as a cylinder having hollow interior 50 for receiving tendon 10 therethrough, however other shapes can be used to accomplish the function described herein. A second end of spindle 44 has threadform 52 for connection to cap 54 . Cap 54 can provide the function of locking pocketformer 56 onto spindle 44 and can have aperture 58 therethrough for permitting withdrawal of tendon 10 therethrough. Threadform 60 provides rotatable engagement with threadform 52 . In another embodiment of the invention cap 54 can be closed to seal the interior of spindle 44 from entry of contaminants into hollow interior 50 .
[0026] In the inventive embodiment shown in FIG. 4, a locked connection between extension 36 and spindle 44 is accomplished without requiring threads or other connector within base 30 . This feature of the invention saves time in the field by permitting quick installation and detachment while eliminating the need for expensive milling of threads into the metallic components of base 30 . This feature of the invention also permits factory assembly of corresponding components before such components are shipped to the field for installation.
[0027] Seal end 62 of pocketformer 56 can be shaped to provide a tight fit with sheath 32 . Preferably such fit can be configured so that engagement of cap 54 urges pocketformer 56 into a fluid tight seal with sheath 32 . Alternatively, a seal (not shown) can be inserted therebetween.
[0028] [0028]FIG. 5 illustrates another embodiment of the invention wherein spindle 64 has an enlarged first end 66 having threadform 68 for rotational engagement with threadform 70 in sheath 32 as shown in FIG. 4. Cylindrical body 72 of spindle 64 includes threadform 74 for engagement with cap 54 to secure pocketformer 56 as described for FIG. 4. This embodiment of the invention provides for spindle 64 to be attached directly to sheath 32 without modifying the configuration of body 30 .
[0029] In another embodiment of the invention as shown in FIG. 6, spindle and pocketformer can be integrated into a single component shown as pocketformer 76 having threadform 78 for rotatable engagement with sheath 32 , spindle section 80 having aperture 82 for permitting passage of tendon 10 therethrough, and threadform 84 on an exterior surface of spindle section 80 for engagement with sealing cap 54 . Cap 54 can selectively provide a seal for closing aperture 82 from fluid intrusion. Alternatively, threadform 84 can provide a connection for an extension tube (not shown) similar to extension 36 extending to a location distal from base 30 .
[0030] Referring to FIG. 4, spindle 44 is capable of extending through base 30 because of the unique formation of shaped aperture 32 therethrough. In one embodiment of the invention as illustrated, shaped aperture 32 can comprise an aperture having a compound surface having at least two different surfaces with different shapes or angles relative to the longitudinal axis illustrated. Surface 86 comprises a truncated conical surface at an angle two degrees from the longitudinal axis. Although such angle is two degrees, the angle can be changed to range between two and five degrees within the scope of the invention. Surface 88 comprises a truncated conical surface seven degrees from the longitudinal axis or centerline, which is the standard angle used in the industry from wedges. The combination of multiple surfaces 86 and 88 permits a larger aperture size to be created through anchor base 30 , thereby permitting the insertion of spindle 44 therethrough. Such configuration continuously enlarges the size of the aperture, thereby preventing restrictions which might impede insertion of tendon 10 therethrough.
[0031] [0031]FIG. 7 illustrates another embodiment of the invention wherein sheath cutter 90 is integrated within anchor base 30 for the purpose of stripping either sheath 16 or sheath 26 or both (if present). By locating cutter 90 in such position, the outer sheath of tendon 10 is automatically stripped as tendon 10 is inserted through base 30 . This feature of the invention dramatically saves installation time and results in a cleaner sheath cut than typically possible in field installations. Various configurations of such cutter are possible, permitting the partial or complete removal of sheath material from the end or middle section of tendon 10 .
[0032] The invention provides superior anti-corrosion protection through the entire tendon length, and especially around the point of engagement with post-tension anchors. The sheath materials can be selected from material classes such as nylon, polymers, metals, or other organic or inorganic or mineral or synthetic materials. An outer second sheath can be formed with a tough material resistant to punctures and stretching damage, while an interior first sheath can be formed with another material for retaining the corrosion resistant material.
[0033] The configuration of base 32 permits installation and tensioning of tendon 10 without removal of sheath 16 from tendon 10 at the location of base 32 . By avoiding substantial disturbance of the manufactured sheath 16 , the most sensitive point of corrosion is completely eliminated. The configuration of the caps and pocket formers described in cooperation with base 32 significantly reduces labor time and cost and provides superior reliability during installation. Such reliability reduces field damage to post tension components and the possibility of corrosion resulting from such damage, and eliminates the need for costly and unreliable field repairs.
[0034] Although the invention has been described in terms of certain preferred embodiments, it will become apparent to those of ordinary skill in the art that modifications and improvements can be made to the inventive concepts herein without departing from the scope of the invention. The embodiments shown herein are merely illustrative of the inventive concepts and should not be interpreted as limiting the scope of the invention. | An apparatus and method for reducing corrosion in post-tension construction is described. An anchor is engagable with a post-tension tendon and comprises an anchor base and sheath engaged with the anchor base, and a cap for sealing the portion of the tendon within the anchor. The sheath can include an extension having a contact end distal from the anchor base for contacting the tendon as the tendon is inserted through the extension and the anchor base aperture. The cap can extend completely through the anchor base for connection to the anchor base of a sheath or sheath extension attached to the base. A pocketformer is attachable to the sheath for generating a void in concrete. | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2009-293178 filed on Dec. 24, 2009, the entire contents of which are incorporated herein by reference.
FIELD
[0002] This embodiments discussed herein are related to an oscillating apparatus.
BACKGROUND
[0003] Some integrated circuits such as a micro-controller have a built-in CR oscillating circuit (or ring oscillator) on a chip, and a clock signal for the micro-controller is supplied from the built-in oscillating circuit. This is because in the case of an oscillating circuit using a crystal resonator or ceramic resonator, the start-up time which means the time from power is turned on until the output frequency of the oscillating circuit stabilizes is long, and it is sometimes desirable to use a CR oscillating circuit, a ring oscillator, or the like having a shorter start-up time as a clock source, even with a decrease in the accuracy of oscillation frequency. More specifically, for applications that frequently repeat starting and stopping of an oscillating circuit, a waiting time occurs at the start-up of the oscillating circuit, and it is sometimes desirable from the viewpoint of overall system performance improvement to reduce the power consumption during this waiting time. Also, an on-chip oscillating circuit is sometimes used for the purpose of cost reduction as well.
[0004] FIG. 1 is a circuit diagram of a CR oscillating circuit. In the CR oscillating circuit, IV 1 , IV 2 , and IV 3 each denote an inverter, C 1 and C 2 each denote a capacitor, R 1 denotes a resistor, ND 1 to ND 4 each denote a node within the oscillating circuit, and GND denotes a ground potential (0 V). The waveform of each of the nodes ND 1 , ND 2 , and ND 3 is the output waveform (rectangular wave) of a CMOS circuit. The waveform of the node ND 4 is such that owing to capacitive coupling between the nodes ND 2 and ND 4 , at the time of a potential change of the node ND 2 , the potential of the node ND 4 changes in the same direction as the node ND 2 , and is thereafter gradually charged/discharged by the potential of the node ND 3 and the resistor R 1 .
[0005] FIG. 2 is a circuit diagram of another oscillating circuit. In FIG. 2 , IV 1 and IV 4 each denote an inverter, C 1 and C 2 each denote a capacitor, NMn (n is an integer) denotes an N-channel MOS transistor, and PMn (n is an integer) denotes a P-channel MOS transistor. In FIG. 2 , Vdd denotes a positive power supply voltage (for example, 3 V), GND denotes a ground potential (0 V), NDn (n is an integer) denotes a node within the oscillating circuit, VBGR denotes a constant voltage (for example, 2 V) generated from a band gap circuit, PB denotes the bias potential of a P-channel MOS transistor PM 1 , and NB denotes the bias potential of an N-channel MOS transistor NM 2 .
[0006] In the circuit illustrated in FIG. 2 , nodes and elements corresponding to those of the circuit illustrated in FIG. 1 are assigned the same symbols to make their correspondence clear. In the circuit illustrated in FIG. 2 , a node ND 5 at one end of the capacitor C 1 is driven by an inverter (transistors PM 3 and NM 3 ) with the constant voltage VBGR as the power supply, thereby controlling the signal amplitude of the node ND 5 to be constant irrespective of temperature. In order to achieve a design in which frequency is independent of temperature, the circuit is so configured as to make the current flowing through transistors PM 2 and NM 1 constant independent of temperature. The bias potentials PB and NB are such potentials that make the current flowing through the transistors PM 2 and NM 1 constant.
[0007] The bias generation circuitry for generating the bias potentials PB and NB is all integrated on a semiconductor chip, and the circuit configuration as described below is adopted to generate a temperature-independent current. To generate a constant current, the potential generated by flowing a current through a resistor, and a reference voltage are made to coincide with each other by feedback control. By taking the temperature dependence of an on-chip resistor into account, temperature dependence is imparted to the reference voltage. The circuit is designed so that by imparting a positive temperature dependence to the reference voltage such that as the resistance becomes larger with a rise in temperature, the reference voltage also becomes larger with temperature, the temperature dependence of the resistor is cancelled out by the temperature dependence of the reference voltage, thereby ensuring that current is independent of temperature. The above-mentioned circuit realizes an oscillating circuit whose oscillation frequency is constant with respect to temperature and power supply voltage.
[0008] Although the circuit illustrated in FIG. 1 succeeds in achieving an oscillation frequency that is independent of power supply voltage by use of the capacitors C 1 and C 2 and the resistor R 1 , the circuit has a drawback in that if the resistor R 1 is dependent on temperature, it is difficult to suppress fluctuation of oscillation frequency. In the case where the resistor R 1 is integrated into a semiconductor chip, for example, it is practically difficult to reduce the temperature dependence of the resistor R 1 below a certain level. Also, when the values of the resistor R 1 and capacitors C 1 and C 2 fluctuate owing to manufacturing variations, so does oscillation frequency. That is, the circuit illustrated in FIG. 1 has the following problems: when the values of the resistor R 1 and capacitors C 1 and C 2 fluctuate owing to manufacturing variations, oscillation frequency also fluctuates; and when the value of the resistor R 1 varies owing to temperature fluctuation, oscillation frequency fluctuates.
[0009] The circuit illustrated in FIG. 2 aims to cancel out the temperature dependence of a resistor by the temperature dependence of a pre-designed built-in reference voltage, and generate the bias potentials PB and NB for charging/discharging the capacitors C 1 and C 2 at constant current, thereby mitigating temperature variation of oscillation frequency. However, an error is present in the actual output potential VBGR of a reference voltage generation circuit. This error also causes the temperature dependence of the potential VBGR to become slightly positive or negative depending on each individual circuit manufactured. Even more ideally, even when the circuit is configured so as to make the current flowing through the transistors PM 2 and NM 1 constant independent of temperature, because an error is also present in this portion, the temperature dependence of the charging/discharging current for the capacitors C 1 and C 2 does not become exactly the same as a designed value, either. Furthermore, the delay time of the inverters IV 1 and IV 4 is also dependent on temperature and each individual circuit manufactured, and thus becomes the cause of an error in the temperature characteristics of oscillation frequency.
[0010] In the circuit illustrated in FIG. 2 , even if it is attempted to control the current that charges the capacitors C 1 and C 2 to be constant by means of the bias potentials PB and NB, when the node ND 4 changes from low level to high level, the transistor NM 1 turns OFF, so the drain potential of the transistor NM 2 becomes the ground potential GND. Since a parasitic capacitance is present at the drain of the transistor NM 2 , when the node ND 4 changes from high level to low level, the discharging current for the node ND 4 does not become exactly the same as the current set by the bias potential NB. An extra electrical charge equivalent to the parasitic capacitance at the drain of the transistor NM 2 being charged from the ground potential GND to a given potential is discharged from the node ND 4 . Likewise, the parasitic capacitance at the drain of the transistor PM 1 also becomes the cause of an error in the setting of current.
[0011] Japanese Laid-open Patent Publication No. 63-304702 discloses an oscillating circuit configured so that, in a ring oscillator in which a plurality of stages of gates are serially connected and the gate output of the last stage is fed back to the gate input of the first stage to thereby excite oscillation, a transfer gate is inserted in between adjacent gates, and the transfer gate is connected to a control potential that may be made variable in an analog manner.
SUMMARY
[0012] According to an aspect of the embodiment, an oscillating apparatus includes: a transfer gate including a P-channel transistor and a N-channel transistor; a first inverter for inverting an output signal of the transfer gate and outputting the inverted output signal of the transfer gate; a second inverter for inverting the output signal of the first inverter and outputting the inverted output signal of the first inverter; a third inverter for inverting the output signal of the first inverter and outputting the inverted output signal of the first inverter, the third inverter being connected to a power supply potential node wire different from a power supply potential node wire for the second inverter; a fourth inverter for inverting the output signal of the third inverter and outputting the inverted output signal of the third inverter to an input-terminal of the transfer gate; a first capacitor connected between an output-terminal of the transfer gate and an output-terminal of the second inverter; and a second capacitor connected between the output-terminal of the transfer gate and a reference potential node, wherein the transfer gate outputs a signal at the input-terminal from the output-terminal in accordance with a gate voltage of each of the P-channel transistor and the N-channel transistor.
[0013] The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
[0014] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a circuit diagram of a CR oscillating circuit;
[0016] FIG. 2 is a circuit diagram of another oscillating circuit;
[0017] FIG. 3 is a circuit diagram illustrating an example of the configuration of a CR oscillating circuit of an embodiment;
[0018] FIG. 4 is a diagram illustrating an example of waveforms in various parts of the circuit illustrated in FIG. 3 ;
[0019] FIG. 5 is a diagram illustrating an example of the configuration of a micro-controller (oscillating apparatus) mounted with the CR oscillating circuit illustrated in FIG. 3 ;
[0020] FIG. 6 is a circuit diagram illustrating an example of the configuration of the band gap circuit illustrated in FIG. 5 ;
[0021] FIG. 7 is a block diagram illustrating an example of the configuration of the CR oscillating circuit illustrated in FIG. 5 ;
[0022] FIG. 8 is a circuit diagram illustrating an example of the configuration of the reference current generation circuit illustrated in FIG. 7 ;
[0023] FIG. 9 is a circuit diagram illustrating an example of the configuration of the variable resistor illustrated in FIG. 8 ;
[0024] FIG. 10 is a circuit diagram illustrating an example of the configuration of each of the amplifier circuits illustrated in FIG. 8 and of the circuit in its vicinity;
[0025] FIG. 11 is a circuit diagram illustrating an example of the configuration of the trimming current DAC circuit illustrated in FIG. 7 ;
[0026] FIG. 12 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit illustrated in FIG. 7 ;
[0027] FIG. 13 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit illustrated in FIG. 7 ;
[0028] FIG. 14 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit illustrated in FIG. 7 ; and
[0029] FIG. 15 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit illustrated in FIG. 7 .
DESCRIPTION OF EMBODIMENTS
[0030] FIG. 3 is a circuit diagram illustrating an example of the configuration of a CR oscillating circuit of an embodiment. FIG. 4 is a diagram illustrating an example of waveforms in various parts of the circuit illustrated in FIG. 3 . The circuit illustrated in FIG. 3 will be described with reference to FIG. 4 . In FIG. 3 , NMn (n is an integer) denotes an N-channel MOS transistor, PMn (n is an integer) denotes a P-channel MOS transistor, Vdd denotes a positive power supply potential (for example, 1.8 V), VR 18 denotes a positive power supply potential (for example, 1.8 V), and GND denotes a reference potential (ground potential: 0 V). In FIG. 3 , NDn (n is an alphanumeric character) denotes a node within the oscillating circuit, IV 1 , IV 4 , and IV 5 each denote an inverter, C 1 , C 2 , CNB, and CPB each denote a capacitor, IBIASROSC denotes a bias current for the circuit illustrated in FIG. 3 , PB denotes the gate bias potential of a transistor PM 5 , NB denotes the gate bias potential of a transistor NM 5 , CLK 1 denotes a clock signal, and VREG 1 denotes a circuit that generates the power supply potential VR 18 . The inverters IV 1 , IV 4 , and IV 5 each output a signal that is the logical inversion of an input signal. In FIG. 3 , elements having the same functions as those in the circuits illustrated in FIGS. 1 and 2 , and the corresponding nodes are assigned the same symbols to indicate their correspondence. The bias current IBIASROSC will be described with reference to the circuit illustrated in FIG. 11 described later.
[0031] A transistor PM 7 has a source connected to the node of the power supply potential Vdd, and a gate connected to the node of the reference potential GND. A transistor PM 8 has a source connected to the drain of the transistor PM 7 , and a gate and a drain that are connected to each other. The bias current IBIASROSC is the drain current of each of the transistors PM 7 and PM 8 . A transistor PM 9 has a source connected to the node of the power supply potential Vdd, and a gate connected to the node of the reference potential GND. A transistor PM 10 has a source connected to the drain of the transistor PM 9 , and a gate connected to the drain of the transistor PM 8 . A transistor NM 7 has a drain and a gate that are connected to the drain of the transistor PM 10 . A transistor NM 8 has a drain connected to the source of the transistor NM 7 , a gate connected to the node of the power supply potential Vdd, and a source connected to the node of the reference potential GND. The capacitor CPB is connected between the node of the power supply potential Vdd and the drain of the transistor PM 8 . The capacitor CNB is connected between the drain of the transistor NM 7 and the node of the reference potential GND.
[0032] A transistor PM 4 has a source connected to the node of the power supply potential Vdd, and a gate connected to the output terminal of the inverter IV 4 . A transistor NM 4 has a drain connected to the drain of the transistor PM 4 , a gate connected to the output terminal of the inverter IV 4 , and a source connected to the node of the reference potential GND. The transistors PM 4 and NM 4 constitute an inverter. A transistor PM 5 has a source connected to the drain of the transistor PM 4 , a gate connected to the drain of the transistor PM 8 , and a drain connected to the input terminal of the inverter IV 1 . A transistor NM 5 has a source connected to the drain of the transistor PM 4 , a gate connected to the drain of the transistor NM 7 , and a drain connected to the input terminal of the inverter IV 1 . The transistors PM 5 and NM 5 constitute a transfer gate. The bias potential PB is the gate potential of the transistor PM 5 . The bias potential NB is the gate potential of the transistor NM 5 . For example, the bias potential PB is 1 V, and the bias potential NB is 0.8 V.
[0033] A node ND 4 is connected to the input terminal of the inverter IV 1 . The capacitor C 2 is connected between the node ND 4 and the node of the reference potential GND. A node ND 1 is connected to the output terminal of the inverter IV 1 . The inverter IV 5 performs logical inversion of the signal of the node ND 1 , and outputs the clock signal CLK 1 . The constant voltage generation circuit VREG 1 generates the power supply potential VR 18 (for example, 1.8 V). A transistor PM 6 has a source connected to the node of the power supply potential VR 18 , a gate connected to the node ND 1 , and a drain connected to a node ND 5 . A transistor NM 6 has a drain connected to the node ND 5 , a gate connected to the node ND 1 , and a source connected to the node of the reference potential GND. The transistors PM 6 and NM 6 constitute an inverter. The capacitor C 1 is connected between the nodes ND 4 and ND 5 . The inverter IV 4 has an input terminal connected to the node ND 1 , and an output terminal connected to a node ND 6 .
[0034] In the circuit illustrated in FIG. 2 , even if it is attempted to control the current that charges the capacitors C 1 and C 2 to be constant by means of the bias potentials PB and NB, when the node ND 4 changes from low level to high level, a transistor NM 1 turns OFF, so the drain potential of a transistor NM 2 becomes the ground potential GND. Since a parasitic capacitance is present at the drain of the transistor NM 2 , when the node ND 4 changes from high level to low level, the discharging current for the node ND 4 does not become exactly the same as the current set by the bias potential NB. An extra electrical charge equivalent to the parasitic capacitance at the drain of the transistor NM 2 being charged from the ground potential GND to a given potential is discharged from the node ND 4 . Likewise, the parasitic capacitance at the drain of a transistor PM 1 also becomes the cause of an error in the setting of current.
[0035] On the other hand, in the circuit illustrated in FIG. 3 , if the speed of the change in the output of each of the transistors PM 4 and NM 4 is sufficiently high, the charging current for the parasitic capacitance at the source (node connected to each of the transistors PM 4 and NM 4 ) of each of the transistors PM 5 and NM 5 is not supplied to the node ND 4 . By adopting the circuit configuration illustrated in FIG. 3 in this way, the accuracy of setting of current by the bias potentials PB and NB may be improved.
[0036] As illustrated in FIG. 3 , an element that restricts current supplied to a load serves as a CMOS transfer gate (transistors PM 5 and NM 5 ). For example, even in the state when the transistor PM 4 is ON and the transistor NM 4 is OFF, not only does the transistor PM 5 supply current to the node ND 4 , but depending on the potential of the node ND 4 , there is a possibility that the transistor NM 5 also turns ON.
[0037] The circuit illustrated in FIG. 3 is configured so that when charging the node ND 4 , current is supplied from only the transistor PM 5 . By driving the node ND 5 at the constant potential VR 18 , the signal amplitude of the node ND 4 becomes constant independent of the power source potential Vdd. By setting C 2 :C 1 as 2:1, for example, the signal amplitude of the node ND 4 may be set to approximately ⅔ of the potential VR 18 . By making the signal amplitude of the node ND 4 small, the withstand voltage of the inverter IV 1 may be made low.
[0038] While the potentials Vdd and VR 18 are both constant at 1.8 V, as will be described later with reference to FIG. 4 , the power supply potential supplied to the elements PM 4 , NM 4 , IV 1 , IV 5 , IV 4 , and the like is set to the potential Vdd, and only the power supply potential supplied to the transistors PM 6 and NM 6 is set as the potential VR 18 .
[0039] The reason for using separate power supply potentials in this way is to minimize fluctuation of the potential VR 18 caused by voltage fluctuation due to power supply current of the inverters IV 1 , IV 5 , and IV 4 , and the like. The intention is to suppress fluctuation of the potential VR 18 as much as possible by using separate wires for the potentials VR 18 and Vdd as illustrated in FIG. 5 .
[0040] Supposing that the ratio between the capacitors C 1 and C 2 is 1:1, when the logic threshold of the inverter IV 1 is 0.9 V, as the node ND 1 changes from low level to high level, the potential of the node ND 5 changes from 1.8 V to 0V. The potential of the node ND 4 changes from 0.9 V to 0 V. The node ND 4 is charged at constant current in the range of 0 V to 0.9 V, and when the potential of the node ND 4 exceeds 0.9 V, and the potential of the node ND 1 changes from high level to low level, the potential of the node ND 4 changes from 0.9 V to 1.8 V. The node ND 4 is discharged at constant current from 1.8 V to 0.9 V, resulting in the waveform as illustrated in FIG. 4 . Fluctuation of oscillation frequency may be thus prevented.
[0041] By setting the capacitors C 2 :C 1 not to 1:1 but, for example, 2:1, the low level of the node ND 4 may be set to a potential higher than 0 V. Also, the high level of the node ND 4 may be set to a potential lower than 1.8 V. Thus, the inverter IV 1 with a low withstand voltage may be used.
[0042] The bias potentials PB and NB in FIG. 3 are each set to such a potential that a predetermined current flows when the source potential of each of the transistors PM 5 and NM 5 is substantially the power supply potential (1.8 V or 0 V). When the node ND 4 is charged, the potential of the node ND 4 may be made higher than 0 V. This allows a design such that when charging the node ND 4 by the transistor PM 5 , the transistor NM 5 remains OFF, thereby preventing the transistor NM 5 from affecting the charging current.
[0043] When discharging the node ND 4 , the transistor NM 4 turns ON, and discharges the node ND 4 at a current set by the transistor NM 5 . By designing the relationship between the capacitors C 1 and C 2 such that the high level of the node ND 4 is a potential lower than the power supply potential Vdd, the transistor PM 5 may be designed so as to remain OFF when discharging the node ND 4 by the transistor NM 5 .
[0044] The transfer gate including the P-channel transistor PM 5 and the N-channel transistor NM 5 outputs a signal at the input terminal from the output terminal in accordance with the gate voltage of each of the P-channel transistor PM 5 and the N-channel transistor NM 5 . The inverter IV 1 takes a signal from the output terminal of the transfer gate PM 5 , NM 5 as input, and outputs the logically inverted signal of the inputted signal. The inverter including the transistors PM 6 and NM 6 takes a signal from the output terminal of the inverter IV 1 as input, and outputs the logically inverted signal of the inputted signal. The inverter including the transistors PM 4 and NM 4 takes the logically inverted signal of the output signal of the inverter IV 1 as input, and outputs the logically inverted signal of the inputted signal to the input terminal of the transfer gate PM 5 , NM 5 . The capacitor C 1 is connected between the output terminal of the transfer gate PM 5 , NM 5 and the output terminal of the inverter PM 6 , NM 6 . The capacitor C 2 is connected between the output terminal of the transfer gate PM 5 , NM 5 and the reference potential node. The inverter IV 4 is connected to a power supply potential wire Vdd different from a power supply potential wire VR 18 for the inverter PM 6 , NM 6 . The inverter IV 4 takes a signal at the output terminal of the inverter IV 1 as input, and outputs the logically inverted signal of the inputted signal to the input terminal of the inverter PM 4 , NM 4 . As described above, the circuit illustrated in FIG. 3 makes it possible to improve the accuracy of setting of charging/discharging current.
[0045] FIG. 5 is a diagram illustrating an example of the configuration of a micro-controller (oscillating apparatus) mounted with the CR oscillating circuit illustrated in FIG. 3 . A CR oscillating circuit OSC 1 has the CR oscillating circuit illustrated in FIG. 3 , and its details will be described later with reference to FIG. 8 . MCU 1 denotes a micro-controller (oscillating apparatus) mounted with the CR oscillating circuit OSC 1 , VDP 5 denotes a positive power supply potential (for example, 5 V), Vdd denotes a positive power supply potential (for example, 1.8 V) generated by a regulator REG 1 , and GND denotes a reference potential (ground potential: 0 V).
[0046] BGR 1 denotes a band gap circuit, REG 1 denotes a regulator including an error amplifier EAMP 1 , an output transistor PMO 1 , and voltage divider resistors RR 1 and RR 2 , LVDH 1 denotes a low voltage detection circuit for monitoring the power supply potential VDP 5 of 5 V, and LVDL 1 denotes a low voltage detection circuit for monitoring the power supply potential Vdd of 1.8 V. OSC 1 denotes a CR oscillating circuit (for example, the circuit illustrated in FIG. 3 ), LOGIC 1 denotes a logic circuit that operates at internal potential Vdd, EAMP 1 denotes an error amplifier of the regulator REG 1 , and PMO 1 denotes an output P-channel MOS transistor of the regulator REG 1 . RR 1 and RR 2 each denote a voltage divider resistor that divides the power supply potential Vdd, VDIV 1 denotes a voltage divided by the resistors RR 1 and RR 2 , RL 1 and RL 2 each denote a resistor that divides the power supply potential VDP 5 , and VDIV 2 denotes a voltage divided by the resistors RL 1 and RL 2 . LVDHOX 1 denotes the output voltage of the low voltage detection circuit LVDH 1 , RL 3 and RL 4 each denote a resistor that divides the power supply potential Vdd, VDIV 3 denotes a voltage divided by the resistors RL 3 and RL 4 , and LVDLOX 1 denotes the output voltage of the low voltage detection circuit LVDL 1 . VBGR denotes the output band gap voltage of the band gap circuit BGR 1 , CO 1 denotes a capacitor that stabilizes the power supply potential Vdd, CMP 1 and CMP 2 each denote a comparator circuit, CLK 1 denotes the output clock signal of the CR oscillating circuit OSC 1 , and VR 18 denotes the power supply potential of the CR oscillating circuit OSC 1 . The power supply potential Vdd of the CR oscillating circuit OSC 1 corresponds to the power supply potential Vdd illustrated in FIG. 3 . In FIG. 5 , elements having the same functions as those in the circuit illustrated in FIG. 3 , and the corresponding nodes are assigned the same symbols to indicate their correspondence.
[0047] In the micro-controller MCU 1 , the power supply potential VDP 5 supplied from the outside is maintained at, for example, 5 V, and the internal potentials Vdd and VR 18 determined by the withstand voltages of internal transistors are generated by the built-in regulator REG 1 . FIG. 5 illustrates an example in which the external power supply potential VDP 5 is 5 V, and the potentials Vdd and VR 18 generated by the built-in regulator REG 1 are 1.8 V.
[0048] In order to supply a constant potential Vdd of 1.8 V even when the power supply potential VDP 5 fluctuates, a reference voltage VBGR is generated by the band bap circuit BGR 1 . On the basis of the reference voltage VBGR, the regulator REG 1 generates the potentials Vdd and VR 18 of 1.8 V, and supplies the potentials to the internal circuits LVDL 1 , OSC 1 , and LOGIC 1 . The low voltage detection circuit LVDH 1 monitors the power supply potential VDP 5 , and when the power supply potential VDP 5 becomes lower than a predetermined potential, sets the output voltage LVDHOX 1 to low level. The low voltage detection circuit LVDL 1 monitors the power supply potential Vdd, and when the power supply potential Vdd becomes lower than a predetermined potential, sets the output voltage LVDLOX 1 to low level.
[0049] The logic circuit LOGIC 1 operates at the power supply potential Vdd, and is supplied with the clock signal CLK 1 from the CR oscillating circuit OSC 1 . The CR oscillating circuit OSC 1 determines a bias current on the basis of the output potential Vdd of the regulator REG 1 and, for example, the band gap voltage VBGR, and generates the clock signal CLK 1 .
[0050] It is desirable for the regulator REG 1 , the low voltage detection circuits LVDH 1 and LVDL 1 , and the CR oscillating circuit OSC 1 mounted to the micro-controller MCU 1 to use a band gap circuit or a circuit similar to a band gap circuit in order to generate a reference potential or reference current. In such a case, as illustrated in FIG. 5 , by employing a circuit configuration in which functions that may be made common is implemented as a common band gap circuit BGR 1 in advance, and lacking functions are added on the basis of this, overlapping functions need not be provided as separate circuits. This enables a reduction in effective circuit area.
[0051] Next, operation of each of the circuits illustrated in FIG. 5 will be briefly described. The description given below assumes that the band gap voltage VBGR is 1.2 V. The regulator REG 1 generates the power supply potential Vdd of 1.8 V from the voltage VBGR of 1.2 V. The error amplifier EAMP 1 and the transistor PMO 1 form a negative feedback circuit, and the power supply potential Vdd is determined so as to make the band gap voltage VBGR and the voltage VDIV 1 coincide with each other. For example, if the resistors RR 1 and RR 2 are designed so that the ratio between their resistances is 1:2, when the power supply potential Vdd is 1.8 V, the divided voltage VDIV 1 is 1.2 V, so the power supply potential Vdd may be set to 1.8 V on the basis of the band gap voltage VBGR. The capacitor CO 1 functions as a stabilizing capacitor for suppressing fluctuation of the power supply potential Vdd when the load current fluctuates abruptly.
[0052] The low voltage detection circuit LVDH 1 functions as a circuit for detecting a drop in the power supply potential VDP 5 when, for example, the power supply potential VDP 5 becomes lower than 2.4 V. By setting the ratio between the resistances of the resistors RL 1 and RL 2 to 1:1 in advance, when the power supply potential VDP 5 becomes lower than 2.4 V, the voltage VDIV 2 becomes lower than the band gap voltage VBGR. By detecting this by the comparator circuit CMP 1 , for example, the output voltage LVDHOX 1 may be set to low level. As described above, when the band gap circuit BGR 1 used by the regulator REG 1 , and the band gap circuit BGR 1 used by the low voltage detection circuit LVDH 1 are made common, this means that the circuits that need to be added to implement the low voltage detection circuit function are, for example, only the resistors RL 1 and RL 2 and the comparator circuit CMP 1 , thereby enabling a reduction in effective circuit area.
[0053] The low voltage detection circuit LVDL 1 functions as a circuit for detecting a drop in the power supply potential Vdd when, for example, the power supply potential Vdd becomes lower than 1.4 V. By setting the ratio between the resistances of the resistors RL 3 and RL 4 to 1:6 in advance, when the power supply potential Vdd becomes lower than 1.4 V, the voltage VDIV 3 becomes lower than the band gap voltage VBGR. By detecting this by the comparator circuit CMP 2 , for example, the output voltage LVDLOX 1 may be set to low level. When the band gap circuit BGR 1 used by the regulator REG 1 and the low voltage detection circuit LVDH 1 , and the band gap circuit BGR 1 used by the low voltage detection circuit LVDL 1 are made common, this means that the circuits that need to be added to implement the low voltage detection circuit function for the power supply potential Vdd are, for example, only the resistors RL 3 and RL 4 and the comparator circuit CMP 2 , thereby enabling a reduction in effective circuit area.
[0054] As in the case of the lower voltage detection circuits LVDH 1 and LVDL 1 , for the CR oscillating circuit OSC 1 as well, circuit function portions that are common to those of the regulator REG 1 or the like are shared, thereby enabling a reduction in effective area in the case when the CR oscillating circuit OSC 1 and the regulator REG 1 are mounted.
[0055] FIG. 5 illustrates a case in which the bias current for the CR oscillating circuit OSC 1 is generated on the basis of the band gap voltage VBGR. Details of the circuit will be described later with reference to other drawings.
[0056] FIG. 6 is a circuit diagram illustrating an example of the configuration of the band gap circuit BGR 1 illustrated in FIG. 5 . NMBn (n is an integer) denotes an N-channel MOS transistor, PMBn (n is an integer) denotes a P-channel MOS transistor, VDP 5 denotes a positive power supply potential (for example, 5 V), and GND denotes a reference potential (ground potential: 0 V). CB 1 denotes a capacitor, RB 1 , RB 2 , RB 3 , and RB 4 each denote a resistor, Q 1 and Q 2 each denote a PNP transistor, BPB denotes a bias potential, IBLVDH denotes a bias current supplied to the low voltage detection circuit LVDH 1 illustrated in FIG. 5 , IBLVDL denotes a bias current supplied to the low voltage detection circuit LVDL 1 illustrated in FIG. 5 , and IBOSC denotes a bias current supplied to the CR oscillating circuit OSC 1 illustrated in FIG. 5 . VBE 1 denotes the emitter potential of the transistor Q 1 , VBE 2 denotes the emitter potential of the transistor Q 2 , IP and IM each denote a node given for the purpose of explanation, and VGBR denotes an output band gap voltage. The emitter potential VBE 1 is used in circuits illustrated in FIGS. 8 , 10 , 14 , and 15 described later.
[0057] In FIG. 6 , nodes corresponding to those in the circuits illustrated in FIGS. 3 and 5 are assigned the same symbols to indicate their correspondence. It is supposed that the numbers indicating multiplication factors attached to the transistors Q 1 and Q 2 in FIG. 6 indicate the relationship between the relative sizes of the respective transistors Q 1 and Q 2 . In the following, likewise, it is supposed that the numbers indicating multiplication factors attached to PNP transistors indicate the relationship between the relative sizes of the respective transistors.
[0058] Since the power supply potential VDP 5 applied to the transistors PMB 1 to PMB 9 and the transistors NMB 1 to NMB 5 is 5 V, the withstand voltage of these transistors needs to be 5 V or more. Although these transistors are different from the transistors for the internal power supply potentials Vdd and VR 18 (1.8 V) used in the circuit illustrated in FIG. 3 in gate length and gate oxide film thickness, for the sake of brevity, and because the correspondence is apparent from the power supply potential, the circuit is expressed using the same transistor symbols as the transistor symbols used in the circuit illustrated in FIG. 3 . In the description that follows, unless otherwise specified, it is supposed that transistors corresponding to the power supply potential are used.
[0059] A circuit formed by the transistors PMB 1 , PMB 2 , NMB 1 , and NMB 2 , and the resistor RB 1 generates a bias current. Since the circuit in this portion is a general one, its detailed description is omitted. Also, for the simplicity of the drawing, elements such as a start-up circuit and a power-down element are not illustrated. By designing the transistors NMB 1 and NMB 2 to which the same gate voltage is applied in such a way that the size (gate width) of the transistor NMB 2 is large relative to that of the transistor NMB 1 , the bias current may be designed on the basis of the difference in gate voltage for flowing the same current, and the resistor RB 1 . The bias potential BPB is determined as a potential at which this bias current flows.
[0060] The transistors PMB 5 , PMB 6 , PMB 3 , NMB 3 , NMB 4 , NMB 5 , and PMB 4 function as an operational amplifier circuit for by performing feedback control so as to make the potential of the node IP and the potential of the node IM coincide with each other, thereby generating the bang gap voltage VBGR. The transistor PMB 3 functions as a current source for the operational amplifier circuit. The operational amplifier formed by the transistors PMB 5 , PMB 6 , PMB 3 , NMB 3 , NMB 4 , NMB 5 , and PMB 4 itself is configured as a general two-stage operational amplifier circuit. The capacitor CB 1 functions as a phase compensation capacitor for the operational amplifier.
[0061] When the potentials of the nodes IP and IM coincide with each other, equal potential differences are applied to the resistors RB 2 and RB 3 , so currents determined by the ratio between the resistors RB 2 and RB 3 flow through the transistors Q 1 and Q 2 . Since the ratio between the emitter sizes of the transistors Q 1 and Q 2 is designed to be, for example, 1:10, in accordance with the ratio between the resistors RB 2 and RB 3 , the current densities of the transistors Q 1 and Q 2 are determined. In accordance with the ratio between the current densities, the difference between the respective emitter potentials VBE 1 and VBE 2 of the transistors Q 1 and Q 2 is determined. The difference between the emitter potentials VBE 1 and VBE 2 is applied to the resistor RB 4 , and currents flowing through the transistors Q 1 and Q 2 are determined. The emitter potential VBE 1 exhibits a negative dependence on absolute temperature, and the currents flowing through the transistors Q 1 and Q 2 are positively proportional to absolute temperature. Herein below, CTAT denotes a negative dependence on absolute temperature, and PTAT denotes a positive dependence on absolute temperature.
[0062] By selecting the values of the resistors RB 2 and RB 3 in such a way that the band gap voltage VBGR is approximately 1.2 V, the band gap voltage VBGR becomes constant independent of temperature. The transistors PMB 7 , PMB 8 , and PMB 9 are provided so that simultaneously with generating the bias potential BPB by the bias circuit in order to determine the current of the current source for the band gap circuit BGR 1 , the bias potential BPB may be also used as the bias current for the low voltage detection circuits LVDH 1 and LVDL 1 , and the CR oscillating circuit OSC 1 . This eliminates the redundant need to provide a bias circuit formed by the transistors PMB 1 , PMB 2 , NMB 1 , and NMB 2 , and the resistor RB 1 in each of the low voltage detection circuits LVDH 1 and LVDL 1 , the CR oscillating circuit OSC 1 , and the like.
[0063] Also, as will be described later, when not only the band gap voltage VBGR but also the emitter potential VBE 1 of the transistor Q 1 is supplied to the CR oscillating circuit OSC 1 in advance, this is convenient in generating a reference current for the CR oscillating circuit OSC 1 .
[0064] The band gap circuit BGR 1 has the PNP transistor Q 1 whose base and collector are each connected to the reference potential node, the PNP transistor Q 2 whose base and collector are each connected to the reference potential node, and the resistor RB 4 whose one end is connected to the emitter of the PNP transistor Q 2 . The band gap circuit BGR 1 generates the band gap voltage VBGR by controlling the potential IM at the other end of the resistor RB 4 and the emitter potential VBE 1 of the PNP transistor Q 1 so as to be equal.
[0065] FIG. 7 is a block diagram illustrating an example of the configuration of the CR oscillating circuit OSC 1 illustrated in FIG. 5 . IREF 1 denotes a reference current generation circuit of the CR oscillating circuit OSC 1 , IDAC 1 denotes a trimming current digital/analog conversion (DAC) circuit for regulating oscillation frequency, OSCCORE 1 denotes the oscillating circuit main body of the CR oscillating circuit OSC 1 , TCA [3:0] denotes, for example, a 4-bit signal for regulating the temperature dependence of frequency, and TRD [7:0] denotes, for example, an 8-bit signal for regulating oscillation frequency. IBIAS and IBIASTRIM each denote a reference current generated by the reference current generation circuit IREF 1 , IBIASROSC denotes a bias current for the CR oscillating circuit main body OSCCORE 1 supplied from the trimming current DAC circuit IDAC 1 , and CLK 1 denotes the output clock signal of the CR oscillating circuit OSC 1 .
[0066] The reference current generation circuit IREF 1 generates the reference currents IBIAS and IBIASTRIM on the basis of the band gap voltage VBGR, the emitter potential VBE 1 , and the like illustrated in FIG. 6 . The trimming current DAC circuit IDAC 1 supplies the bias current IBIASROSC to the CR oscillating circuit main body OSCCORE 1 on the basis of the reference currents IBIAS and IBIASTRIM. The CR oscillating circuit main body OSCCORE 1 is configured like, for example, the CR oscillating circuit illustrated in FIG. 3 . In FIG. 7 , nodes corresponding to those in the circuits illustrated in FIGS. 3 and 5 are assigned the same symbols to indicate their correspondence.
[0067] The temperature-dependence regulation signal TCA [3:0] functions as a signal for regulating the temperature dependence of the reference currents IBIAS and IBIASTRIM. The frequency regulation signal TRD [7:0] functions as a signal for regulating the absolute value of the bias current IBIASROSC in order to regulate the absolute value of frequency.
[0068] FIG. 8 is a circuit diagram illustrating an example of the configuration of the reference current generation circuit IREF 1 illustrated in FIG. 7 . PMRn (n is an integer) denotes a P-channel MOS transistor, AMP 1 and AMP 2 each denote an amplifier circuit (operational amplifier), RR 1 denotes a resistor, RR 2 denotes a variable resistor, and Q 3 denotes a PNP transistor. BPTAT 1 denotes a PTAT current generation circuit, BCTAT 1 denotes a CTAT current generation circuit, VBGR generates a band gap voltage generated by the band gap circuit BGR 1 illustrated in FIG. 6 , and PGO is a bias voltage generated by the PTAT current generation circuit BPTAT 1 . IPTAT 1 denotes a current flowing through the transistor Q 3 , RVBE 3 denotes a node within the PTAT current generation circuit BPTAT 1 , VBE 1 denotes a potential VBE 1 generated by the band gap circuit BGR 1 illustrated in FIG. 6 , and PGO 2 denotes a bias voltage generated by the CTAT current generation circuit BCTAT 1 . ICTAT 1 denotes a current flowing through the variable resistor RR 2 , VFB denotes a node within the CTAT current generation circuit BCTAT 1 , IBIAS and IBIASTRIM respectively denote the currents IBIAS and IBIASTRIM illustrated in FIG. 7 , VR 18 denotes a positive power supply potential (for example, 1.8 V) generated by the regulator REG 1 illustrated in FIG. 5 , and GND denotes a reference potential (ground potential: 0 V).
[0069] In FIG. 8 , nodes or elements corresponding to those in the circuits illustrated in FIGS. 3 , 5 , and 6 are assigned the same symbols to indicate their correspondence. It is supposed that the number indicating a multiplication factor attached to the transistor Q 3 in FIG. 8 indicates the relationship between the relative sizes of the transistors Q 1 , Q 2 , and Q 3 .
[0070] Since the band gap circuit BGR 1 and the regulator REG 1 illustrated in FIG. 5 are each a circuit that generates the power supply potential Vdd of 1.8 V from the power supply potential VDP 5 of 5 V, its power supply potential may be the potential VDP 5 . On the other hand, since the CR oscillating circuit OSC 1 is a circuit for supplying the clock signal CLK 1 to the logic circuit LOGIC 1 that operates at the power supply potential Vdd, its power supply potential may be the potential Vdd. When the potential Vdd is taken as the power supply potential, since the potential Vdd is a potential generated by the regulator REG 1 , there is an advantage in that the range of fluctuation of the power supply potential Vdd is small. In portions where current is constant, it is advantageous from the viewpoint of noise to perform wiring in such a way as to minimize the influence of the power supply potential of the logic circuit LOGIC 1 . Thus, in FIG. 8 , the potential VR 18 is used as the power supply potential in the sense that the power supply potential may be wired separately from the potential Vdd.
[0071] As is apparent from the configuration illustrated in FIG. 3 , the signal amplitude of the CR oscillating circuit main body OSCCORE 1 illustrated in FIGS. 3 and 7 is kept substantially constant independent of temperature by the regulator REG 1 ( FIG. 5 ). To keep oscillation frequency constant, it is necessary to keep the charging/discharging current for the capacitance of the CR oscillating circuit main body OSCCORE 1 constant irrespective of temperature and the power supply potential VDP 5 . For this purpose, a constant current that is independent of temperature is generated by the circuit illustrated in FIG. 8 .
[0072] The principle for generating a constant current that is independent of temperature is substantially the same as that for the band gap circuit BGR 1 . The current IPTAT 1 that is positively proportional to absolute temperature and the current ICTAT 1 that has a negative dependence on absolute temperature are summed to generate each of the currents IBIAS and IBIASTRIM that are substantially independent of temperature.
[0073] The PTAT current generation circuit BPTAT 1 generates the current IPTAT 1 that is positively proportional to absolute temperature, and the CTAT current generation circuit BCTAT 1 generates the current ICTAT 1 that has a negative dependence on absolute temperature. A current that is positively proportional to absolute temperature flows through each of transistors PMR 2 and PMR 3 whose gate voltage PGO is the same as that of a transistor PMR 1 . A current that has a negative dependence on absolute temperature flows through each of transistors PMR 5 and PMR 6 whose gate voltage PGO 2 is the same as that of a transistor PMR 4 . Since the currents IBIAS and IBIASTRIM are each the sum of the current in the transistor PMR 2 , PMR 3 and the current in the transistor PMR 5 , PMR 6 , the reference currents IBIAS and IBIASTRIM become independent of temperature.
[0074] Next, the principle for generating the current PTAT 1 that is positively proportional to absolute temperature by the PTAT current generation circuit BPTAT 1 will be described. A forward voltage VBE 3 on the PNP transistor Q 3 exhibits a substantially negative proportionality to absolute temperature. For example, the forward voltage VBE 3 may be approximated by such a straight line that the voltage exhibits a value of about 1.2 V at absolute zero, and about 600 mV in the vicinity of room temperature. The band gap voltage VBGR generated by the band gap circuit BGR 1 illustrated in FIG. 6 becomes a constant value at about 1.2 V independent of temperature. By performing feedback control by the amplifier circuit AMP 1 so that the band gap voltage VBGR and the voltage of the node RVBE 3 coincide with each other, the voltage of the node RVBE 3 becomes the same as the band gap voltage VBGR, and is constant at about 1.2 V independent of temperature. Incidentally, since the voltage VBE 3 exhibits a substantially negative proportionality to absolute temperature, the voltage applied to the resistor RR 1 is positively proportional to absolute temperature. Since the voltage applied to the resistor RR 1 is proportional to absolute temperature, the current IPTAT 1 flowing through the resistor RR 1 becomes proportional to absolute temperature. Since the current flowing through the transistor PMR 1 is the current IPTAT 1 , like the current IPTAT 1 , the current flowing through each of the transistors PMR 1 , PMR 2 , and PMR 3 whose gate voltage is the voltage PGO is also proportional to absolute temperature.
[0075] On the other hand, like the voltage VBE 3 , the potential VBE 1 supplied from the band gap circuit BGR 1 illustrated in FIG. 6 exhibits a substantially negative proportionality to absolute temperature. By performing feedback control by the amplifier circuit AMP 2 so that the potential VBE 1 and the potential of the node VFB coincide with each other, the potential of the node VFB becomes the same as the potential VBE 1 , and exhibits a substantially negative proportionality to absolute temperature. The potential applied to the variable resistor RR 2 exhibits a substantially negative proportionality to absolute temperature. Since the voltage applied to the variable resistor RR 2 exhibits a negative proportionality to absolute temperature, the current ICTAT 1 flowing through the variable resistor RR 2 becomes negatively proportional to absolute temperature. Since the current flowing through the transistor PMR 4 is the current ICTAT 1 , like the current ICTAT 1 , the current flowing through each of the transistors PMR 4 , PMR 5 , and PMR 6 whose gate voltage is the voltage PGO 2 is also negatively proportional to absolute temperature. The resistor RR 2 is formed as a variable transistor in order to make the value of the current ICTAT 1 variable. The circuit of this portion will be described later in further detail.
[0076] The reference currents IBIAS and IBIASTRIM may be made independent of temperature by summing the currents flowing through the transistors PMR 2 and PMR 5 , and the currents flowing through the transistors PMR 3 and PMR 6 , respectively, at an appropriate ratio. By generating the reference currents IBIAS and IBIASTRIM that are independent of temperature in the circuit illustrated in FIG. 8 , the number of PNP transistors may be advantageously reduced.
[0077] For example, in the band gap circuit BGR 1 illustrated in FIG. 6 , by using the transistors Q 1 and Q 2 of different sizes, these transistors are biased at different current densities, and the difference between their forward voltages is used in order to generate a PTAT current. For this reason, a PNP transistor with a size equivalent to 11 times the size of the transistor Q 1 is used. On the other hand, in the circuit illustrated in FIG. 8 , by keeping the potential of the resistor RR 1 connected in series with the transistor Q 3 constant irrespective of temperature, the PTAT current IPTAT 1 is generated by a single transistor Q 3 (a single PNP transistor) whose size is 1 time as large. That is, the use of the band gap voltage VBGR significantly reduces the area of PNP transistor necessary for generating the PTAT current IPTAT 1 .
[0078] The reference current generation circuit IREF 1 has a positive dependence (PTAT) current generation circuit BPTAT 1 that generates the positive dependence current IPTAT 1 having a positive dependence on absolute temperature, and a negative dependence (CTAT) current generation circuit BCTAT 1 that generates the negative dependence current ICTAT 1 having a negative dependence on absolute temperature. The reference current generation circuit IREF 1 generates each of the reference current IBIAS and IBIASTRIM by summing the positive dependence current IPTAT 1 and the negative dependence current ICTAT 1 . A voltage corresponding to each of the reference currents IBIAS and IBIASTRIM is applied to each of the gates of the P-channel transistor PM 5 and the N-channel transistor NM 5 .
[0079] The positive dependence current generation circuit BPTAT 1 has the PNP transistor Q 3 whose collector and base are each connected to the reference potential node, and the resistor RR 1 whose one end is connected to the emitter of the PNP transistor Q 3 , and a first control circuit that controls the positive dependence current IPTAT 1 flowing through the resistor RR 1 in such a way that the potential of the node RVBE 3 at the other end of the resistor RR 1 and a first potential (band gap voltage) VBGR become equal to each other. The first control circuit has the amplifier circuit AMP 1 and the transistor PMR 1 . The amplifier circuit AMP 1 takes the band gap voltage VBGR of the band gap circuit BGR 1 illustrated in FIG. 6 as input.
[0080] The negative dependence current generation circuit BCTAT 1 has the resistor RR 2 whose one end is connected to the reference potential node, and a second control circuit that controls the negative dependence current ICTAT 1 flowing through the resistor RR 2 in such a way that the potential of the node VFB at the other end of the resistor RR 2 and a second potential VBE 1 become equal to each other. The second control circuit has the amplifier circuit AMP 2 and the transistor PMR 4 . The amplifier circuit AMP 2 takes the emitter potential VBE 1 of the PNP transistor Q 1 of the band gap circuit BGR 1 illustrated in FIG. 6 as input.
[0081] As described above, by using the reference current generation circuit IREF 1 illustrated in FIG. 8 , the element area may be advantageously reduced.
[0082] FIG. 9 is a circuit diagram illustrating an example of the configuration of the variable resistor RR 2 illustrated in FIG. 8 . NMVn (n is an integer) denotes an N-channel MOS transistor, RVn (n is an integer) denotes a resistor, VFB denotes the node VFB illustrated in FIG. 8 , and GND denotes a reference potential (ground potential: 0 V).
[0083] In FIG. 9 , nodes or elements corresponding to those in the circuit illustrated in FIG. 8 are assigned the same symbols to indicate their correspondence. The numbers from 0000 to 1110 attached to the respective gates of transistors NMV 1 to NMV 15 indicate an example of combination of the values of a 4-bit regulation signal TCA [3.0] with which the corresponding gates become high level, in the case when the variable resistor RP 2 in FIG. 9 is controlled by the 4-bit regulation signal TCA [3:0] ( FIG. 7 ). By means of the 4-bit regulation signal TCA [3:0], it is possible to select 16 different temperature dependences of reference current. To regulate the temperature dependence of reference current, the value of the current ICTAT 1 is changed. To change the value of the current ICTAT 1 , the resistance of the variable resistor RR 2 is changed. In the circuit illustrated in FIG. 9 , the value of the variable resistor RR 2 may be changed in accordance with the temperature dependence regulation signal TCA [3:0].
[0084] When the regulation signal TCA [3:0] is 0000, the transistor NMV 1 turns ON, and the resistance (the value of the resistor RR 2 ) between the node VFB and the node of the reference potential GND becomes the value of a resistor RV 1 . When the regulation signal TCA [3:0] is 1111, the transistors NMV 1 to NMV 15 all turn OFF, and the value of the variable resistor RR 2 becomes the sum of the values of resistors RV 1 to RV 16 . When the regulation signal TCA [3:0] is 0011, the transistors NMV 1 to NMV 3 turn OFF, and the transistor NMV 4 turns OFF. The value of the variable resistor RR 2 becomes the sum of the resistors RV 1 to RV 4 .
[0085] In this way, the circuit illustrated in FIG. 9 may be used as the variable resistor RR 2 illustrated in FIG. 8 . By making the resistance of the variable resistor RR 2 variable, it is possible to change the temperature dependence of the reference currents IBIAS and IBIASTRIM by, for example, the regulation signal TCA [3:0] illustrated in FIG. 7 . Since the reference currents IBIAS and IBIASTRIM are each generated by the sum of the currents IPTAT 1 and ICTAT 1 , by changing the value of the variable resistor RR 2 , the temperature dependence of the reference currents IBIAS and IBIASTRIM may be changed.
[0086] The reference current generation circuit IREF 1 generates each of the reference currents IBIAS and IBIASTRIM by summing the positive dependence current IPTAT 1 and the negative dependence current ICTAT 1 while changing their summation ratio in accordance with the temperature dependence regulation signal TCA [3:0]. The resistor RR 2 is a variable resistor whose resistance varies in accordance with the temperature dependence regulation signal TCA [3:0].
[0087] An error is present in the actual output potential VBGR of the reference voltage generation circuit generated in FIG. 6 . This error also causes the temperature dependence of the band gap voltage VBGR to become slightly positive or negative depending on each individual circuit manufactured. For this reason, the values of the potentials Vdd and VR 18 generated by the regulator REG 1 illustrated in FIG. 5 also become slightly positive or negative depending on each individual circuit manufactured.
[0088] For this reason, even if the reference currents IBIAS and IBIASTRIM generated by the circuit illustrated in FIG. 8 are perfectly ideal, the temperature dependence of oscillation frequency differs slightly for each individual circuit. Further, the temperature dependence of the reference currents IBIAS and IBIASTRIM generated by the circuit illustrated in FIG. 8 itself also differs for each individual circuit. For this reason, to attain a desirable temperature dependence of oscillation frequency, it is necessary to regulate the temperature dependence for each individual circuit. By configuring the variable resistor RR 2 of the reference current generation circuit in FIG. 8 as illustrated in FIG. 9 , the temperature dependence of the reference currents IBIAS and IBIASTRIM in FIG. 8 may be made electrically variable.
[0089] Thus, it is possible to regulate the temperature dependence of oscillation frequency for each individual circuit, thereby enabling setting of frequency with higher accuracy.
[0090] FIG. 10 is a circuit diagram illustrating an example of the configuration of each of the amplifier circuits AMP 1 and AMP 2 illustrated in FIG. 8 and of the circuit in its vicinity. PMRn (n is an integer) denotes a P-channel MOS transistor, NMRn (n is an integer) denotes an N-channel MOS transistor, RR 1 and RR 3 each denote a resistor, RR 2 denotes a variable resistor, and Q 3 denotes a PNP transistor. VBGR denotes a bang gap voltage generated by the band gap circuit BGR 1 illustrated in FIG. 6 , PGO denotes a generated bias voltage, RVBE 3 denotes an internal node, and VBE 1 denotes a potential VBE 1 generated by the band gap circuit BGR 1 illustrated in FIG. 6 . PGO 2 denotes a generated bias voltage, VFB denotes an internal node, VR 18 denotes a positive power supply voltage (for example, 1.8 V) generated by the regulator REG 1 illustrated in FIG. 5 , and GND denotes a reference potential (ground potential: 0 V). IBOSC denotes a bias current IBOSC supplied from the band gap circuit BGR 1 illustrated in FIG. 6 , OPB, ONCB, and ONB each denote a bias potential generated from the current IBOSC, and CR 1 denotes a capacitor.
[0091] In FIG. 10 , nodes or elements corresponding to those in the circuits illustrated in FIGS. 3 , 5 , 6 , 8 , and the like are assigned the same symbols to indicate their correspondence. It is supposed that the number indicating a multiplication factor attached to the transistor Q 3 in FIG. 10 indicates the relationship between the relative sizes of the transistors Q 1 , Q 2 , and Q 3 . It is supposed that FIG. 10 represents an example of the transistor-level circuit of each of the amplifier circuits AMP 1 and AMP 2 illustrated in FIG. 8 , although a part of the circuit such as the transistors PMR 2 , PMR 3 , and the like illustrated in FIG. 8 is omitted.
[0092] Transistors PMR 7 , PMR 8 , NMR 2 , NMR 3 , and NMR 4 illustrated in FIG. 10 function as the amplifier circuit AMP 1 illustrated in FIG. 8 . Since this is a general differential circuit, description of the operation of this portion is omitted. The differential circuit according to this example is such that since the band gap voltage VBGR is 1.2 V, and the power supply potential VR 18 is 1.8 V, the N-channel MOS transistors NMR 2 and NMR 3 are input transistors. In this regard, it is possible to modify the differential circuit so that P-channel MOS transistors are input transistors if the reference potential VBGR is closer to the reference potential GND.
[0093] In order for the transistors PMR 7 , PMR 8 , NMR 2 , NMR 3 , and NMR 4 to operate, the gate voltage of the transistor NMR 4 may be so biased that a predetermined current flows. For this purpose, the bias current IBOSC is received from the band gap circuit BGR 1 illustrated in FIG. 6 , and converted by the transistor NMR 1 into a gate voltage for the transistor NMR 4 .
[0094] This configuration eliminates the need to provide an independent bias circuit on the amplifier circuit AMP 1 side, thereby making it advantageously possible to save circuit area.
[0095] Transistors PMR 11 to PMR 15 and transistors NMR 8 to NMR 11 illustrated in FIG. 10 function as the amplifier circuit AMP 2 illustrated in FIG. 8 . The capacitor CR 1 functions as a phase compensation capacitor. Since the amplifier circuits AMP 1 and AMP 2 are both used as feedback circuits, phase compensation is performed. Since the amplifier circuit AMP 2 illustrated in FIG. 10 is a general folded cascode circuit, description of the operation of this portion is omitted. A folded cascode circuit in which the P-channel MOS transistors PMR 12 and PMR 13 are input transistors is used because the potential VBE 1 is close to the reference potential GND.
[0096] Like the amplifier circuit AMP 1 illustrated in FIG. 10 , the amplifier circuit AMP 2 illustrated in FIG. 10 also needs to be supplied with a bias potential. For example, as illustrated in FIG. 10 , it is possible to generate the potentials OPB, ONB, and ONCB on the basis of the current IBOSC, and by supplying the bias current IBOSC from the circuit illustrated in FIG. 6 , circuit area may be reduced. The current IBOSC in FIG. 6 is provided for this purpose, and it is needless to mention that the currents IBLVDH and IBLVDL in FIG. 6 may be also used in the same manner.
[0097] Since the configuration of the portion of the circuit for generating the potentials OPB, ONB, and ONCB from the current IBOSC is also a general one, description of the operation of this portion is also omitted.
[0098] As described above, the amplifier circuits AMP 1 and AMP 2 may be implemented by the circuits as illustrated in FIG. 10 , for example, and by supplying the bias current IBOSC from the circuit illustrated in FIG. 6 , the number of elements for generating the bias current may be reduced.
[0099] FIG. 11 is a circuit diagram illustrating an example of the configuration of the trimming current DAC circuit IDAC 1 illustrated in FIG. 7 . NMDPn (n is an integer), NMDASn (n is an integer), NMDAn (n is an integer), NMDA, NMDB, and NMDB 1 each denote an N-channel MOS transistor. IBIASTRIM denotes the current IBIASTRIM illustrated in FIG. 8 , IBIAS denotes the current IBIAS illustrated in FIG. 8 , PD 18 denotes a power-down signal, and IBIASROSC denotes the bias current IBIASROSC illustrated in FIG. 3 . GND denotes a reference potential (ground potential: 0 V), IBIASTRIMLSB denotes a current corresponding to 1 LSB (least significant bit) of the current DAC circuit IDAC 1 , and IBIASOFFSET denotes a current for an offset serving as the minimum current of the output current IBIASROSC. In FIG. 11 , nodes or elements corresponding to those in the circuits illustrated in FIGS. 3 , 5 , 7 , 8 , and the like are assigned the same symbols to indicate their correspondence.
[0100] The circuit illustrated in FIG. 11 functions as a current DAC circuit for controlling the absolute value of the bias current IBIASROSC by the 8-bit signal TRD [7:0] as illustrated in FIG. 7 . N-channel MOS transistors NMDAS 1 to NMDAS 256 indicate that, for example, 256 N-channel MOS transistors of the same size are provided. Likewise, N-channel MOS transistors NMDA 1 to NMDA 256 also indicate that 256 N-channel MOS transistors of the same size are provided.
[0101] The node of the current IBIASTRIM is connected to the node of the current IBIASTRIM illustrated in FIG. 8 , and converts the bias current IBIASTRIM into a gate voltage by the transistor NMDA. This gate voltage is supplied to the transistors NMDA 1 to NMDA 256 , so the same current may be made to flow through the transistors NMDA 1 to NMDA 256 . The current IBIASTRIMLSB illustrated in FIG. 11 denotes a current that flows per one transistor NMDAn (n is 1 to 256). By appropriately designing the sizes of the transistor NMDA and transistors NMDA 1 to NMDA 256 , the current IBIASTRIMLSB of a value may be obtained on the basis of the current IBIASTRIM. For example, the transistor NMDA and the transistors NMDA 1 to NMDA 256 are all in the same size, and the current IBIASTRIMLSB of 1 μA may be made to flow through each of the transistors.
[0102] The transistors NMDA 1 to NMDA 256 and the transistors NMDAS 1 to NMDAS 256 are respectively connected in series. By controlling the number of gates to be set to high level among the respective gates of the 256 transistors NMDAS 1 to NMDAS 256 , the value of the bias current IBIASROSC supplied to the CR oscillating circuit main body OSCCORE 1 illustrated in each of FIG. 3 and FIG. 7 may be controlled. Each of the numbers 1 to 256 attached to the respective gates of the transistors NMDAS 1 to NMDAS 256 means a control signal for the corresponding gate. Since 256 different bias currents IBIASROSC may be controlled by the 8-bit digital signal TRD [7:0] as illustrated in FIG. 7 , for example, the value of the bias current IBIASROSC may be regulated by the current DAC circuit illustrated in FIG. 11 .
[0103] The minimum value of the bias current IBIASROSC is, for example, one IBIASTRIMLSB+IBIASOFFSET in FIG. 11 . This current may be designed so as to be the minimum current for frequency regulation of the CR oscillating circuit main body OSCCORE 1 illustrated in FIG. 7 . The current IBIASOFFSET may be designed to an arbitrary value by appropriately designing the size ratio between the transistors NMDB and NMDB 1 on the basis of the current IBIAS in advance. Also, by setting the gate voltage PD 18 of each of transistors NMDP 1 and NMDP 2 to high level, the gate voltage of each N-channel MOS transistor becomes 0, thus achieving a power-down state.
[0104] The current digital/analog conversion (DAC) circuit IDAC 1 converts a digital signal TRD [7:0] into an analog bias current IBIASROSC by using the reference current IBIASTRIM. A voltage corresponding to the bias current IBIASROSC is applied to each of the gates of the P-channel transistor PM 5 and N-channel transistor NM 5 illustrated in FIG. 3 .
[0105] As described above, a mechanism that makes the bias current IBIASROSC for frequency regulation variable may be implemented by the circuit as illustrated in FIG. 11 , on the basis of the current IBIASTRIM generated by the reference current generation circuit IREF 1 illustrated in FIG. 8 .
[0106] FIG. 12 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit IREF 1 illustrated in FIG. 7 . PMRBn (n is an integer) denotes a P-channel MOS transistor, AMP 3 and AMP 4 each denote an amplifier circuit (operational amplifier), RR 4 denotes a resistor, RR 5 denotes a variable resistor, and Q 4 and Q 5 each denote a PNP transistor. BPTAT 2 denotes a PTAT current generation circuit, BCTAT 2 denotes a CTAT current generation circuit, PGO 3 denotes a bias potential generated by the PTAT current generation circuit BPTAT 2 , and IPTAT 2 denotes a current flowing through the transistor Q 5 . RVBE 5 and VBE 4 each denote a node within the PTAT current generation circuit BPTAT 2 , PGO 4 denotes a bias potential generated by the CTAT current generation circuit BCTAT 2 , and ICTAT 2 denotes a current flowing through the variable resistor RR 5 . VFB denotes a node within the CTAT current generation circuit BCTAT 2 , IBIAS and IBIASTRIM respectively denote the currents IBIAS and IBIASTRIM illustrated in FIG. 7 , VR 18 denotes a positive power supply voltage (for example, 1.8 V) generated by the regulator REG 1 illustrated in FIG. 5 , and GND denotes a reference potential (ground potential: 0 V). In FIG. 12 , nodes or elements corresponding to those in FIG. 8 and the like are assigned the same symbols to indicate their correspondence, and thus repetitive description is omitted.
[0107] Herein below, the difference between the circuit illustrated in FIG. 12 and the circuit illustrated in FIG. 8 will be described. In FIG. 12 as well, the PTAT current IPTAT 2 is generated by the PTAT current generation circuit BPTAT 2 , and the CTAT current ICTAT 2 is generated by the CTAT current generation circuit BCTAT 2 . These currents IPTAT 2 and ICTAT 2 are summed to generate each of the currents IBIAS and IBIASTRIM. The circuit illustrated in FIG. 12 is also the same as the circuit illustrated in FIG. 8 in that by changing the resistance of the variable resistor RR 5 , the value of the CTAT current ICTAT 2 may be changed, thereby making it possible to regulate the temperature dependence of reference current.
[0108] In the circuit illustrated in FIG. 8 , the band gap voltage VBGR and the potential VBE 1 are supplied from the band gap circuit BGR 1 illustrated in FIG. 6 , and the PTAT current IPTAT 1 and the CTAT current ICTAT 1 are generated on the basis of these. By using the potentials VGBR and VBE 1 from the band gap circuit BGR 1 , the number of elements for generating a reference current is reduced.
[0109] On the other hand, in FIG. 12 , the PTAT current IPTAT 2 and the CTAT current ICTAT 2 are generated only within the reference current generation circuit IREF 1 on the basis of the transistors Q 4 and Q 5 . Although the number of elements increases, the configuration as illustrated in FIG. 12 is also possible. When arranging these circuits in a location far from the band gap circuit BGR 1 of the regulator REG 1 , it is also possible to adopt the reference current generation circuit IREF 1 as illustrated in FIG. 12 .
[0110] The circuit illustrated in FIG. 12 is the same as the band gap circuit BGR 1 illustrated in FIG. 6 in that the PTAT current IPTAT 2 that is proportional to absolute temperature may be generated by controlling the potential of the node RVBE 5 and the potential of the node VBE 4 so as to coincide with each other, and appropriately designing the ratio between the current densities of the transistors Q 4 and Q 5 . The circuit illustrated in FIG. 12 is also the same as the circuit illustrated in FIG. 8 in that the CTAT current ICTAT 2 may be generated by generating current on the basis of the voltage of the node VBE 4 which is the forward voltage of the PNP transistor Q 4 .
[0111] When the circuit illustrated in FIG. 12 is adopted, although the advantage of area reduction as in the case of the circuit illustrated in FIG. 8 is not obtained, the advantages described with reference to FIG. 7 , such as enabling regulation of the temperature dependence of reference current, and enabling regulation of oscillation frequency, may be obtained.
[0112] FIG. 13 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit IREF 1 illustrated in FIG. 7 . Since the only difference between the circuit illustrated in FIG. 13 and the circuit illustrated in FIG. 8 is the negative input of the amplifier circuit AMP 2 , only the difference in this respect will be described. The names of circuit elements, the names of nodes, and the like are also completely the same as those in FIG. 8 , and thus repetitive description is omitted.
[0113] In the circuit illustrated in FIG. 8 , the negative input of the amplifier circuit AMP 2 is the voltage VBE 1 of the band gap circuit BGR 1 ( FIG. 6 ). On the other hand, in the circuit illustrated in FIG. 13 , the negative input of the amplifier circuit AMP 2 is the voltage VBE 3 of the PTAT current generation circuit BPTAT 1 . Since the PTAT current IPTAT 1 flows through the transistor Q 3 in FIG. 13 as well, the voltage VBE 3 in FIG. 13 becomes substantially the same node voltage as the voltage VBE 1 in FIG. 6 , and its temperature characteristics also exhibit a negative proportionality to absolute temperature. Therefore, the connections as illustrated in FIG. 13 also make it possible to generate the reference currents IBIAS and IBIASTRIM in the same manner as in the circuit illustrated in FIG. 8 .
[0114] When the connections as illustrated in FIG. 13 are adopted, only the band gap voltage VBGR and the current IBOSC suffice as the potential and bias current to be supplied to the reference current generation circuit IREF 1 ( FIG. 13 ) from the band gap circuit BGR 1 illustrated in FIG. 6 , thereby advantageously reducing the number of signal lines.
[0115] On the other hand, in the configuration illustrated in FIG. 8 , the reference potential (the negative input of the amplifier circuit AMP 2 ) VBE 1 of the CTAT current generation circuit BCTAT 1 is the potential VBE 1 that is already stable, which provides an advantage in that the stabilization time for the reference current when starting the CR oscillating circuit may be shortened. In the circuit illustrated in FIG. 13 , after the potential VBE 3 of the PTAT current generation circuit BPTAT 1 stabilizes, the potential of the node VFB stabilizes on the basis of this, so the time until the reference current stabilizes is longer than that in the case of the circuit illustrated in FIG. 8 .
[0116] The amplifier circuit AMP 1 takes the band gap voltage VBGR of the band gap circuit BGR 1 illustrated in FIG. 6 as input, and controls the positive dependence current IPTAT 1 flowing through the resistor RR 1 in such a way that the band gap voltage VBGR and the potential of the node RVBE 3 at the other end of the resistor RR 1 become equal to each other. The amplifier circuit AMP 2 controls the negative dependence current ICTAT 1 flowing through the resistor RR 2 in such a way that the emitter potential VBE 3 of the PNP transistor Q 3 and the potential of the node VFB at the other end of the resistor RR 2 become equal to each other.
[0117] FIG. 14 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit IREF 1 illustrated in FIG. 7 . PMRCn (n is an integer) denotes a P-channel MOS transistor, AMP 5 and AMP 6 each denote an amplifier circuit (operational amplifier), RR 4 denotes a resistor, RR 7 denotes a variable resistor, and Q 5 denotes a PNP transistor. BPTAT 3 denotes a PTAT current generation circuit, BCTAT 3 denotes a CTAT current generation circuit, PGO 5 denotes a bias potential generated by the PTAT current generation circuit BPTAT 3 , and IPTAT 3 denotes a current flowing through the transistor Q 5 . RVBE 5 denotes a node within the PTAT current generation circuit BPTAT 3 , PGO 6 denotes a bias potential generated by the CTAT current generation circuit BCTAT 3 , and ICTAT 3 denotes a current flowing through the variable resistor RR 7 . VFB denotes a node within the CTAT current generation circuit BCTAT 3 , IBIAS and IBIASTRIM respectively denote the currents IBIAS and IBIASTRIM in FIG. 7 , VR 18 denotes a positive power supply potential (for example, 1.8 V) generated by a regulator REG 1 , GND denotes a reference potential (ground potential: 0 V), and VBE 1 denotes the potential VBE 1 generated in FIG. 6 . In FIG. 14 , nodes or elements corresponding to those in other drawings such as FIG. 8 are assigned the same symbol to indicate their correspondence, and thus repetitive description is omitted.
[0118] In FIG. 8 , the current IPTAT 1 that is proportional to absolute temperature is generated on the basis of the band gap voltage VBGR. On the other hand, in the circuit illustrated in FIG. 14 , the PTAT current IPTAT 3 is generated on the basis of the potential VBE 1 of the band gap circuit BGR 1 .
[0119] In FIG. 12 , the PTAT current IPTAT 2 may be generated by controlling the potentials of the nodes RVBE 5 and VBE 4 so as to coincide with each other. Since the potential of the node VBE 4 in FIG. 12 and the potential VBE 1 in FIG. 6 are substantially equal, a PTAT current may be generated also by substituting the potential of the node VBE 4 by the potential VBE 1 . In FIG. 14 , the PTAT current IPTAT 3 is generated by controlling the potential of the node RVBE 5 and the potential VBE 1 so as to coincide with each other by the amplifier circuit AMP 5 . Adopting the configuration as illustrated in FIG. 14 makes it possible to reduce the number of elements in comparison to the circuit illustrated in FIG. 12 .
[0120] The amplifier circuit AMP 5 takes the emitter potential VBE 1 of the PNP transistor Q 1 of the band gap circuit BGR 1 illustrated in FIG. 6 as input, and controls the positive dependence current IPTAT 3 flowing through the resistor RR 4 in such a way that the emitter potential VBE 1 and the potential of the node RVBE 5 at the other end of the resistor RR 4 become equal to each other. The amplifier circuit AMP 6 takes the emitter potential VBE 1 of the PNP transistor Q 1 of the band gap circuit BGR 1 illustrated in FIG. 6 as input, and controls the negative dependence current ICTAT 3 flowing through the resistor RR 7 in such a way that the emitter potential VBE 1 and the potential of the node VFB at the other end of the resistor RR 7 become equal to each other.
[0121] FIG. 15 is a circuit diagram illustrating another example of the configuration of the reference current generation circuit IREF 1 illustrated in FIG. 7 . PMRDn (n is an integer) denotes a P-channel MOS transistor, AMP 7 and AMP 8 each denote an amplifier circuit (operational amplifier), RR 1 denotes a resistor, RR 2 denotes a variable resistor, and Q 3 denotes a PNP transistor. BPTAT 4 denotes a PTAT current generation circuit, BCTAT 4 denotes a CTAT current generation circuit, PGO 7 denotes a bias potential generated by the PTAT current generation circuit BPTAT 4 , and IPTAT 4 denotes a current flowing through the transistor Q 3 . RVBE 3 denotes a node within the PTAT current generation circuit BPTAT 4 , PGO 8 denotes a bias potential generated by the CTAT current generation circuit BCTAT 4 , ICTAT 4 denotes a current flowing through the variable resistor RR 2 , and VFB denotes a node within the CTAT current generation circuit BCTAT 4 . IBIAS and IBIASTRIM respectively denote the currents IBIAS and IBIASTRIM illustrated in FIG. 7 , VDP 5 denotes a positive power supply voltage (for example, 5 V), GND denotes a reference potential (ground potential: 0 V), VBE 1 and VBGR respectively denote the potentials VBE 1 and VBGR generated in FIG. 6 , and OPCB denotes a bias potential for a cascode circuit. In FIG. 15 , nodes or elements corresponding to those in other drawings such as FIG. 8 are assigned the same symbol to indicate their correspondence, and thus repetitive description is omitted.
[0122] The configuration illustrated in FIG. 15 is such that the power supply potential VR 18 in the circuit illustrated in FIG. 8 is substituted by the power supply potential VDP 5 , and the current source is a cascode circuit. Since the basic operation principle is the same as that of the circuit illustrated in FIG. 8 , detailed description of operation is omitted.
[0123] In the circuit illustrated in FIG. 8 , the PTAT current IPTAT 1 is generated on the basis of the band gap voltage VBGR, and the positive-side power supply potential of its current source is the potential VR 18 . The circuit may be operated also when this power supply potential VR 18 is changed to the power supply potential VDP 5 , and FIG. 15 illustrates such an example. The current source is a cascode circuit because there are cases when the drain voltages of current sources PMRD 3 , PMRD 4 , and the like are large and also the power supply potential VDP 5 fluctuates greatly. The bias potential OPCB serves as a bias potential for this purpose. The bias potential OPCB may be generated by the method as illustrated in FIG. 10 . It is possible to adopt the configuration as illustrated in FIG. 15 in cases where the absolute value of the power supply potential VR 18 or power supply potential Vdd is small, and it is more desirable to generate a reference current by using the power supply potential VDP 5 . While FIG. 15 illustrates an example in which the power supply potential in the circuit illustrated in FIG. 8 is substituted by the potential VDP 5 , it is needless to mention that in the case of other circuit examples as well, if it is necessary to substitute the power supply potential VR 18 by the power supply potential VDP 5 , the current source may be configured as a cascode circuit.
[0124] As described above, as illustrated in FIG. 3 , the CR oscillating circuit according to this embodiment employs the inverter PM 4 , NM 4 in FIG. 3 and the CMOS transfer gate (transistor) PM 5 , NM 5 connected in series to its output, as means for controlling the charging/discharging current for a load to be constant. The capacitor C 2 is provided to ensure a design such that the signal amplitude of the node ND 4 to be charged/discharged at constant current is smaller than the power supply potential Vdd. Also, as illustrated in FIG. 7 , in the CR oscillating circuit, the signal TCA [3:0] is provided to regulate the temperature dependence of the reference current of the oscillating circuit from positive to negative. Also, as illustrated in FIG. 5 , in the micro-controller MCU 1 , the band gap circuit BGR 1 , and the error amplifier EAMP 1 and the regulator output transistor PMO 1 that constitute the regulator REG 1 are provided. The internal voltage Vdd (for example, 1.8 V) is generated by using the output band gap voltage VBGR of the band gap circuit BGR 1 . This internal voltage Vdd (for example, 1.8 V) is supplied to the CR oscillating circuit OSC 1 . Also, as illustrated in FIG. 5 , the band gap circuit BGR 1 supplies the band gap voltage VBGR to the low voltage detection circuits LVDH 1 and LVDL 1 . Also, the reference current generation circuit IREF 1 illustrated in FIG. 8 generates the bias currents IBIAS and IBIASTRIM for the CR oscillating circuit OSC 1 on the basis of the band gap voltage VBGR.
[0125] As illustrated in FIG. 3 , the CR oscillating circuit employs the inverter PM 4 , NM 4 , and the CMOS transfer gate (transistor) PM 5 , NM 5 connected in series to its output, and the capacitor C 2 is provided to ensure a design such that the signal amplitude of the node ND 4 to be charged/discharged at constant current is smaller than the power supply potential Vdd. Therefore, when switching from charging to discharging or from discharging to charging of a load, it is unnecessary to charge/discharge a parasitic capacitance for ON/OFF of the MOS transistor by the current supplied to the load itself, thereby making it possible to suppress the influence of the parasitic capacitance on the current supplied to the load.
[0126] Also, as illustrated in FIG. 7 , by providing the signal TCA [3:0] for regulating the temperature dependence of the reference currents IBIAS and IBIASTRIM of the CR oscillating circuit from positive to negative, it is possible to regulate the temperature dependence of the oscillation frequency of the oscillating circuit for each individual circuit manufactured, thereby enabling an improvement in the accuracy of the oscillation frequency.
[0127] Also, as illustrated in FIG. 5 , the band gap circuit BGR 1 , and the error amplifier EAMP 1 and the regulator output transistor PMO 1 that constitute the regulator REG 1 are provided, the internal voltage Vdd (for example, 1.8 V) is generated by using the output band gap voltage VBGR of the band gap circuit BGR 1 , the bias current IBIASROSC for the CR oscillating circuit OSC 1 is generated on the basis of the band gap voltage VBGR, the band gap voltage VBGR is supplied to each of the low voltage detection circuits LVDH 1 and LVDL 1 . Therefore, the band gap circuit BGR 1 may be shared by the regulator REG 1 , the low voltage detection circuits LVDH 1 and LVDL 1 , and the CR oscillating circuit OSC 1 , thereby enabling a reduction in circuit area as compared with a case where a band gap circuit is provided in each of these circuits.
[0128] According to this embodiment, fluctuation of oscillation frequency due to temperature variation of resistance may be prevented. Also, it is possible to prevent the parasitic capacitance at the drain of a transistor from introducing an error in the setting of current. In addition, it is possible to prevent a situation where the temperature dependence of reference voltage or the temperature dependence of reference current differs slightly for each individual circuit, and thus the temperature dependence of oscillation frequency differs for each individual circuit, introducing a large error in oscillation frequency. Moreover, the micro-controller MCU 1 may be mounted with another circuit such as the regulator circuit REG 1 .
[0129] All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiment(s) of the present inventions have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention. | An oscillating apparatus includes: a transfer gate including a P-channel transistor and a N-channel transistor; a first inverter for inverting an output signal of the transfer gate and outputting the inverted output signal of the transfer gate; a second inverter for inverting the output signal of the first inverter and outputting the inverted output signal of the first inverter; a third inverter for inverting the output signal of the first inverter and outputting the inverted output signal of the first inverter; a fourth inverter for inverting the output signal of the third inverter and outputting the inverted output signal of the third inverter to an input-terminal of the transfer gate; a first capacitor connected between an output-terminal of the transfer gate and an output-terminal of the second inverter; and a second capacitor connected between the output-terminal of the transfer gate and a reference potential node. | 7 |
[0001] The present patent application claims the priority benefit of French patent application FR13/61350 which is herein incorporated by reference.
BACKGROUND
[0002] The present application relates to a device and to a method for recharging rechargeable electric or hybrid vehicles.
DISCUSSION OF THE RELATED ART
[0003] The number of rechargeable electric vehicles and hybrid vehicles used continuously increases. As an example, the French Electricity Union (UFE: Union Française de l'Electricité) estimates that by 2030, nearly six million rechargeable electric or hybrid vehicles will be in circulation in France.
[0004] Such vehicles have batteries which should be regularly recharged by the electric power grid. The recharge of rechargeable electric and hybrid vehicles will have, with no specific measures being taken, a significant impact on the French national power consumption curve. Indeed, one million rechargeable electric or hybrid vehicles in slow simultaneous recharge draw from 3,000 to 6,000 MW.
[0005] It is desirable to control the electric power demand for the recharge of rechargeable electric and hybrid vehicles in order to avoid consumption peaks and thus to limit the modifications to be made to the current electric power grid, like the reinforcement of power lines. It is further desirable that the largest possible part of the electric energy used for the recharge of rechargeable electric or hybrid vehicles originates from renewable energy sources, such as photovoltaic power plants, wind power stations, hydraulic power plants, etc.
[0006] There exist methods for recharging rechargeable electric or hybrid vehicles which enable to control the electric power supplied to the vehicles. However, such methods generally require communicating, to a management module, a number of parameters relative to the electric or hybrid vehicles to be recharged, for example, the vehicle type, the capacity of the battery of each vehicle, the recharge profile of the battery of each vehicle, etc. It may be difficult to collect a large number of data to transmit them to the management module. Further, such methods may require controlling the number of vehicles to be recharged while this number is in practice variable and/or controlling the times of beginning or of end of recharge while these times can in practice not be controlled. Further, when the recharge is performed from the electric energy provided by a renewable energy electric power plant, recharge methods may require knowing an estimate of the energy which will be supplied by this power plant. However, such an estimate may be unavailable or be different from the real production of electric energy by the electric power plant.
SUMMARY
[0007] An object of an embodiment is to overcome all or part of the disadvantages of previously-described methods and devices for recharging rechargeable electric and hybrid vehicles.
[0008] Another object of an embodiment is to limit the number of data relative to the vehicles to be recharged necessary for the implementation of the recharge method.
[0009] Another object of an embodiment is that the recharge method can be implemented in real time.
[0010] Another object of an embodiment is that it enables to favor the use of renewable energies for the recharge of vehicles.
[0011] Thus, an embodiment provides a method of recharging electric or hybrid vehicles by means of charging stations connected to an electric power grid, the method comprising the steps of:
[0012] supplying, for each vehicle to be recharged, a control module built into said vehicle or into the charging station of said vehicle with data representative of a total electric power required for recharging the vehicles;
[0013] measuring the total electric power supplied by the electric power grid for recharging the vehicles and supplying data representative of the measured total electric power to said control module for each vehicle to be recharged; and
[0014] determining, by means of said control module for each vehicle to be recharged, a setting of the electric charge power of said vehicle based on the difference between the required total electric power and the measured total electric power.
[0015] According to an embodiment, the setting for the electric charge power of said vehicle is further determined based on the state of charge of the vehicle, on the recharge time of the vehicle.
[0016] According to an embodiment, the data representative of the required total electric power are supplied by the power grid manager and/or by at least one electric power plant selected from the group comprising a photovoltaic power plant, a wind power station, a hydraulic power plant, or a tidal power station.
[0017] According to an embodiment, the method comprises determining, by means of said control module for each vehicle to be recharged, a first coefficient by fuzzy logic based on the state of charge of the vehicle and the recharge time of the vehicle and determining the setting for the electric charge power of said vehicle based on the first coefficient.
[0018] According to an embodiment, the method further comprises the step of multiplying the maximum electric charge power of said vehicle by a second coefficient obtained from the first coefficient and from the measured total electric power.
[0019] According to an embodiment, the method comprises the steps of:
determining the difference between the required total electric power and the measured total electric power; and determining the second coefficient based on the product between the first coefficient and said difference.
[0022] According to an embodiment, the second coefficient is equal to the integral of the product between the first coefficient and said difference.
[0023] According to an embodiment, the determination of the first coefficient by fuzzy logic comprises determining first values of first membership functions of first fuzzy sets associated with the state of charge of the vehicle and of second values of second membership functions of second fuzzy sets associated with the vehicle recharge time.
[0024] According to an embodiment, the determination of the first coefficient by fuzzy logic comprises using a first inference table and a third membership function for the first coefficient on decrease of the required total electric power, and a second inference table, different from the first inference table, and a fourth membership function for the first coefficient different from the third membership function, on increase of the required total electric power.
[0025] An embodiment also provides a device for recharging electric and hybrid vehicles, comprising charging stations connected to an electric power grid, each charging station being connected to one of the vehicles to be recharged, the device further comprising, for each vehicle to be recharged, a control module built into said vehicle or into the charging station of said vehicle, the device comprising means for transmitting, to the control module for each vehicle to be recharged, data representative of a total electric power required for recharging the vehicles, the device further comprising a sensor capable of measuring the total electric power supplied by the electric power grid for recharging said vehicles and means for transmitting data representative of the measured total electric power to said control module for each vehicle to be recharged, said control module for each vehicle to be recharged being capable of determining a setting for the electric power for recharging said vehicle based on the state of charge of the vehicle, on the recharge time of the vehicle, and on the difference between the required total electric power and the measured total electric power.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, among which:
[0027] FIG. 1 partially and schematically shows an embodiment of a device for recharging rechargeable electric or hybrid vehicles;
[0028] FIG. 2 shows in more detailed fashion a portion of FIG. 1 ;
[0029] FIG. 3 shows in the form of a block diagram an embodiment of a method of recharging a rechargeable electric or hybrid vehicle;
[0030] FIGS. 4, 5, 6A, and 6B show curves of the variation of membership functions of fuzzy sets, respectively of the variables of state of charge, recharge time, and variation coefficient k of the electric charge power for two operating modes, implemented by an embodiment of a method of recharging rechargeable electric or hybrid vehicles;
[0031] FIGS. 7 and 8 show examples of three-dimensional surfaces of variation of coefficient k according to the state of charge and to the recharge time for two variation configurations of the available total electric power;
[0032] FIGS. 9 and 10 illustrate the principle of determination of coefficient k for two examples of variation of the available electric power;
[0033] FIGS. 11A, 11B, and 11C show curves of the variation, respectively, of the states of charge of vehicles to be recharged, of the electric power supplied to each vehicle, and of the total electric power supplied to the vehicles in the absence of a control of the electric power supplied to each vehicle; and
[0034] FIGS. 12A, 12B, and 12C, 13A, 13B, and 13C, 14A, 14B, and 14C, 15A, 15B, and 15C, and 16A, 16B, and 16C show curves respectively similar to the curves of FIGS. 11A, 11B, and 11C for different implementation modes of an embodiment of a recharge method.
[0035] For clarity, the same elements have been designated with the same reference numerals in the different drawings.
DETAILED DESCRIPTION
[0036] FIG. 1 shows an embodiment of a device 10 for recharging a fleet of N rechargeable electric or hybrid vehicles VE i where i is an integer varying from 1 to N. As an example, N may vary from 10 to 100 vehicles being recharged.
[0037] Device 10 is connected to a main electric power grid 12 . Device 10 comprises a local electric power grid 14 connected to main system 12 by a connection module 16 . Local electric power grid 14 is capable of transmitting electric energy to N charging stations B i , with i varying from 1 to N. Connection module 16 may comprise a transformer, for example, capable of supplying an electric power which may vary from 200 kW to 2,000 kW. Connection module 16 further comprises a sensor capable of measuring the total electric power P s supplied by main electric power grid 12 to local electric power grid 14 .
[0038] A rechargeable electric or hybrid vehicle VE i may be connected to one of charging stations B i to be recharged by an electric power transmission link LP i . As an example, link LP i corresponds to a power transmission cable. As a variation, the electric power transmission to electric vehicle VE i may be performed remotely, for example, by induction. In the present embodiment, each electric VE i comprises a control module M i capable of controlling an operation of recharge of electric vehicle VE i . Each control module M i may comprise a dedicated processor and/or electronic circuit.
[0039] Device 10 comprises a local management module 17 which is capable of receiving data representative of the measured total electric power P s supplied by connection module 16 and is capable of transmitting to control module M i of each vehicle VE i the data representative of the measured total electric power P s over a data transmission link LD i , with i varying from 1 to N. It may be a wire link or a wireless link. Link LD i may correspond to a RS-232 link or to a RS-485 link having data transmitted thereover according to a communication protocol, for example, the Modbus protocol. The transmission of the data representative of the measured total electric power P s of local management module 17 to control modules M i may be performed at regular intervals.
[0040] A grid management module 18 is capable of transmitting to local management module 17 data representative of an electric power P s *, called reference electric power, and corresponding to the required total electric power to be used for the recharge of vehicles VE i . Local management module 17 is capable of transmitting the data representative of an electric power P s * to control module M i of each vehicle VE i over the corresponding communication link LD i . A new value of reference power P s * may be transmitted only when this power varies. According to an example, reference power P s * may vary in stages and a new value of reference power P s * is transmitted by local management module 17 to control modules M i only at the beginning of each new stage. According to another example, reference power P s * varies continuously.
[0041] FIG. 2 shows a more detailed embodiment of certain components of electric vehicle VE i . Each electric vehicle VE i comprises a battery 20 intended to power equipment, not shown, of vehicle VE i . Battery 20 is connected to an AC/DC converter 22 (AC/DC) which, during the recharge of the battery, is connected to station B i by power transmission link LP i . Each vehicle VE i comprises a battery control system 24 (BMS) which is capable, in particular, of controlling the power supplied by converter 22 to battery 20 during an operation of charge of battery 20 . Control module M i is capable of transmitting a power setting to battery control system 24 , based on which battery control system 24 controls converter 22 . As a variation, control module M i may be provided at the level of each charging station B i . In this case, control module M i is capable of exchanging data with battery control system 24 , for example, over a wire link or over a wireless link.
[0042] When a vehicle VE i is connected to station B i , control module M i is supplied with the expected end time t stopi . According to an example, the user of vehicle VE i enters this information on an interface module of vehicle VE i for example comprising a keyboard, a touch screen, a microphone, etc. The time at the beginning of the recharge i starti of vehicle VE i is automatically identified by control module M i .
[0043] Control module M i internally recovers once, at the beginning of the recharge, the maximum power P MAX _ EVi to which the battery of vehicle VE i can be recharged.
[0044] During the recharge of vehicle VE i , data representative of state of charge SOC i of the vehicle are regularly transmitted to control module M i of vehicle VE i . As a variation, data representative of state of charge SOC i of the vehicle are transmitted to control module M i only at the beginning of the recharge, the control module determining the variation of state of charge SOC i of vehicle VE i based on the electric power supplied to recharge vehicle VE i . Such data relative to state of charge SOC i and to maximum power P MAX _ EVi are transmitted to control module M i with no intervention of the user.
[0045] According to an embodiment, control module M i may operate according to a basic operating mode where it performs no regulation of the electric power to be supplied to recharge vehicle VE i . In this case, the power supplied to each vehicle is for example equal to maximum power P MAX _ EVi .
[0046] According to an embodiment, control module M i may operate according to a regulation operating mode where it determines in real time a setting P EVi , for example, for battery control system 24 , of the electric power to be supplied to recharge vehicle VE i .
[0047] FIG. 3 shows in the form of a block diagram an embodiment of the method implemented by control module M i in regulation mode. Control module M i comprises a module 30 of determination of a correction coefficient k i . Module 30 receives state of charge SOC i of the vehicle and the time T i for which vehicle VE i will be recharging. State of charge SOC i corresponds to the state of charge of vehicle VE i when a new value of coefficient k i is determined. Time T i corresponds to the difference between time t stopi and the time of beginning of the recharge t starti . Control module M i comprises a subtractor 32 receiving electric powers P S * and P S and determining differences ΔP s between electric powers P s * and P s .
[0048] A weighting coefficient Coeff i is determined from coefficient k i and from difference ΔP S . As an example, the regulation is of integral type, where difference ΔP S is multiplied by coefficient k i and is integrated. As a variation, it may be a correction of proportional-integral-derivative type.
[0049] Power setting P EVi corresponds to the product of the value of maximum power P MAX _ EVi and of coefficient Coeff i .
[0050] The control method may be implemented by the execution of a sequence of instructions by a processor. As a variation, it may be implemented by a dedicated electronic circuit.
[0051] According to an embodiment, for each control module M i , coefficient k i is determined by fuzzy logic. For this purpose, the variables used by control module M i are the state of charge, SOC, the recharge time, T, and the correction coefficient, k.
[0052] The “state of charge” variable, SOC, is associated with a plurality of fuzzy sets, for example, five in the present embodiment, corresponding to a plurality of state of charge levels of the battery of vehicle VE i .
[0053] FIG. 4 shows examples of membership functions which characterize five fuzzy sets socP, socMP, socM, socMG, and socG of variable SOC respectively reflecting the fact that the state of charge is around 0%, 25%, 50%, 75%, and 100%.
[0054] The “recharge time” variable, T, is associated with a plurality of fuzzy sets, for example, five in the present embodiment, corresponding to a plurality of ranges of values of the recharge time.
[0055] FIG. 5 shows examples of membership functions which characterize five fuzzy sets tP, tMP, tM, tMG, and tG of variable SOC respectively reflecting the fact that the recharge time is around 0 hr, 3 hrs, 6 hrs, 9 hrs, and 12 hrs.
[0056] The “correction coefficient” variable, k, is associated with a plurality of fuzzy sets, for example, five in the present embodiment, corresponding to a plurality of ranges of values of the correction coefficient.
[0057] According to an embodiment, coefficient k i is determined differently in case of a decrease or of an increase of the reference total electric power P s *.
[0058] FIGS. 6A and 6B show, respectively in the case of a decrease of power P s * and of an increase of power P s *, examples of membership functions which characterize five fuzzy sets P, MP, M, MG, and G of variable k respectively reflecting the fact that the correction coefficient is “low”, “relatively low”, “average”, “relatively high”, and “high”.
[0059] The membership functions of the fuzzy sets of the “state of charge”, “recharge time”, and “correction coefficient” variables may be stored in memories of each control module M i .
[0060] In FIGS. 4, 5, 6A, and 6B , the membership functions correspond to broken lines. However the membership functions may have another shape, for example, a bell shape.
[0061] An example of a detection array, or inference table, in the case of a decrease in power P s * is given by the following table (1):
[0000]
TABLE (1)
State of charge SOC
socP
socMP
socM
socMG
socG
Recharge
tP
P
P
MP
M
MG
time T
tMP
P
MP
MP
MG
G
tM
P
MP
M
MG
G
tMG
MP
M
M
MG
G
tG
MP
M
MG
G
G
[0062] In the case of a decrease in power P s *, the membership function of variable k shown in FIG. 6A is used.
[0063] The reading of the fuzzy rule corresponding, for example, to the first box at the top left of inference table (1) is the following: if the state of charge is low (socP) and if the recharge time is short (tP), then coefficient k is low (P). This means that variable k belongs to fuzzy set P at a degree which depends on the degree of validity of the premises, in other words on the degree of membership of variable SOC to fuzzy set socP and on the degree of membership of variable T to fuzzy set tP.
[0064] Table (1) is not symmetrical. This illustrates the fact that coefficient k i is low as a priority as soon as the state of charge is low. Indeed, the object is that the state of charge is at 100% at the time where the electric vehicle is disconnected from the associated charging station.
[0065] An example of the inference table in the case of an increase in power P s * is given by the following table (2):
[0000]
TABLE (2)
State of charge SOC
socP
socMP
socM
socMG
socG
Recharge
tP
G
G
MG
M
MP
time T
tMP
G
MG
MG
MP
P
tM
G
MG
M
MP
P
tMG
MG
M
M
MP
P
tG
MG
M
MP
P
P
[0066] In the case of an increase in power P s *, the membership function of variable k shown in FIG. 6B is used.
[0067] The reading of the fuzzy rule corresponding, for example, to the first box at the top left of inference table (2) is the following: if the state of charge is low (socP) and if the recharge time is short (tP), then coefficient k is high (G). This means that variable k belongs to fuzzy set G at a degree which depends on the degree of validity of the premises, in other words on the degree of membership of variable SOC to fuzzy set socP and on the degree of membership of variable T to fuzzy set tP.
[0068] Table (2) is not symmetrical. This illustrates the fact that coefficient k i is high as a priority as soon as the state of charge is low. Indeed, the object is for the state of charge to be at 100% at the time where the electric vehicle is disconnected from the charging station.
[0069] In fuzzy logic, coordinating conjunction “and” which connects the premises translates as a fuzzy operator and linker “then” connecting the conclusion to the premises translates as a fuzzy implication.
[0070] As an example, the Zadeh fuzzy operators may be used. Intersection operator AND connecting two fuzzy sets then returns the minimum of the membership functions of the two fuzzy sets.
[0071] Generally, the fuzzy implication defines how to delimit, according to the specific values of variables SOC and T of the premises of the fuzzy rule, a portion of the surface under the curve of the membership function of the fuzzy set of the conclusion of the fuzzy rule, that is, the obtaining of a subset.
[0072] As an example, the fuzzy implication used may be the Mamdani implication or the Larsen implication.
[0073] For specific values SOC i and T i of variables SOC and T, each fuzzy rule of the inference table results in the obtaining of a subset, possibly zero, for variable k. the subsets are aggregated by using, for example, operator MAX. The determination of the final value of coefficient k i from the aggregated subsets is called defuzzification. As an example, the defuzzification step implements the mean-of-maxima method or the center-of-gravity method.
[0074] FIGS. 7 and 8 show an example of a three-dimensional representation of the variation of coefficient k i according to state of charge SOC i and to recharge time T i on implementation, respectively, of inference table (1) and of inference table (2) by using Zadeh's fuzzy “AND” operator, Mamdani's fuzzy implication and the step of defuzzification by the center-of-gravity method.
[0075] As an illustration, two vehicles VE 1 and VE 2 are considered. State of charge SOC 1 of vehicle VE 1 is higher than state of charge SOC 2 of vehicle VE 2 and charge time T 1 of vehicle VE 1 is longer than charge time T 2 of vehicle VE 2 .
[0076] FIG. 9 shows curves D 1 and D 2 of the variation of the electric power P Ev1 supplied to vehicle VE 1 and of the electric power P EV2 supplied to vehicle V E2 according to the total available electric power P s respectively when a decrease in the total available power from P 0 s to P 1 s is indicated by system management module 18 at stations B i , with i varying from 1 to N. Curves D 1 and D 2 correspond to straight lines, coefficient k 1 corresponding to the slope of line D 1 and coefficient k 2 corresponding to the slope of line D 2 .
[0077] FIG. 9 shows that, on decrease of the total available electric power, the decrease in the electric power supplied to a vehicle is all the more significant as its state of charge is high and as the recharge time is long.
[0078] FIG. 10 shows variation curves D′ 1 and D′ 2 similar to respective lines D 1 and D 2 when an increase in the total available power from P 0 s to P 1 s is indicated by system management module 18 to control modules M i , with i varying from 1 to N.
[0079] FIG. 10 shows that, on increase of the total available electric power, the increase in the electric power supplied to a vehicle is all the more significant as its state of charge is low and as the recharge time is short.
[0080] An advantage of the present embodiment is that it is essentially formed locally by each control module of the electric vehicle and only requires the remote transmission of a small number of data.
[0081] Another advantage of the present embodiment is that it requires no information which may be difficult to obtain, for example, the type of vehicle to be recharged.
[0082] Another advantage of the present embodiment is that it does not require knowing in advance the number of vehicles to be recharged or the times of arrival of the vehicles to be recharged.
[0083] Another advantage of the present embodiment is that it may be implemented in real time.
[0084] Another advantage of the present embodiment is that the electric power setting P VEi supplied by control module M i of each vehicle VE i may be determined continuously so that the total electric power P s supplied to all the electric vehicles may continuously follow reference power P s *.
[0085] Another advantage of the present embodiment is that reference power P s * does not have to be determined in advance. Thereby, reference power P s * may follow the electric power supplied by an electric power plant, particularly a photovoltaic power plant, a wind power station, a hydraulic power plant, or a tidal power plant.
[0086] Simulations have been performed by the inventors. For all these simulations, twenty electric vehicles each having a battery having a 24-KWh capacity with a maximum charge power of 3 kW have been considered.
[0087] For the first simulation, initial state of charge SOC ini of the electric vehicles was between 40% and 60% and has been obtained by a random selection according to a uniform distribution. Time t start of beginning of the recharge was 7 am for all vehicles and end time t stop of the recharge was between 4:30 pm and 7 pm and has been obtained by random selection. These values are gathered in the following table (3):
[0000]
TABLE 3
T start
T stop
SOC ini
VE
(hrs from midnight)
(hrs from midnight)
(%)
1
7
18.6
45
2
7
18.0
50
3
7
17.9
54
4
7
18.8
58
5
7
17.2
60
6
7
18.4
51
7
7
18.4
42
8
7
17.5
43
9
7
17.9
45
10
7
16.7
57
11
7
16.6
45
12
7
17.8
57
13
7
18.4
45
14
7
18.8
59
15
7
16.8
47
16
7
17.9
44
17
7
17.7
45
18
7
16.5
52
19
7
17.3
49
20
7
16.9
47
[0088] For the first simulation, there is no determination of a charge power setting, each vehicle being recharged to the maximum charge power.
[0089] FIGS. 11A, 11B, and 11C show curves of the variation, respectively, of states of charge SOC of the electric vehicles, of electric power P EV supplied to each electric vehicle, and of total electric power P s1 supplied to the electric vehicles for the first simulation.
[0090] As appears in the drawings, each vehicle has been recharged with the maximum 3-kW charge power during the entire recharge period. Total electric power P S1 was thus as high as 60 kW as long as all vehicles were recharging and then decreased down to 0 kW as the state of charge of each vehicle reached 100%.
[0091] A second simulation has been carried out with the same conditions as the first simulation, with the difference that the total reference power starting from 7 am was 25 kW.
[0092] FIGS. 12A, 12B, and 12C are curves similar to the respective curves of FIGS. 11A, 11B, and 11C for the second simulation. The total supplied power P S2 has been kept at 25 kW and the state of charge of all the vehicles was 100% at the end time.
[0093] A third simulation has been performed with the same conditions as the second simulation, with the difference that the time of beginning of the recharge t start was between 7 am and 12 am and has been obtained by random selection and that total reference power P* S3 was successively 25 kW from 12 am to 9 am, 15 kW from 9 am to 11 am, 20 kW from 11 am to 2 pm, and 40 kW from 2 pm to midnight. A new value of total reference power P* S3 was thus transmitted to each charging station at 12 am, 9 am, 11 am, and 2 pm.
[0094] FIGS. 13A, 13B, and 13C are curves similar to the respective curves of FIGS. 11A, 11B, and 11C for the third simulation. FIG. 13C shows, in addition to total power P S3 , the curve of variation of the total reference power P* S3 by a thick line. The total supplied power P S3 follows the variation curve of the total reference power P* S3 and the state of charge of all the vehicles was 100% at the end time.
[0095] A fourth simulation has been carried out in the case where the electric vehicles are further capable of supplying electric energy to the main power grid. The fourth simulation has been performed with the same conditions as the third simulation, with the difference that total reference power P* S4 was successively 25 kW from midnight to 9 am, −15 kW from 9 am to 11 am, 20 kW from 11 am to 2 pm, and 40 kW from 2 pm to midnight. A new value of total reference power P* S4 was thus transmitted to each charging station at midnight, 9 am, 11 am, and 2 pm.
[0096] FIGS. 14A, 14B, and 14C are curves similar to the respective curves of FIGS. 11A, 11B, and 11C for the fourth simulation. FIG. 14C shows, in addition to total power P S4 , the curve of variation of the total reference power P* S4 by a thick line. The total supplied power P S4 follows the variation curve of the total reference power P* S4 and the state of charge of all the vehicles was 100% at the end time.
[0097] A fifth simulation has been carried out in the absence of a control. For the fifth simulation, initial state of charge SOC ini of the electric vehicles was between 20% and 80% and has been obtained by a random selection according to a uniform distribution. The time t start of beginning of the recharge was in the range from 7 am to midnight and has been obtained by random selection and end time t stop of the recharge was between 7 pm and 9 pm and has been obtained by a random selection. These values are gathered in the following table (4):
[0000]
TABLE 4
T start
T stop
SOC ini
VE
(hrs from midnight)
(hrs from midnight)
(%)
1
8.02
20.5
54.67
2
7.97
19.5
36.07
3
8.85
20
60.47
4
10.22
20.38
63.02
5
11.17
20.77
55.36
6
8.12
20.92
57.73
7
8.95
20.08
57.29
8
8.65
19.27
46.77
9
7.52
19.28
54.66
10
8.47
19.5
40.14
11
8.18
20.67
56.18
12
10.4
19.5
35.95
13
8.43
20.62
43.31
14
8.83
19.48
36.39
15
8.18
20.58
37.91
16
9.08
19.68
59.7
17
8.37
19.38
55.84
18
9.58
19.5
44.51
19
10.68
20.22
63.51
20
11.8
19.93
56.03
[0098] For the fifth simulation, there is no determination of a charge power setting, each vehicle being recharged to the maximum charge power.
[0099] FIGS. 15A, 15B, and 15C are curves similar to the respective curves of FIGS. 11A, 11B, and 11C for the fifth simulation. In FIG. 15C , curve P S5 shows the curve of variation of the total electric power and curve P PV shows the electric power supplied by a photovoltaic power plant.
[0100] For the fifth simulation, the solar coverage is 55.62%, that is, 55.62% of the total electric power P s supplied to the vehicles to be recharged has been provided by the photovoltaic power plant.
[0101] A sixth simulation has been performed with the same conditions as the fifth simulation, with the difference that the setting for total available power P* S corresponds to the electric power P PV shown in FIG. 15C .
[0102] FIGS. 16A, 16B, and 16C are curves similar to the respective curves of FIGS. 11A, 11B, and 11C for the sixth simulation.
[0103] For the sixth simulation, the solar coverage is 97.88%, that is, 97.88% of the total electric power P S6 supplied to the vehicles to be recharged has been provided by the photovoltaic power plant.
[0104] Specific embodiments have been described. Various alterations and modifications will readily occur to those skilled in the art. | The invention relates to a method for recharging electric or hybrid vehicles (VE 1 ) by charging stations (B 1 ) connected to an electric power grid ( 14 ). The method comprises supplying, for each vehicle to be recharged, a control module (M 1 ) built into said vehicle or to the charging station of said vehicle, with data representing a total electric power required (PS*) for recharging the vehicles, measuring the total electric power (PS) supplied by the electric power grid ( 14 ) for recharging the vehicles, and sup- plying data representing the total electric power measured to said control module for each vehicle to be recharged, and determining, by said control module for each vehicle to be recharged, a setting of the electric power for recharging said vehicle according to the difference between the total electric power required and the total electric power measured. | 1 |
CROSS RELATED APPLICATION
[0001] This application claims the benefit of application Ser. No. 61/362,037 filed Jul. 7, 2010, which is incorporated in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to a method and system for feeding comminuted cellulosic fibrous material (referred to as “chips”) to a treatment vessel, such as a batch digester. In particular, the invention relates to creating a slurry, providing heat for the slurry and cooking liquor addition to the batch digester to which the chips being fed.
[0003] The terms “wood”, “chips” and “wood chips” refers generally to comminuted cellulosic fibrous material, such as chipped hardwoods and softwoods, and other lignocellulosic material.
[0004] A batch digesting system may include a chip feed system and a batch digester vessel. The chip feed system intermittently delivers chips, with liquor and optionally steam heat, to the batch digester vessel. The conventional process cycle of a batch digester vessel includes the sequential steps of: (i) filling the vessel with chips from the chip feed system, (ii) adding steam and liquor to the batch digester vessel (the liquor may be added simultaneously with the filling of the chips); (iii) capping the filled vessel and operating the vessel at conditions, e.g., above-atmospheric temperature and pressures, to digest, e.g., “cook”, the chips in the vessel and thereby convert the chips to pulp, and (iv) discharging, e.g., emptying, the pulp and liquor from the vessel. The “cycle time” is the period required for steps (i), (ii), (iii) and (iv) of the process. The cycle is repeated to successively process “batches” of chips in the digester vessel. Between capping the digester vessel and discharging the pulp from the vessel, time is needed to extract liquor through screens of the vessel and add steam heat to the chips in the vessel.
BRIEF DESCRIPTION OF THE INVENTION
[0005] A system and method has been conceived to reduce the cycle time of batch digester vessel. The cycle time is reduced by extracting liquor from the vessel while chips continue to flow into the vessel and prior to the capping of the vessel. The vessel is filled such that a chip level is established to be above the top of an extraction screen in the vessel. Liquor is extracted through the extraction screen while the chips slurry continues to fill the batch digester vessel. Optionally, cooking liquor and steam may be added to the digester vessel while liquor is extracted from the vessel and while the chip slurry continues to fill the vessel. Cooking liquor and steam may also be added to the vessel after the desired volume of chips have been added to the vessel and the slurry stops filling the vessel. The described filling method may result in a shorter cycle time than the cycle time of conventional batch digester operations.
[0006] Reducing the cycle time allows for an increase in the volume of chips that may be processed by a batch digester vessel during a given period. Similarly, reducing the period during which chips are retained in a digester vessel during each cycle may allow for reduced cycle times and smaller digester vessels to achieve a desired flow rate of chips through a batch digesting system.
[0007] Liquor is added to the chips in the chip feed system to transport the chips (as a chip slurry) through the conduits, e.g., pipes, of the chip feed system. The proportion of liquor to chips in the chip slurry needed to transport the chips is substantially greater than the proportion of liquor to chips needed during cooking. The ratio of liquor to chips tends to be lower when cooking the chips in the vessel than is the ratio used to transport chips to the vessel. To reduce the liquor to chip ratio liquor is removed from the batch digester vessel. It is conventional to start the removal of liquor from a batch digester vessel after the vessel is capped. What is not conventional is to start the removal of liquor before the vessel is capped and while chips are being fed into the vessel.
[0008] The cycle time for a batch digester vessel may be reduced by removing, e.g., extracting, liquor as the vessel is filled with chips and before the vessel is capped to start of the digesting operation. The extraction of liquor during filling may begin after a minimum level of chips is established in the digester vessel. The minimum chip level may be at an elevation in the vessel at or above the top of the extraction screen.
[0009] Extracting liquid from the batch digester after establishment of minimum chip level and while chips continue to flow into the vessel allows for the liquid level to be drawn down in the vessel. As the liquid level is drawn down, space is formed in the batch digester vessel to add cooking liquor after the chips have been transported to the vessel.
[0010] The chemical composition of liquor used to transport chips, e.g., water, may be different than the chemical composition of liquor used to cook the chips in the vessel. If water or other non-cooking liquor is used to transport the chips to the vessel, cooking liquor is added to the vessel. In an embodiment of the present invention, cooking liquor may be added to the vessel before the vessel is capped.
[0011] Cooking liquor may be added to the chips in the chip feed system and used to transport the chips to the vessel. If cooking liquor is used as the transport liquor, the extraction of liquid from the batch digester vessel during the filling of the vessel may be regulated to ensure that sufficient cooking liquor remains in the vessel. Further, steam may be added to the chips in the chip feed system to start the heating the chips prior to the capping of the batch digester vessel. This early addition of steam may also shorten the cycle time.
[0012] A method has been conceived for chemically digesting cellulosic fibrous material, the method comprises: forming a slurry of cellulosic fibrous material; optionally adding heat energy (via steam for example) to the cellulosic fibrous material or the slurry; transporting the heated slurry through a high pressure transfer device and into a batch digester vessel; filling the batch digester vessel with the slurry to establish a minimum chips level; extracting transport liquor from the batch digester; optionally replacing the transport liquor with cooking liquor and when appropriate stopping extraction of the transport liquor from the batch digester vessel to provide sufficient cooking liquor in the batch digester vessel; ceasing the filling of the digester vessel and thereafter converting the cellulosic material in the vessel to a pulp, and discharging the pulp from the batch digester vessel before restarting the transporting of the slurry into the digester vessel.
[0013] A method for chemically digesting cellulosic fibrous material has been conceived comprising: forming a slurry of cellulosic fibrous material; transporting the slurry through a high pressure transfer device and into a batch digester vessel and forming a chip level in the vessel; determining when the chip level exists above an extraction screen in the batch digester vessel; after establishing the chip level, extracting liquor from the batch digester vessel while the feeding continues of the slurry to the batch digester vessel; adding cooking liquor to the batch digester vessel; ceasing the transport of the slurry into the batch digester vessel and thereafter converting the cellulosic material in the vessel to a pulp, and discharging the pulp from the batch digester vessel before restarting the transporting of the slurry into the digester vessel.
[0014] The steps of transporting the slurry of chips and liquor, filling the vessel with the slurry, converting the chips to pulp in the vessel and the discharging the pulp from the vessel are sequentially repeated. The high pressure transfer device may be one or more chip pumps which pressurizes the slurry in series or parallel as needed to meet the design of the system (meet static head requirements, flexibility for production turndown or increase, the need to feed multiple vessels, or other design specific requirements). The step of adding heat may include adding steam heat to the cellulosic material or slurry in a chip feed system coupled to the digester vessel and including the high pressure transfer device. The steam heat may be recovered heat from the extracted cooking liquor. The ratio of liquor to cellulosic material (L/W by weight) may be in a range of five to eight as the slurry flows through the high pressure transfer device, and in a range of three to five during the conversion of the cellulosic material to the pulp in the vessel.
[0015] A method has been conceived for chemically digesting cellulosic fibrous material comprising: adding a liquor to cellulosic fibrous material to form a slurry in a chip feed system; transporting the slurry from the chip feed system to a batch digester vessel; determining when a chip level rises above an extraction screen in the batch digester vessel; after the chip level rises above the extraction screen, extracting liquor from the batch digester vessel while the transport continues of the slurry into the batch digester vessel; ceasing the transport of the slurry into the batch digester vessel and thereafter converting the cellulosic material in the vessel to a pulp, and discharging the pulp from the batch digester vessel before restarting the transporting of the slurry into the digester vessel.
[0016] The method may include adding heat energy to the cellulosic fibrous material or the slurry before the slurry is transported into the batch digester vessel. A cooking liquor may be added to the slurry before the slurry enters the batch digester vessel.
[0017] Liquor may be extracted from the batch digester vessel during the transport of the slurry into the vessel. The extracted liquor may be used to heat the liquor added to the chip feed system. Steam heat may be added to the cellulosic material or slurry in the chip feed system. The steam heat is added at a lower end of a chip tube coupled to an inlet of a high pressure transfer device.
[0018] A liquor to cellulosic material ratio on a weight basis may be in a range of five to eight as the slurry flows through a high pressure transfer device of the chip feed system, and in a range of three to five during the conversion of the cellulosic material to the pulp in the batch digester vessel.
[0019] A method has been conceived for batch digesting method for pulping cellulosic fibrous material, the method comprising: adding a liquor to cellulosic fibrous material to form a slurry in a chip feed system; transporting the slurry from the chip feed system to an upper inlet to a batch digester vessel; as the slurry is being transported into the batch digester vessel and after a liquid or chip level in the vessel rises above an extraction screen in the vessel, extracting liquor from the batch digester vessel; ceasing the transport of the slurry into the batch digester vessel; while the transport of the slurry is ceased, converting the cellulosic material in the vessel to a pulp, and discharging the pulp from the batch digester vessel. The steps of transporting, ceasing and converting are performed sequentially and separately, and may be performed repeatedly.
[0020] Heat energy may be added to the cellulosic fibrous material or slurry before the slurry is transported to the upper inlet of the batch digester vessel. In addition, a cooking liquor may be added to the material in an impregnation vessel of the chip feed system and before the slurry enters the batch digester vessel. Further, heat may be transferred from liquor extracted from the batch digester vessel to the liquor added in the chip feed system. In addition, cooking liquor may be added to the cellulosic fibrous material in the chip feed system and the batch digester vessel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic diagram of a chip feed and steaming system coupled to a batch digester vessel for chemically processing cellulosic fibrous material, wherein the figures show a cycle of operation of the batch digester vessel.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 is a schematic diagram of a chip feed system 10 and a batch digester vessel 12 for chemically processing cellulosic fibrous material. The batch digester vessel 12 operates in a repeating sequence of filling, cooking and discharge.
[0023] During the filling step, chips from the chip feed system flow into a top inlet 46 of the vessel. Cooking liquor 14 or transport liquor 60 flows with the chips into the vessel. Cooking liquor may also be added separately to the vessel during the filling step. In addition, steam 20 may be added via conduit 40 to the vessel during the filling step. The flow of chips into the vessel ceases at the end of the filling step.
[0024] The cooking step follows the filling step. After the top inlet is capped, e.g., sealed, the cooking step involves impregnating the chips in the vessel with the cooking liquor, maintaining the chips under conditions, e.g., 5 to 10 kilogram/centimeter squared (kg/cm 2 ) and at elevated temperatures of 140 to 200 degrees Celsius (° C.), favorable to cooking of cellulosic fibrous material. During the cooking step, the cooking chemicals, e.g., alkaline solutions of sodium sulfate (kraft process) or sodium hydroxide, delignify the chips and allow for separation of the fibers in the chips to produce pulp. After the cooking step, the pulp 54 is discharged from the vessel during the discharge step.
[0025] Chips 22 may be supplied to the chip feed system. For example, the wood yards of conventional pulp mills store wood chips 22 in open chip piles or in chip storage silos. Chips 22 are conveyed by conventional means, e.g., a conveyor or front-end loader (not shown), to a chip bin 24 of the chip feed system.
[0026] The chip bin 24 may be a DIAMONDBACK® chip bin marketed by the Andritz Group and as disclosed in U.S. Pat. No. 5,000,083, or other conventional chip storage vessel. The chip bin may have near an outlet a one-dimensional convergence and side relief and a rotary or vibratory discharge mechanism. The chip bin 24 may have an upper inlet connected to an airlock 26 which monitors and controls the flow of chips into the bin. The conveyor for the chips 22 feed the chips to the inlet of the airlock. If the chip bin is pressurized, a vent 28 at the top of chip bin regulates the pressure in the bin, such as in a range of 5 to 10 kg/cm 2 .
[0027] The chip bin 24 may be operated at atmospheric or super-atmospheric pressure, for example at 0.1 to 5 bar. If the chip bin is operated at super-atmospheric pressure, a pressure isolation device 30 , e.g., a rotary valve low pressure feeder, may be located at the chip inlet (possibly instead of the air lock) of the chip bin to prevent the release of pressure from the bin. The low pressure feeder may be a star-type isolation device or a screw-type feeder having a sealing capacity. The pressure isolation device isolates the pressurized chip bin from the unpressurized chip supply 22 that is at atmospheric pressure.
[0028] The chip bin 24 discharges to a metering device for example a Chip Meter sold by Andritz Group or other screw-type metering device. The metering device 32 may discharge chips to a pressure isolation device 36 and thereafter to an optional chip impregnation vessel 34 .
[0029] White cooking liquor 14 may be added to one or more of the chips in the chip bin 24 , pressure isolation device 36 , impregnation vessel 34 and batch digester vessel via central liquor pipe 64 . The cooking liquor may be, by way of examples, kraft white, black or green liquor. White cooking liquor 14 may be a strongly alkaline solution including sodium hydroxide and sodium sulfide used for Kraft pulping. As an alternative to or in addition to adding cooking liquor to the chip bin, cooking liquor may be added to a chip impregnation vessel that temporarily holds the chips at atmospheric pressure or at an elevated pressure. The addition of white liquor to the chip feed system via conduits 52 starts the process of impregnation of the chips with the cooking liquor before the chips enter the batch digester vessel 12 .
[0030] To feed the chips to the vessel, liquor, such as transport liquor 60 , e.g., water, and white cooking liquor 14 , is injected in the chip feed system to establish a slurry. Transport liquor 60 may be water, for example. The ratio of liquor to chips, e.g., cellulosic material, on a weight basis may be in a range of five to eight for transporting the chips to the vessel. The ratio of the liquor to chips may be in a range of three to five during the cooking process in which the cellulosic material is converted to the pulp. In view of the higher ratio of liquor to chips for transport as compared to cooking, a substantial amount of liquor is removed from the chips after they have entered the vessel.
[0031] A portion of the liquor added in the chip feed system may be liquor extracted from the batch digester vessel, such as through screens 16 or a top separator 18 in the vessel. Conduit 62 transports extracted liquor from the vessel 12 to the chip feed system, such as to the discharge of the chip bin 24 .
[0032] Extraction of liquor from the batch digester vessel occurs during the chip filling step and starts after the chip level 61 in the vessel 10 has risen above the top of the extraction screens 16 . Liquor is extracted while chips continue to be fed into the vessel. The extraction of the liquor as the batch digester vessel is filled with a desired mass of chip allows the liquid level in the vessel to be drawn down prior to the addition of cooking liquor. Optionally, while liquor is extracted from the screens 16 into conduit 62 , white cooking liquor 14 may added to the vessel. Further, liquor may be extracted and additional cooking liquor added during the cooking step.
[0033] Steam 20 may be injected via conduit 40 to the chips in the feed system 10 to provide heat energy to the chips and increase the temperature of the chips to or near a cooking temperature, e.g., between 140° C. to 180° C., before the chips enter the batch digester vessel. By adding liquor and optionally steam to the chips in the chip feed system, the process time may be reduced in the batch digester vessel as compared to the conventional approach of adding steam after the chips enter the batch digester vessel and extracting liquor only after the vessel has been capped for the cooking step. Steam 20 may also be added directly to the batch digester vessel via conduit 41
[0034] The period during which the chips are impregnated in the impregnation vessel 34 depend on the level of chip impregnation desired to be reached before the chips are fed to the batch digester vessel. The period of chip impregnation may be very short, e.g., 0.1 second (as the chips enter the digester vessel) to long, such as a two (2) hour retention period in the impregnation vessel 34 . If the period for chip impregnation is shorter than the period in the cycle for cooking in the digester vessel, the cooking liquor may be added to the impregnation vessel after the chips fed to the impregnation vessel and at a time selected to achieve the desired impregnation period before the chips are fed to the digester vessel. The impregnation vessel may be large if needed to retain the chips in the vessel for a period longer than the period in the cycle for cooking in the digester vessel. The addition of cooking liquor in the chip feed system may also be accomplished without an impregnation vessel such as by adding the liquor to the chip bin 24 via conduit 40 , to the chips in prior to the pumps 44 coupled to conduit 42 or to another component of the chip feed system such as the pressure isolation device 36 .
[0035] Steam, such as fresh steam 20 or flashed steam 38 produced from the evaporation of waste liquor, may be added to chip bin 24 , to the chip impregnation vessel 34 or to other sections of the chip feed system 10 . Steam conduits 40 direct the steam from the steam supply 20 of fresh steam or flashed steam 38 from a flash tank 39 to one or more components, e.g., chip bin 24 and impregnation vessel 34 , of the chip feed system 10 .
[0036] The steam 20 added in the chip feed system increases the temperature of the chips before entering the digester vessel and thereby reduces the period needed to heat the chips in the batch digester vessel. The steam also facilitates removal of air from the chips. By way of example, the steam may be added to the chip feed system moments before the chips enter the digester vessel or as much as 2 hours before the chips enter the digester vessel.
[0037] A slurry of chips and liquor is fed through conduits 42 from the chip bin 24 , the chip impregnation vessel 34 (if present), the pressure isolation device 30 or 36 to a high pressure transfer device 44 , such as one or more chip pumps, such as disclosed in U.S. Pat. No. 5,753,075, the entirety of which is incorporated by reference. These pumps, as described in U.S. Pat. No. 5,753,075 may be arranged in series or parallel as needed to meet specific design criteria, such as the necessary head for the pumps, volume of material to pump, and flexibility in operations of the one or multiple batch digesters. Another example of a high pressure transfer device is disclosed in U.S. Pat. No. 5,236,285, the entirety of which is incorporated by reference. The pressure isolation device may include a chip tube that receives at an upper inlet the chips and a lower outlet that feeds the chips to a pump. The chip slurry is pressurized in the high pressure transfer device 44 to a pressure substantially equal to the pressure in the digester vessel 12 .
[0038] From the high pressure transfer device 44 , the chips and liquor slurry flows to a top inlet 46 of the digester vessel. The chips and liquor flow into the digester vessel through the top inlet and fill the digester vessel. The chips and liquor may be added simultaneously to the digester in a chip slurry.
[0039] The quantity of liquor added the chip feed system 10 to transport the chips from the chip bin 24 to the digester vessel 12 may be in a range of 5 to 8 times the quantity of chips by weight (that is a liquor to wood ratio of 5:1 to 8:1, L/W of 5:1 to 8:1 or L/W of 5 to 8 by weight). This range of L/W of 5 to 8 of liquor to chips is particularly suitable where the high pressure transport device is one or more chip pumps.
[0040] The quantity of liquor needed for treating, e.g., cooking, the chips in the batch digester vessel is typically 3 to 5 times liquor to chips (a L/W ratio of 3 to 5). The quantity of liquor needed for chip treatment in the digester vessel may be less than the quantity of liquor needed to transport the chips through the chip feed system, particularly if the chip pumps form the high pressure transfer device.
[0041] Liquor can be extracted from the digester vessel through screens 16 that may extend partially or fully around the circumference of the vessel and be at a mid-elevation of the vessel. The positioning and arrangement of the screens is a matter of design choice for the designer of the digester vessel. Alternative types of screening devices for extracting liquor from the digester vessel include a top separator 18 that may be included in the vessel at the top inlet 46 . These screening devices extract liquor from the chip slurry in the digester vessel while blocking chip fibers from leaving the vessel. Liquor may be extracted from the screens 16 separately from the top separator 18 . Liquor may be extracted from screen 16 after the liquor level in the vessel 10 rises above the screen 16 , even though the top separator is not immersed in liquor.
[0042] Some of the liquor may be extracted via screen as the chip slurry fills the digester vessel and before the start of the formal batch cooking process. As the chip slurry flows through the top inlet 46 and accumulates in the digester vessel, the slurry will fill the vessel and form a liquor liquid level and a chip pile in the vessel. When the chip pile level 61 exceeds the elevation of the screens 16 , a portion of the liquor may be extracted through the screens.
[0043] The extracted liquor may be used to heat, via a heat exchanger 56 , the white liquor 14 that supplies liquor to conduits 52 connected to one or more of the chip bin 24 , impregnation vessel 34 and other components in the chip feed system 10 . If a top separator 18 is present, a portion of the liquor may be extracted as the chip slurry flows through the inlet 46 and into the vessel. The amount of liquor removed as the chip slurry fills the vessel may be such that the amount of liquor remaining in the vessel is sufficient for cooking the chips, e.g., in a range of L/W of 3 to 5 liquor to chips weight ratio.
[0044] The extraction of liquor is started before the chip slurry has fully filled the batch digester vessel 12 . The extracted liquor may be replaced by cooking liquor. In particular, the transport liquor may be extracted and drawn down to allow replacement by cooking liquor once the extraction has stopped. By extracting liquor before the formal cooking process is started in the batch digester vessel, the time taken in reducing the liquor amount to the that needed for cooking does not delay (or at least minimizes any delay) the start of the formally cooking process. Additional time is saved in the batch digesting cycle by filling the digester vessel with chips and liquor simultaneously, rather than by the conventional sequential processes of separately adding chips and liquor to the batch digester. Cycle time may also be saved by preheating the chips in the chip feed system rather than waiting to heat the chips after they fill the vessel.
[0045] After the batch digester vessel 12 has received an appropriate or specified volume or amount of chips, the vessel is capped such that the flow of chips and liquor into the vessel ceases. After the vessel has been capped, the vessel digests, e.g., cooks, the chips using the cooking liquor, heat and pressure to dissolve or remove lignin from the chips and convert the chips to pulp. After completion of the digesting process, the pulp 54 is discharged from the vessel for further processing.
[0046] While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A method for chemically digesting cellulosic fibrous material including: adding a liquor to cellulosic fibrous material to form a slurry in a chip feed system; transporting the slurry from the chip feed system to a batch digester vessel; determining when a chip level rises above an extraction screen in the batch digester vessel; after the chip level rises above the extraction screen, extracting liquor from the batch digester vessel while the transport continues of the slurry into the batch digester vessel; adding cooking liquor to slurry in the batch digester vessel; ceasing the transport of the slurry into the batch digester vessel and thereafter converting the cellulosic material in the vessel to a pulp, and discharging the pulp from the batch digester vessel before restarting the transporting of the slurry into the digester vessel. | 3 |
TECHNICAL FIELD
[0001] This application relates generally to wireless communication. More particularly, this application relates to enhancing connection acquisition using an array antenna.
BACKGROUND
[0002] Radio frequency (RF) signals are commonly used for transmitting and receiving communications wirelessly. Antenna design has played an integral part in technological advancements made with respect to radio communications. Conventionally, a single antenna element such as a dipole antenna has provided an omnidirectional gain, at least within a particular dimensional plane (e.g., the earth's surface). Omnidirectional gain may be characterized by an antenna transmitting somewhat equal amounts of electromagnetic radiation in all directions within the plane, or likewise being equally sensitive to receiving radio frequencies from sources at equal distances around the antenna.
[0003] Clusters of antenna elements transmitting related signals, called array antennas, have been known to strengthen and/or weaken the collective gain of RF signals in particular directions and/or at particular times. For example, four antenna elements transmitting the same signal placed at strategic locations near each other (e.g., one half wavelength apart), may produce a beam, or strengthened gain, within a particular direction extending out from the antenna. Likewise, other directions achieve diminished gain. This is due at least in part to constructive and destructive interference caused by electromagnetic waves emitted from or transmitted to nearby elements. The effect can extend the reach of an array antenna over greater distances or into and through obstacles such as buildings. The effect can also be used to position areas of diminished gain so as to avoid disruptive radio sources or reflections in particular directions.
[0004] Advanced array antennas controlled by digital signal processors can adaptively modify the direction and strength of beams by, for example, making slight modifications to the phase of signals transmitted or received by the various elements of an array antenna. This process is referred to as beamforming, and beams formed in this fashion can extend the range of the array antenna beyond the normal omnidirectional range under equal transmitted power that the antenna might otherwise be limited to. Beamforming techniques have been used to extend the reach of an antenna and also to reduce the interference to the environment in order to maintain ongoing communications with a remote wireless subscriber. However, acquiring connections to wireless subscribers has been limited to the smaller omnidirectional range of the array antenna. This prevents the array antenna from acquiring connections to subscribers outside the omnidirectional range, but within the reach of beams.
SUMMARY
[0005] It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0006] According to one or more embodiments described herein, methods, systems, and computer-readable media provide for enhancing acquisition of connections to wireless subscribers. A beam of an array antenna is allocated for use as an acquisition beam and a coverage area is defined for the beam. The acquisition beam is directed to move around within the coverage area and determine whether a service request signal is received from a wireless subscriber. In this fashion, the wireless subscriber can be located in an area lying beyond the omnidirectional range of the array antenna, but within the beam reach of the array antenna.
[0007] Other embodiments provide methods and systems of enhancing acquisition of connections to wireless subscribers using multiple acquisition beams simultaneously. As the array antenna nears capacity, acquisition beams can be reallocated for the purpose of maintaining ongoing communications with connected subscribers.
[0008] Other systems, methods, and/or computer program products according to embodiments will be or become apparent to one with skill in the art upon review of the following drawings and Detailed Description. It is intended that all such additional systems, methods, and/or computer program products be included within this description, be within the scope of the present invention, and be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a network diagram depicting an example of a base station and system in which one or more embodiments may be implemented;
[0010] FIGS. 2 and 3 are radiation pattern diagrams depicting array antenna gain according to one or more embodiments; and
[0011] FIG. 4 is a flow diagram depicting a process for enhancing the acquisition of connections to wireless subscribers using an array antenna according to one or more embodiments.
DETAILED DESCRIPTION
[0012] The following detailed description is directed to methods, systems, and computer-readable media for enhancing connection acquisition using an array antenna. In the following detailed description, references are made to the accompanying drawings that form a part hereof, and which are shown, by way of illustration, using specific embodiments or examples. Referring now to the drawings, in which like numerals represent like elements through the several figures, aspects of the methods, systems, and computer-readable media provided herein will be described.
[0013] FIG. 1 and the following discussion are intended to provide a brief, general description of a suitable operating environment in which embodiments of the invention may be implemented. While embodiments of the invention will be described in the general context of program modules that execute in a computer system, those skilled in the art will recognize that other embodiments of the invention may also be implemented in combination with other systems and program modules. Generally, program modules include routines, programs, components, data structures, and other types of structures that perform particular tasks or implement particular abstract data types. Moreover, those skilled in the art will appreciate that embodiments of the invention may be practiced with other computer system configurations, including hand-held devices, multiprocessor systems, microprocessor-based or programmable consumer electronics, minicomputers, mainframe computers, set top boxes, and other system configurations capable of executing the methods described. Embodiments of the invention may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a network. In a distributed computing environment, program modules may be located in both local and remote memory storage devices.
[0014] With reference to FIG. 1 , embodiments of the invention may include a system 100 for enhancing wireless connection acquisition using an array antenna 102 . The system 100 may include a base station 103 working in conjunction with the array antenna 102 to enhance the range within which a wireless subscriber 111 may connect his or her wireless equipment 101 to the base station 103 in order to engage in ongoing wireless communication. As used herein, the term wireless subscriber 111 is intended to encompass all users and devices capable of utilizing wireless services and that may be authorized to do so.
[0015] The wireless communication may include data communications between a subscriber's computer 110 with other computers via a network 104 , which may include the Internet. Likewise, the wireless communication may include voice communications (e.g., cellular phone service, Voice over Internet Protocol (VOIP)), broadcast communications (e.g., cable television, Internet Protocol Television (IPTV)), and other services usable over a wireless communication link.
[0016] In acquiring a new connection to the wireless equipment 101 of the wireless subscriber 111 , the base station 103 may communicate with a server 105 via the network 104 in order to authenticate the wireless subscriber 111 and ensure that the subscriber should receive wireless communication access. The wireless equipment 101 may include, for example, a wireless modem, or any other device capable of making a wireless communications connection. The wireless equipment 101 may be handheld in size, or larger, and may utilize one or more wireless communication standards including, but not limited to, Worldwide Interoperability for Microwave Access (WiMAX), third-generation mobile phone (3G), Universal Mobile Telecommunications System (UMTS), Code Division Multiple Access (CDMA), CDMA2000, High-Speed Downlink Packet Access (HSDPA), Global System for Mobile Communication (GSM), Enhanced Data Rates for GSM Evolution (EDGE), General Packet Radio Services (GPRS), Enhanced GPRS (EGPRS), Advanced Mobile Phone System (AMPS), and Digital AMPS (D-AMPS).
[0017] In the configuration of FIG. 1 , the base station 103 includes at least one processing unit 133 , a memory 134 , radio frequency (RF) components 131 , and one or more digital signal processors (DSPs) 132 . The various functional components of the base station 103 may communicate with each other via one or more buses 130 . Other techniques for passing information among components of the base station 103 may be available.
[0018] Components within base station 103 may communicate with other devices, such as the server 105 , via a network such as via a network connection 135 over the network 104 , further discussed below. The network connection 135 may communicate with the network 104 over a wired or wireless communications link. For example, the network connection 135 may facilitate communication over a high-speed optical fiber connected to the network 104 . Alternatively, the network connection 135 may facilitate communication between the base station 103 and the network 104 using a wireless medium, such as a microwave link, for example.
[0019] Within the base station 103 , the processing unit 133 may include one or more microprocessors, microcontrollers, co-processors, field programmable gate arrays (FPGAs), complex programmable logic devices (CPLDs), application specific integrated circuits (ASICs), and other devices capable of executing the methods and operations set forth below. Depending on the configuration of the base station 103 , the memory 134 may be volatile (e.g., Random Access Memory (RAM)), non-volatile (e.g., Read-Only Memory (ROM), flash memory, hard drives), or some combination thereof.
[0020] The memory 134 may serve as a storage location for an operating system, one or more program modules, and/or program data, as well as other modules and data. In various embodiments, the program modules stored in the memory 134 may include an enhanced acquisition module 136 , an application including similar logic, or any other set of instructions comprising such logic. It should be noted that the logic of the enhanced acquisition module 136 may be distributed and/or shared across multiple devices, including the base station 103 , the server 105 , the wireless equipment 101 , and other devices in communication with the base station 103 . More information regarding the function of the enhanced acquisition module 136 is provided below.
[0021] The base station 103 may include general and/or specialized digital signal processors 132 for use in conjunction with the analog radio signals transmitted and received via the RF components 131 . The digital signal processors 132 may convert analog radio frequency signals to digital values, process the digital values, and convert the processed digital values back to analog signals for transmission over the RF components 131 . Processing the digital values may include encoding data into and decoding data from the analog signals. Processing the digital values may further include introducing variations (e.g., phase variations) between analog signals sent for transmission on different elements 120 a - 120 n of the array antenna 102 . These variations may result in differences in the directionality of, or sensitivity to, a radiation pattern for the collection of elements 120 a - 120 n that make up the array antenna 102 . The practice of introducing variations between elements 120 a - 120 n of the array antenna 102 in order to modify the radiation pattern may be referred to as beamforming. The functionality of the DSPs 132 may be replaced or assisted by digital signal processing program modules executing on the processing unit 133 .
[0022] The RF components 131 may include components typically associated with radio transmitters and receivers, including RF amplifiers, modulators, and demodulators. Other components utilized to transmit or receive radio signals via the array antenna 102 may also be part of the RF components 131 . It should be noted that although the array antenna 102 and the base station 103 are depicted as separate components joined by a transmission line 137 , the functionality of the array antenna 102 and the base station 103 may be combined or divided in other ways. For example, the RF components 131 and the DSPs 132 may be packaged with the array antenna 102 , and the remaining components of the base station 103 may communicate with such an antenna package via a digital bus or serial communication line, for example.
[0023] The array antenna 102 is depicted in FIG. 1 as having 16 antenna elements 120 a - 120 n , but other quantities of elements may be used, from two on up. Additional elements may add to the processing complexity required for beamforming, but additional elements may also incrementally increase the range of the antenna, as well as allow for additional simultaneous beams to be formed. The array antenna 102 may be a variety of smart antenna which, in concert with the digital signal processors 132 and RF components 131 , is capable of determining a direction of arrival of an incoming signal and then use beamforming techniques to track the source of the incoming signal and maintain communication. The array antenna 102 may further be a multiple input multiple output (MIMO) type antenna, which is capable of increasing the speed, range, reliability and spectral efficiency of wireless communications.
[0024] The base station 103 may include additional features and functionality other than those shown. For example, the base station 103 may include additional computer storage media, including media implemented in any method or technology for storage of information, including computer readable instructions, data structures, program modules, or other data. Examples of computer storage media can include RAM, ROM, electrically-erasable programmable ROM (EEPROM), flash memory, CD-ROM, DVD, cassettes, magnetic tape, and magnetic disks. Any such computer storage media may be accessed by components within the base station 103 , or which are external to the base station 103 and connected via a communications link (e.g., Bluetooth®, USB, parallel, serial, infrared).
[0025] The base station 103 may also include one or more input devices (not shown) for accepting user input. Examples of the input devices include a keyboard, mouse, digitizing pen, microphone, touchpad, touch-display, and combinations thereof. Similarly, the base station 103 may incorporate or communicate with output devices such as video displays, speakers, printers, and combinations thereof. It should be understood that the base station 103 may also include additional forms of storage, input, and output devices, including communication ports and associated hardware for communicating with external input and output devices rather than including only components within the base station 103 .
[0026] The base station 103 may include one or more network connections 135 that include hardware and/or software which enable the base station 103 and the wireless subscriber 111 to communicate with other devices over the network 104 . The network 104 may include a wireless network such as, but not limited to, a Wireless Local Area Network (WLAN) such as a WiFi network, a Wireless Wide Area Network (WWAN), a Wireless Personal Area Network (WPAN) such as one enabled by Bluetooth® technology, a Wireless Metropolitan Area Network (WMAN) such as a WiMAX network, a cellular network, and/or a satellite network. Alternatively, the network 104 may include a wired network such as, but not limited to, a cable television network, a telecommunications network, a wired Wide Area Network (WAN), a wired (Local Area Network) LAN such as the Ethernet, a wired Personal Area Network (PAN), and/or a wired Metropolitan Area Network (MAN). The network 104 may also include any combination of the networks described above. Communication media, in the form of computer readable instructions, data structures, program modules, or other data in a modulated data signal, may be shared with and by the base station 104 via the communication connection 135 . A modulated data signal may mean a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal, and may include a modulated carrier wave or other transport mechanism.
[0027] FIG. 2 depicts the array antenna 102 with multiple nearby subscribers 204 a , 204 b , 204 c , 204 d , 204 e , 204 f (collectively, the subscribers 204 ), in addition to the omnidirectional coverage 202 , and multiple beams 203 a , 203 b , and 203 c (collectively, the beams 203 ). The depiction of FIG. 2 can be interpreted as a top-down view of the array antenna 102 and subscribers 204 . The top-down view can be interpreted as showing no obstacles between the subscribers 204 and the array antenna 102 . The omnidirectional coverage 202 area may be defined by the overlapping gains of each antenna element 120 a - 120 n considered without constructive and/or destructive interference.
[0028] The array antenna 102 may be a sectored antenna, in that it does not service fully 360 degrees of coverage. Such a sectored antenna may be in use with other sectored antennas, each taking a portion of the compass. Such a configuration may be suited for use on multiple faces of a cell tower, for example. The array antenna 102 may use one or more communication techniques to enable communications with multiple subscribers 204 simultaneously. Communication techniques may include frequency division duplexing (FDD), where different frequencies may be utilized for transmitting and receiving with particular subscribers 204 , and time division duplexing (TDD), where particular subscribers 204 are assigned particular slots of time to transmit or receive information.
[0029] In FIG. 2 , the subscribers 204 a , 204 c , 204 f have successfully initiated their connections with the array antenna 102 , or been acquired. The array antenna 102 , under the command of the base station 103 , has adaptively extended the beams 203 to each of the acquired subscribers 204 a , 204 c , 204 f upon acquisition, possibly to strengthen or extend ongoing communications and/or to increase throughput. Other reasons that the beams 203 may be adaptively extended to the acquired subscribers 204 a , 204 c , 204 f include avoiding or accounting for reflections or other obstacles preventing higher throughput, or to avoid interference or noise from other sources. Although subscriber 204 a is presently outside the omnidirectional range 202 , the subscriber 204 a started inside the omnidirectional range 202 and moved beyond the range. The connection of the subscriber 204 a is maintained because the subscriber 204 a is still within the beam reach of the array antenna 102 . The array antenna 102 , at the behest of the digital signal processors 132 or instructions processed by the processing unit 133 , may adaptively move and modify beam 203 a to account for movements by the subscriber 204 a.
[0030] In some embodiments, when the array antenna 102 acquires a new connection to a subscriber, such as the wireless subscriber 111 , successful acquisition may rely on the wireless subscriber 111 being within the omnidirectional range 202 at some point in time. In FIG. 2 , subscribers 204 b , 204 d , 204 e have not been acquired by the array antenna 102 under this approach because they are outside the omnidirectional range 202 . Although these unacquired subscribers 204 b , 204 d , 204 e could be serviced by additional beams 203 , they are not presently in communication with the array antenna 102 .
[0031] FIG. 3 depicts an alternative method for acquiring connections to nearby subscribers 204 . Here, a beam 301 of the antenna array 102 has been allocated specifically for acquiring connections to subscribers 204 . The acquisition beam 301 extends the acquisition range from beyond the omnidirectional range 202 , at least for the slice of the compass to which it is directed at time t 0 . In order to increase the acquisition range for other slices of the compass, the acquisition beam 301 is move to a second position t 1 after a period of time. After another period of time, a third position t 2 is selected for the acquisition beam 301 .
[0032] The acquisition beam 301 may continue to sweep across the range of the array antenna 102 until it reaches the end of the beam's coverage area 303 , here a sector. At that point, the acquisition beam 301 may be repositioned to a different coverage area or restart in the current coverage area. As the subscribers 204 are detected by the acquisition beam 301 , they may be handed off for processing in order to provision service for ongoing wireless communication with each subscriber. Utilizing the acquisition beam 301 to acquire the subscribers 204 effectively extends the acquisition range of the array antenna 102 from the omnidirectional range 202 to a beam range 302 .
[0033] Although depicted in FIG. 3 as a single sweep through a single coverage area, other embodiments may utilize the acquisition beam 301 differently. Embodiments may, for example, allocate multiple beams as acquisition beams 301 . Each acquisition beam 301 may be responsible for a portion of the available range in a multiple acquisition beam embodiment. For example, two acquisition beams may divide up the coverage area 303 of the array antenna 201 in FIG. 3 . In this example, the coverage area 303 could be divided up into two sections, and a second acquisition beam could start at a position t 10 , for example, moving through the remainder of the sector at the same time that the acquisition beam 301 is moving through the first half of the sector. In a time division duplexing (TDD) communication environment, different numbers of acquisition beams 301 may be allocated during each of multiple time slots.
[0034] In some embodiments, the acquisition beams 301 may additionally be allocated or deallocated depending on the current capacity of the antenna array 102 and the base station 103 . If additional connections are available, and subsequently fewer beams are in use for ongoing communications, additional acquisition beams 301 may be allocated to speed the acquisition process. As the additional subscribers 204 are acquired, and the need for beams for ongoing communications increases, some or all of the acquisition beams 301 may be deallocated or reallocated. Other embodiments need not utilize a sweep of the acquisition beam 301 . It should be noted that the acquisition beam 301 need not move in only a stepped fashion, as depicted in FIG. 3 . The acquisition beam 301 may move in a smooth sweep. Likewise, the acquisition beam 301 or beams may jump from location to location and still accomplish a search for subscribers 204 . Jumping rather than sweeping may be useful when the subscribers 204 are found within particular predictable portions of the acquisition range, for example. Acquisition beams 301 may further be modified in an effort to acquire the subscribers 204 . For example, the strength and breadth of the acquisition beams 301 may be extended or diminished depending on the actual or likely locations of the subscribers 204 , obstacles, radio sources, and other environmental particulars which may affect subscriber acquisition.
[0035] Turning now to FIG. 4 , a flowchart depicting a process 400 for enhancing subscriber acquisition using an antenna array is described. The process 400 may be implemented on one or more computing devices, such as the base station 100 , and may be utilized by embodiments of the enhanced acquisition module 136 . The logical operations of the various implementations presented, may be (1) a sequence of computer implemented acts or program modules running on one or more computing devices, such as the base station 100 , and/or (2) interconnected machine logic circuits or circuit modules within the base station 100 . The implementation is a matter of choice dependent on the performance requirements of the base station 100 on which the embodiments are implemented. Accordingly, the functional operations making up the implementations are referred to variously as operations, structural devices, acts, or modules. It will be recognized by one skilled in the art that these operations, structure devices, acts, and modules may be implemented in software, in firmware, in special purpose digital logic, and/or any combination thereof without deviating from the spirit and scope of the attached claims. Moreover, it will be apparent to those skilled in the art that the operations described may be combined, divided, reordered, skipped, and otherwise modified, also without deviating from the spirit and scope of the attached claims.
[0036] The process 400 begins at operation 401 , when the enhanced acquisition module 136 allocates a beam for use as the acquisition beam 301 . The operation 401 may involve assigning the acquisition beam 301 the task of listening to receive a service request from an unacquired subscriber 204 . Likewise, the acquisition beam 301 may be assigned the task of transmitting a subscriber seeking signal and then awaiting responses. At an operation 402 , the acquisition beam 301 is positioned at the start of its sweep or sequence of locations. This may be an arbitrary location on the compass, or one selected based on the probability of finding a subscriber at that location.
[0037] From the operation 402 , the process 400 continues with an operation 403 , where the acquisition beam 301 listens for service requests, possibly following the transmission of a subscriber seeking signal. Subscriber equipment 101 may repeatedly send a service request signal at a particular frequency or at a particular time, and the acquisition beam 301 may be used to listen for such subscribers. At a decision 404 , the enhanced acquisition module 136 determines whether a request for service is received, then direction and distance information may be forwarded by the enhanced acquisition module 136 to another module for service provisioning at an operation 405 . Direction and distance information may be derived using triangulation techniques based on differences in the phase and amplitude of the service request signal by the different elements 120 a - 120 n of the array antenna 102 . Direction and distance information may alternatively be derived by the subscriber equipment 101 providing a location, such as an address or longitude and latitude coordinates, and the enhanced acquisition module 136 calculating the difference between the locations of the subscriber equipment 101 and the array antenna 102 .
[0038] Service provisioning during processing of the service request at operation 405 may involve authenticating the subscriber equipment 101 and/or the wireless subscriber 111 . If the subscriber equipment 101 achieves sufficiently high throughput utilizing the omnidirectional aspects of the array antenna 102 , then a beam may not be allocated for ongoing communication. However, if throughput is not sufficiently high, then power levels at both the array antenna 102 and the subscriber equipment 101 may be adjusted and/or a beam may be allocated for use by the subscriber equipment 101 . Authentication may involve confirming the identity of the wireless subscriber 111 requesting service. Identity may be confirmed by matching a credential or subscriber identifier with a record in a database of all subscribers 204 . The database of subscribers may be located within the base station 103 locally, or it may be located remotely at the server 105 . When authenticating the identity of the wireless subscriber 111 , a service level associated with the subscriber 111 may be determined, possibly leading to further adjustments of any allocated beams to increase or throttle signal throughput appropriately.
[0039] If the enhanced acquisition module 136 determines that a service request has not been received at decision 404 , or once the service request has been processed or handed off for processing at the operation 405 , then at a decision 406 , the acquisition enhancement module 136 determines whether the current location of the acquisition beam 301 is the last within the particular coverage area defined for the acquisition beam 301 . This determination may be made based solely on the predetermined sweep or sequence, or it may be made based on the need to reallocate the acquisition beam 301 for use in ongoing communication with a recently acquired subscriber 204 . If the current location is not the last location for the acquisition beam 301 , then at an operation 407 , the acquisition beam 301 is repositioned, and the process continues at the operation 403 where a service request signal is awaited.
[0040] Although the subject matter presented herein has been described in conjunction with one or more particular embodiments and implementations, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structure, configuration, or functionality described herein. Rather, the specific structure, configuration, and functionality are disclosed as example forms of implementing the claims.
[0041] The subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims. | An array antenna is utilized to enhance the adaptive acquisition capability of a communication connection with one or more wireless subscribers. Subscribers who are located outside the omnidirectional range of the array antenna are acquired by using adaptive beamforming techniques to create an acquisition beam dedicated to acquiring new connections with wireless subscribers. The acquisition beam may sweep through the coverage of the array antenna seeking subscribers who lie beyond the omni range of the array antenna, but fall within the acquisition range using adaptive beamforming. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates in general to a medication applicator, and more particularly concerns apparatus for the personally adjustable, accurate and sanitary application of vaginal medication.
2. Description of the Prior Art
Known devices for the intravaginal application of medication typically consist of a hollow tubular applicator having an internal piston. The medication, generally of cream-like consistency, is disposed within the hollow applicator and is extruded therefrom by means of the internal piston in the manner of a large, crude hypodermic syringe.
Typical devices for the application of vaginal medication are disclosed for example in U.S. Pat. Nos. 4,496,341; 4,557,720; 5,330,427; 5,397,312; and 5,788,664. Such devices are generally lacking in the control and adjustability of the depth of insertion and amount of medication dispensed.
In order to assure sanitary use and low risk of reinfection, disposable devices have been available which are discarded following a single use. However, such disposable units are generally sold with the medication already contained therein, and are intended to dispense their entire content of medication as a single dose. Such devices are generally not adaptable to variation in the medication type or dosage to accommodate the specific needs of particular individuals.
It is accordingly an object of the present invention to provide a disposable dispenser for the controlled application of vaginal medications.
It is another object of this invention to provide a dispenser as in the foregoing object which facilitates visual and tactile monitoring of medication being dispensed.
It is a further object of the present invention to provide a dispenser of the aforesaid nature permitting comfortable and adjustable insertion.
It is yet another object of this invention to provide a dispenser of the aforesaid nature of simple construction amenable to low cost manufacture.
These objects and other objects and advantages of the invention will be apparent from the following description.
SUMMARY OF THE INVENTION
The above and other beneficial objects and advantages are accomplished in accordance with the present invention by a device for controllably dispensing substances having a paste-like or cream-like consistency comprising:
a) a transparent plastic container member having a cylindrical bore elongated upon a straight axis between open leading and trailing extremities and having demarcation means disposed at spaced intervals along said axis to denote successive regions within said bore of known volume, and
b) a plunger member elongated between forward and rearward extremities and removably associated with said container member by way of slidable engagement with said bore upon a common axis, said forward extremity having a transverse force-applying surface and surrounding outwardly protruding wiping lip, and said rearward extremity having abutment means interactive with the trailing extremity of said bore.
BRIEF DESCRIPTION OF THE DRAWING
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawing forming a part of this specification and in which similar numerals of reference indicate corresponding parts in all the figures of the drawing:
FIG. 1 is a sectional side view of an embodiment of the dispensing device of the present invention.
FIG. 2 is a sectional view taken in the direction of the arrows upon the line 2 — 2 of FIG. 1 .
FIG. 3 is an exploded perspective view of the embodiment of FIG. 1, with a portion broken away to reveal interior details.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 - 3 , an embodiment of the dispensing device 10 of the present invention is shown comprised of container member 11 and plunger member 12 .
Said container member is fabricated of plastic material as a monolithic structure having a cylindrical bore 13 defined by sidewall 20 and elongated upon straight axis 14 between open leading and trailing extremities 15 and 16 , respectively. Said cylindrical bore is preferably of circular cylindrical configuration, having an inside diameter of about 1.50 inch and a length between 6 and 7 inches. Leading extremity 15 is defined by a circular edge 22 , which is rounded for comfort. Demarcation means in the form of a series of annular grooves 17 are fashioned within the smooth interior surface 18 of bore 13 at spaced intervals along axis 14 . Said grooves denote successive regions 19 of known volume within said bore. A first groove 23 of said series is preferably located 1.25 inches from leading extremity 15 . A second groove 24 of said series is preferably located 2.5 inches from said leading extremity, and a third groove 25 is located 3.25 inches from said leading extremity. The spacing of said grooves, in conjunction with the inside diameter of the bore creates incrementally cumulative regions 26 , 27 and 28 which respectively hold approximately 2, 3.5 and 5 grams of cream type medications. Indicia may be located on exterior surface 37 of said container member adjacent said demarcation means to show the corresponding volume of the bore or approximate weight of medication.
The thickness of sidewall 20 , and the nature of the plastic employed to fabricate said container member are chosen so as to cause said sidewall to be transparent. The term “transparent”, as employed herein is intended to define a sidewall structure which permits the external visual discernment of opaque paste-like medication 21 disposed within said bore. Suitable plastics useful in providing the necessary transparency and rigidity of said container member include polyvinyl chloride, acrylic polymers, polycarbonates, cellulose butyrate, ionomer resins and olefin terpolymers. The outside diameter of sidewall 20 is between 1.75 and 2.0 inches.
Plunger member 12 is of cylindrical rod or tube construction, elongated between forward and rearward extremities 29 and 30 , respectively, said extremities having first and second transverse surfaces, 31 and 32 , respectively. Said plunger member is dimensioned and configured to make close fitting insertive sliding engagement with interior surface 18 of bore 13 . First transverse surface 31 is adapted to apply an advancing force to medication disposed within bore 13 . A surrounding lip 33 is disposed about the circular perimeter of said first transverse surface, preferably as a continuous integral extension thereof. Said lip protrudes outwardly from the exterior side wall surface 34 of said plunger, the extent of said outward protrusion being less than 1 millimeter.
The function of lip 33 is to engage grooves 17 within the interior surface 18 of bore 13 . The nature of such engagement is slight, but sufficient to produce a tactile feeling of a discontinuity in the otherwise smooth forward motion of plunger member 12 within bore 13 . In some embodiments, the nature of such engagement may be such as to produce an audible click. It is further to be noted that the seated position of lip 33 within one of the grooves 17 is visually discernible because of the transparent nature of said container member.
Abutment means in the form of collar 35 extends outwardly from rearward extremity 30 of plunger member 12 as a continuous integral extension thereof. One function of collar 35 is to limit forward movement of said plunger member by way of abutment with the trailing extremity 16 of said container member. Another function of collar 35 is to permit manipulative gripping of said plunger member by the user.
In operation, the user will enter medications 21 having paste-like consistency into said container member in desired amounts employing said demarcation grooves as volumetric measuring indicia. Suitable medications are generally sold in squeeze dispensers which facilitate transfer of the medication into said container member. Plunger member 12 is then placed within bore 13 and advanced so as to obtain an accurate, squared off displacement of the medication relative to said grooves. The leading extremity 15 of said container member is then inserted into the vagina and the plunger member is depressed until a click is felt or heard or until the plunger member has come to rest by the action of abutment collar 35 .
The two monolithic plastic components of the dispenser device are of such simple construction and attendant low manufacturing cost as to justify one-time use and disposal of the dispenser.
While particular examples of the present invention have been shown and described, it is apparent that changes and modifications may be made therein without departing from the invention in its broadest aspects. The aim of the appended claims, therefore is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | A hand-operated disposable device for controllably dispensing medications having a paste-like or cream-like consistency includes a transparent plastic container member having a cylindrical medication-holding bore, and a plunger member which slidably engages the bore. The bore has a series of annular grooves corresponding to incremental volumes of the bore, and the plunger has a lip which interacts with the grooves. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to digital video signal processing, and more particularly to pattern generation using a wipe solid generator to provide scaling of a switcher lever arm during wipes between video images that always results in the pattern transition ending or beginning just as the lever arm reaches its limit.
Video switchers or mixers typically include pattern generators as a standard resource. These generators allow wipes from one video signal to another via a changing geometric shape, allow present pattern effects such as spotlights, darkened anonymous faces and split screens, and allow masking effects so that a key is active only within a certain region of a display screen. These pattern generators typically provide a variety of shapes, such as circle, square, diamond, heart, etc., and also include pattern modification controls for position, aspect, rotation, modulation, replication, edge softness and border width.
The wipe patterns are traditionally generated using a wipe solid approach as illustrated in U.S. Pat. No. 4,805,022 issued Feb. 14, 1989 to John Abt entitled "Digital Wipe Generator." To visualize this method, picture an inverted cone, pointing down. By applying a clip and gain function to this three-dimensional shape, a circle is generated. As the clip point moves from the bottom (point of the cone) to the top (base of the cone) of the inverted cone, the circle grows. This is how a circle wipe transition is formed. Many modifiers affect the wipe solid itself. By changing the location of the cone's point on the video screen, the wipe position is modified. By changing the symmetry of the cone, the aspect is changed. Rotation is accomplished by mixing the x and y coordinates of the cone via sine and cosine functions. Modulation is accomplished by varying the position of the cone with various waveforms. Multiple circles are generated by creating a wipe solid consisting of numerous cones. Other modifiers affect the clip and gains. A border is generated by using two clip and gain functions, each with a different clip. The clip separation defines the border width. A low gain produces a soft pattern. By inverting the gain and changing the direction of the clip, the pattern is reversed.
Several problems have traditionally plagued a wipe system. These problems include lever-arm scaling, constant position and consistent sizing.
1. Lever-arm scaling. Each modifier may potentially change the clip values at which the pattern first appears on the screen and vanishes from the screen. This causes difficulty in setting the clip range. Ideally the switcher's lever-arm which controls the clip values causes the pattern to start immediately after it is moved from its end stop, and the pattern vanishes just as the lever-arm travel is complete. Many current switchers lack dynamic lever-arm scaling. Wipes start and end partway through the lever-arm travel, and at extreme pattern positions the wipes "snap" to completion at the end of lever-arm travel.
2. Constant position. One solution to the lever-arm scaling problem is to center the pattern position as the wipe grows. This artifact is often undesirable. It also precludes numerous clip and gain resources from using the same wipe solid since the position of pattern 2 may be modified by the size, i.e., lever-arm position, of pattern 1.
3. Consistent sizing. Some generators provide lever-arm scaling to the detriment of pattern size consistency. A circle in the center of the screen must traverse one-half screen for the pattern to finish the transition. A circle starting from the screen's corner must traverse the entire screen to finish the transition. Therefore, a pattern at fifty percent (50%) lever-arm travel is twice as big if it originates from a corner than if it originates from the screen center. This operation is correct for static pattern position, but the pattern "breathes", i.e., grows or shrinks, as the pattern position is changed to traverse the screen while the lever-arm is not at an end stop. Further a normal wipe features a growing pattern which reveals the new video, while a reversed wipe features a shrinking pattern which conceals the old video. At ten percent (10%) into a circle wipe a small circle is exposed with the new video in the center. For a reversed circle wipe a ten percent transition reveals a large circle with the old video in the center. Pressing the reverse button in the middle of a transition causes the pattern to jump from large to small or vice-versa. What is desired is consistent size regardless of whether the new and old videos are swapped or the direction of movement changes.
SUMMARY OF THE INVENTION
Accordingly the present invention provides pattern generation using a wipe solid generator that provides lever-arm scaling while maintaining size consistency during pattern modification. The wipe solid generator includes H and V ramp generators, modulators, rotation and scaling matrix, offset adders and a variety of ALU functions as well as clip and gain circuits with an offset adder for the clip level, a barrel shifter and multiplier for a high range of gain, and limiters allowing an effective range from zero to unity. The wipe solid generator first generates the values that are used to produce a wipe solid. The minimum and maximum values of the wipe solid are then determined that describe the range of the clip as generated by the lever-arm. The clip range is extended to provide for borders, either sharp pattern edges or soft edges, so that the pattern is fully ON or OFF at the end of the lever-arm travel. Then the lever-arm is scaled by calculating the clip and gain values that are provided to the necessary hardware based upon the minimum, maximum, border and lever-arm position values using recursive values for dynamic scaling.
The objects, advantages and other novel features of the present invention are apparent from the following detailed description when read in conjunction with the appended claim and attached drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a block diagram of a wipe solid generator for generating patterns according to the present invention.
FIG. 2 is a flow chart for pattern generation using the wipe solid generator according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 a wipe solid generator 10 has a waveform generator 12 that receives a video sync input, either composite sync or separated horizontal and vertical syncs, and produces X and Y output digital waveforms. The waveform generator 12 uses conventional H and V counters together with modulators, associated multipliers for rotation and adders for position adjustment. The X and Y waveforms are input to a digital solid generator 14, such as that disclosed in U.S. Pat. No. 4,805,022, to produce a wipe solid (WS) output digital waveform. The waveform generator 12 and solid generator 14 are connected together by a bus 16 to which also is connected a microprocessor 18. The microprocessor 18 provides appropriate control waveforms, data and clock signals to the various modules connected to the bus 16 according to inputs received via an input/output (I/O) port.
Within the waveform generator 12 the slope of the ramp generators is controlled by the microprocessor 18 according to the H and V increments for the respective counters used. The ramp generators output a sawtooth digital signal that is input to a sawtooth to triangle wave converter. Each cycle of the triangle wave output from the converter generates a pair of wipe solids. For non-replicated patterns the gain is set such that the full triangle covers a multiple of full video screens, such as six full video screens or one wipe solid per three video screens. The oversized pattern allows dynamic range for position and modulation functions. The H and V increments are increased for replicated patterns such that the triangle wave occurs multiple times per screen as necessary. The triangle wave ranges from -1 to +1.
The microprocessor 18 controls the initialization of the ramp generators by setting the position of the wipe solids. For non-repeated patterns only one slope of the triangle wave is generated during an active screen. The zero crossing is at the screen center for a centered position. By adding waveforms to the triangle waves modulation is achieved by a modulator. Modulation variables include frequency, phase and amplitude as well as waveform type for both H and V dimensions. Rotation is accomplished by mixing the modulated H and V triangles to form the X and Y outputs. Scaling to optimize dyanmic range and to set aspect ratio also are accomplished in the rotation matrix section according to the following functions:
X=A1*H+B1*V
Y=B2*V+A2*H
where A1, A2, B1 and B2 are generated by the microprocessor 18. Absolute value and invert functions follow the rotation matrix section. The X and Y waveforms without the absolute value function are used to generate edge to edge wipes, while the absolute value function is used to generate center to edge wipes like squares and diamonds. The invert function complements the slope of the ramps and triangles. Aspect adders may be used to modify the aspect of certain rectangular patterns like squares and corner wipes, the aspect values being provided by the microprocessor 18.
The X and Y waveforms are combined by an arithmetic logic unit (ALU) in the solid generator 14 to form the wipe solid (WS). Minimum and maximum functions are used for squares, rectangles and boxes, addition is used for diamonds and diagonals, passing only the X or Y waveform is used for one dimension patterns, and the square root of the sum of the squares is used for circular patterns. The selection of the particular ALU function is provided by the microprocessor 18. Complex patterns, such as hearts, stars and triangles, may be generated by combining various wipe patterns and using more complex ALU functions.
The minimum and maximum values of WS are determined either by using a complex mathematical expression, taking all WS variables into account, or by "simulation." One way to determine the minimum and maximum WS values during the active screen is by selecting the ramp values from up to nine points on the screen, processing these values using the same logic as is implemented by the solid generator 14 with the current variables, and then comparing these values to find the minimum and maximum. For example, the values used may include the center point, the four corners of the screen and the four edge portions to the right, left, top and bottom of the center point. If the center point is outside the active screen, it is not included, nor are the edge intersection points included if they do not intersect an edge of the active screen. These minimum and maximum values describe the range of the clip generated by a lever-arm input to the microprocessor 18 for hard patterns without borders. Simply scaling the lever-arm to generate a clip value to match the range determined by the measured minimum and maximum values results in the undesired breathing pattern.
At the end of the lever-arm travel the pattern is required to be fully OFF or ON depending upon whether the pattern is reversed or not. For sharp pattern edges (high gain) the clip needs to range from just below the minimum to just above the maximum value as determined during the pattern measurement process described above. For soft edges (low gain) this range is insufficient. The clip and gain function may be described as follows:
Output=(Input-Clip.sub.-- Level)*Gain/2+1/2
where the output is limited to a range of zero to one and Clip -- Level and Input range from minus to plus one. For the Output to saturate at a value of one, the Input exceeds the Clip -- Level by a value of 1/Gain. For the Output to clip at a value of zero, the Clip -- Level exceeds the Input by a value of 1/Gain. Therefore the clip range is extended as follows:
MAXIMUM=Maximum+1/Gain
MINIMUM=Minimum-1/Gain
The clip range also is extended for borders. Since the lever-arm ranges from zero to one:
Clip1=Lever.sub.-- Arm*(MAXIMUM-(MINIMUM-Border))+(MINIMUM-Border)
Clip2=Lever.sub.-- Arm*((MAXIMUM+Border)-MINIMUM)+MINIMUM
The Clip1 and Clip2 values are separated by the Border value, and Clip1 and Clip2 are limited to the maximum allowable range of the clip and gain function, i.e., minus to plus one. To reverse the pattern, Gain is inverted and Lever -- Arm is complemented:
Reverse.sub.-- Gain=-Gain
Reverse.sub.-- Lever.sub.-- Arm=1-Lever.sub.-- Arm
The microprocessor 18 calculates the values used by the solid generator 14 based on the most recent set of user inputs. These values are downloaded to the hardware from the microprocessor 18 during a vertical interval interrupt. The extent (minimum and maximum) of WS are measured within the active picture screen. The clip extensions for border size and softness (1/gain) are calculated. At this point the microprocessor 18 selects one of three scaling functions for the lever-arm depending upon whether input changes have been made that (i) do not cause pattern breathing without pattern reversal, (ii) do not cause pattern breathing with pattern reversal, or (iii) induce pattern breathing (reset pattern size as in selection of a new pattern). Using the appropriate scaled lever-arm value, the clip and gain values are calculated and downloaded to the hardware.
The wipe solid generator 10 may have multiple clip and gain functions associated with it. Each clip and gain function may have independent lever-arm values, softnesses and border sizes. Each clip and gain function then needs independent recursive memory for the lever-arm scaling function. Each lever-arm scaling function has as inputs (i) the lever-arm value, (ii) a pointer to the measured minimum and maximum WS values, and (iii) a pointer to the memory area specific to the particular clip and gain function. The last pointer references the previously calculated clip extensions due to border size and softness as well as recursive memory locations for Old -- Clip, Old -- Lever and Synth -- Lever. The outputs of the scaling functions are stored in the three recursive memory locations.
1. No Pattern Breathing without Reversal
The basic concept is to calculate a virtual lever-arm position after a change in minimum or maximum WS values while maintaining the same clip levels, and then to change this virtual lever-arm value based on the change in position of the actual lever-arm. The new clip values are then based on the new synthesized lever-arm and the new minimum and maximum WS values.
The virtual lever-arm value after a minimum or maximum value change is determined as follows:
MINIMUM=Minimum--Softness.sub.-- Extend--(Border.sub.-- Extend/2)
MAXIMUM=Maximum+Softness.sub.-- Extend+(Border.sub.-- Extend/2)
Virtual.sub.-- Lever.sub.-- Arm= (Old.sub.-- Clip-MINIMUM)/(MAXIMUM-MINIMUM)
For example if the old MAXIMUM was 0.75, the old MINIMUM was 0.25 and the previous lever-arm and clip values were 0.5, and the new MINIMUM after a pattern position change becomes zero, then Virtual -- Lever -- Arm becomes 0.667, since to maintain a clip level of 0.5 the virtual lever-arm needs to be at a two-thirds position. Once Virtual -- Lever -- Arm is determined, then six cases are considered when determining the outputs.
A. Actual Lever-Arm at Minimum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MINIMUM
Old.sub.-- Lever=0
Synth.sub.-- Lever=0
B. Else Actual Lever-Arm at Maximum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MAXIMUM
Old.sub.-- Lever=1
Synth.sub.-- Lever=1
C. Else (Old-Clip=<MINIMUM) and (Lever -- Arm>=Old -- Lever)
In this case the pattern is not started, yet the lever-arm is mid-way and may be decreasing. For example, this occurs when a partially open pattern is moved off screen. The following is entered into the recursive memory for input to the next set of calculation:
Old.sub.-- Clip=Virtual.sub.-- Lever.sub.-- Arm*(MAXIMUM-MINIMUM)+MINIMUM
Old.sub.-- Lever=Lever-Arm
Synth.sub.-- Lever=Virtual.sub.-- Lever.sub.-- Arm
The value of Old -- Clip may likely be less than MINIMUM since Virtual -- Lever -- Arm likely is less than zero.
D. Else (Old -- Clip>=MAXIMUM) and (Lever -- Arm>=Old -- Lever)
In this case the pattern is complete, yet the lever-arm is mid-way and may be increasing. For example, this occurs when a large pattern is moved from off-screen to on-screen. The following is entered into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=Virtual.sub.-- Lever.sub.-- Arm*(MAXIMUM-MINIMUM)+MINIMUM
Old.sub.-- Lever=Lever.sub.-- Arm
Synth.sub.-- Lever=Virtual.sub.-- Lever.sub.-- Arm
The value of Old -- Clip may be greater than MAXIMUM since Virtual -- Lever -- Arm likely is greater than one.
E. Else Lever -- Arm>Old -- Lever
In this case the pattern is partially open and the lever-arm is in transition and is increasing. The following is entered into the recursive memory for input to the next set of calculations: ##EQU1##
Old.sub.-- Lever=Lever.sub.-- Arm
The synthesized lever-arm is based on the virtual lever-arm plus the lever-arm change scaled by the ratio of the distance of the virtual lever-arm to its end stop to the distance of the actual lever-arm to its end stop.
F. Else
In this case the pattern is partially open and the lever-arm is in transition and is decreasing or has not changed. The following is entered into the recursive memory for input to the next set of calculations:
Synth.sub.-- Lever=Virtual.sub.-- Lever.sub.-- Arm+((Lever.sub.-- Arm-Old.sub.-- Lever)*(Virtual.sub.-- Lever.sub.-- Arm-0)/(Lever.sub.-- Arm-0))
Old.sub.-- Clip=Synth.sub.-- Lever*(MAXIMUM-MINIMUM)+MINIMUM
Old.sub.-- Lever=Lever.sub.-- Arm
The synthesized lever-arm is based on the virtual lever-arm plus the lever-arm change scaled by the ratio of the distance of the virtual lever-arm to its beginning stop to the distance of the real lever-arm to its beginning stop.
2. No Pattern Breathing with Reversal
The basic concept is the same as the first scaling function. The virtual lever-arm value after a minimum or maximum change is determined as in the first scaling function. The corresponding six cases are determined as follows.
A. Actual Lever-Arm at Minimum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MAXIMUM
Old.sub.-- Lever=0
Synth.sub.-- Lever=1
B. Else Actual Lever-Arm at Maximum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MINIMUM
Old.sub.-- Lever=1
Synth.sub.-- Lever=0
C. Else (Old -- Clip>=MAXIMUM) and (Lever -- Arm=<Old -- Lever)
In this case the pattern is not started (fully open), yet the lever-arm is midway and may be decreasing. For example, this occurs when a large pattern is moved from off-screen to on-screen. The following is entered into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=Virtual.sub.-- Lever.sub.-- Arm*(MAXIMUM-MINIMUM)+MINIMUM
Old.sub.-- Lever=Lever.sub.-- Arm
Synth.sub.-- Lever=Virtual.sub.-- Lever.sub.-- Arm
Old -- Clip may likely be greater than MAXIMUM since Virtual -- Lever -- Arm likely is greater than one.
D. Else (Old -- Clip=<MINIMUM) and (Lever -- Arm>=Old -- Lever)
In this case the pattern is complete (fully closed), yet the lever-arm is midway and may be increasing. For example, this occurs when a small pattern is moved off-screen. The following is entered into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=Virtual.sub.-- Lever.sub.-- Arm*(MAXIMUM-MINIMUM)+MINIMUM
Old.sub.-- Lever=Lever.sub.-- Arm
Synth.sub.-- Lever=Virtual.sub.-- Lever.sub.-- Arm
Old -- Clip may likely be less than MINIMUM since Virtual -- Lever -- Arm likely is less than zero.
E. Else Lever -- Arm>Old -- Lever
In this case the pattern is partially open and the lever-arm is in transition and is increasing. The following is entered into the recursive memory for input to the next set of calculations: ##EQU2## The synthesized lever-arm is based on the virtual lever-arm minus the lever-arm change scaled by the ratio of the distance of the virtual lever-arm to its beginning stop to the distance of the actual lever-arm to its end stop.
F. Else
In this case the pattern is partially open and the lever-arm is in transition and is decreasing or has not changed. The following is entered into the recursive memory for input to the next set of calculations: ##EQU3## The synthesized lever-arm is based on the virtual lever-arm minus the lever-arm change scaled by the ratio of the distance of the virtual lever-arm to its end stop to the distance of the actual lever-arm to its beginning stop.
3. Breathing Pattern (Reset Pattern Size)
The basic concept in this function is to determine a new clip value, as compared to lever-arm position, after a change in minimum or maximum WS values while maintaining the same virtual lever-arm value. The new clip value after such a change is:
New.sub.-- Clip=Synth.sub.-- Lever*(MAXIMUM-MINIMUM)+MINIMUM
For example if the old MAXIMUM was 0.75, the old MINIMUM was 0.25, and the synthetic lever-arm and clip values were 0.5, and the new MINIMUM after a pattern position change becomes zero, then the new clip value is 0.375 since Synth -- Lever of 0.5 selects a clip value midway between the new MINIMUM and MAXIMUM values. In this case there are five cases to consider.
A. Actual Lever-Arm at Minimum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MINIMUM
Old.sub.-- Lever=0
Synth.sub.-- Lever=0
B. Else Actual Lever -- Arm at Maximum End Stop
The system is reset by entering the following into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=MAXIMUM
Old.sub.-- Lever=1
Synth.sub.-- Lever=1
C. Else New -- Clip<MINIMUM
In this case the pattern is not started, yet the lever-arm is between end stops. For example, this occurs when a partially open pattern is moved off-screen and this function is called due to a new pattern selection. The system is reset as in Case A.
D. Else New -- Clip>MAXIMUM
In this case the pattern transition is complete, yet the lever-arm is between end stops. For example, this occurs when a large off-screen pattern is moved on-screen and this function is called due to a new pattern selection. The system is reset as in Case B.
E. Else
In this case the pattern is partially open, the lever-arm is not at its end stops and a new pattern has been selected, engaging this function. The following is entered into the recursive memory for input to the next set of calculations:
Old.sub.-- Clip=New.sub.-- Clip
Old.sub.-- Lever=Old.sub.-- Lever
Synth.sub.-- Lever=Synth.sub.-- Lever
Synth -- Lever and Old -- Lever are not changed because this function does not handle lever-arm changes, but merely resets the size of a newly selected pattern.
Once the proper scaling function has been executed, then the clip levels are determined by Synth -- Lever as well as Border -- Extend and Soft -- Extend, with special consideration given to reversed patterns. To ensure there is no hint of a pattern when Synth -- Lever is at the extremes, the clip levels are set at -1 when Synth -- Lever=0 and at +1 when Synth -- Lever=1.
For non-reversed patterns: ##EQU4##
For reversed patterns: ##EQU5## The gain is sent directly to the clip and gain functions for non-reversed patterns, and is inverted for reversed patterns.
Although a particular set of mathematical expressions have been given as an illustration of the present invention, these expressions may be altered so that the recursive variables may include the old minimum and maximum values or differences between a calculated lever-arm position and the actual position. Any implementation of pattern generation that is based on wipe solids and uses recursive values to dynamically scale the lever-arm is contemplated by the present invention.
Thus the present invention provides pattern generation using a wipe solid generator by dynamically scaling the lever-arm using wipe solids and recursive values so that a pattern transition ends or begins just as the lever-arm reaches its end stops while maintaining size consistency during changes in position, pattern selection and other modifiers including pattern reverse. | A method of pattern generation for a screen using a wipe solid generator and a recursive memory includes generating from operator inputs a wipe solid. An extent of the generated wipe solid is measured to produce maximum and minimum values. These maximum and minimum values are extended to encompass a desired border size and softness. A lever-arm scaling function is selected based upon whether a change in operator input causes a reversal in pattern and/or causes the pattern to "breathe." The selected lever-arm scaling function uses prior values from the recursive memory to generate new values that are stored in the recursive memory. From the stored values clip levels are determined such that completion of lever-arm movement to a limit position coincides with completion of the pattern without distortion of the size of the pattern. | 7 |
BACKGROUND
[0001] The present invention relates to switching devices and, more specifically, to field effect transistors (FETs) formed with carbide drains and sources.
[0002] Switching devices based on nanostructures such as carbon nanotubes, graphene, or semiconducting nanowires have potential due to the high carrier mobility and small dimensions that such nanostructures can provide. However, one of the many challenges a technology based on such nanostructures must overcome is compatibility with the high layout density that traditional silicon CMOS technology currently supports. For high layout density, the source/drain and gate contacts to the switching device built around each nanostructure must all be precisely positioned. In silicon CMOS, this precise positioning is enabled by using gate shadowing to define implanted junction profiles and by the self-aligned silicide process.
SUMMARY
[0003] According to one embodiment of the present invention, a field effect transistor is disclosed. The field effect transistor of this embodiment, a metal carbide source portion, a metal carbide drain portion, an insulating carbon portion separating the metal carbide source portion from the metal carbide portion. The field effect transistor also includes a nanostructure formed over the insulating and carbon portion and connecting the metal carbide source portion to the metal carbide drain portion and a gate stack formed on over at least a portion of the insulating carbon portion and at least a portion of the nano structure.
[0004] According to another embodiment a method of forming a field effect transistor is disclosed. The method of this embodiment includes forming a substrate; forming an insulating layer over the substrate; forming an insulating carbon layer over the substrate; depositing one or more nanostructures on an upper surface of the insulating carbon layer; covering at least a portion of the one or more nanostructures and any insulating carbon under the covered nanostructures with a gate stack; and converting exposed portions of the insulating carbon layer to a metal carbide.
[0005] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with the advantages and the features, refer to the description and to the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The forgoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0007] FIG. 1 shows an early stage in the production of FET according to one embodiment of the present invention;
[0008] FIG. 2 shows the structure of FIG. 1 after an active region has been patterned into the carbon layer.
[0009] FIG. 3 shows the structure shown in FIG. 2 after a gate stack has been formed over a portion of the active region.
[0010] FIG. 4 shows the structure of FIG. 3 after spacers have been formed on the sidewalls of the gate stack.
[0011] FIG. 5 shows the structure of FIG. 4 after the carbon first portion and carbon second portion have been converted to a metal carbide.
DETAILED DESCRIPTION
[0012] One embodiment of the present invention is directed to a self-aligned carbide source/drain contact formation process for a FET having a nanostructure based channel region. In particular, disclosed herein is a platform for building self-aligned devices from any deposited nanostructure, including carbon nanotubes, graphene, or semiconducting nanowires. The nanostructures are deposited on an insulating carbon underlayer, and a gate stack is patterned atop the nanostructures. Metal is then deposited everywhere. Any region of the carbon under-layer not protected by the gate stack is converted to a metal carbide contact, and the metal is then removed selectively to the metal carbide contacts, resulting in metal carbide source/drain contacts which are self-aligned to the gate stack.
[0013] With reference now to FIG. 1 , an example of a wafer in the production process of a FET according to one embodiment of the present invention is shown. The wafer includes a substrate 102 . The substrate 102 may be formed of any material but, in one embodiment, is formed of silicon or a silicon based material. An insulating layer 104 is formed on top of the substrate 102 . The insulating layer 104 may be formed of any electrical insulator. In one embodiment, the insulating layer 104 is formed of a silicon nitride. In another embodiment, the insulating layer 104 is a Buried silicon OXide (BOX) layer.
[0014] A carbon layer 106 is formed over the insulating layer 104 . As will be shown in greater detail below, both the source and drain of a FET is formed in this layer. In one embodiment, the carbon layer 106 is an insulating carbon layer that remains insulating even when exposed to high (greater than annealing) temperatures. On example of such an insulating carbon is a diamond based layer. The diamond based layer may be a crystalline film, a polycrystalline film, or a nano or ultranano crystalline diamond film. The diamond film may be deposited by a variety of chemical vapor deposition (CVD) processes including, without limitation, thermal, hot-wire or microwave assisted CVD. In one embodiment, the carbon layer may be a diamondlike, or an amorphous carbon material.
[0015] One or more nanostructures 108 are formed or deposited on top of the carbon layer 106 . For example, the nanostructures 108 may be carbon nanotubes, graphene, or semiconducting nanowires. In one embodiment, the nanostructures 108 become conductive when voltage is applied to them and non-conductive otherwise. As shown in greater detail below, the nanostructures 108 form the channel of a FET in one embodiment.
[0016] FIG. 2 shows the structure of FIG. 1 after an active region 202 has been patterned into the carbon layer 106 . As shown, a disposable hard mask such as silicon dioxide may have been deposited and patterned over the active region, and then the exposed portions of the carbon layer 106 removed. Of course, the carbon layer 106 could have been formed as shown in FIG. 2 directly. Alternately, instead of removing the non-active regions of the carbon, the non-active regions of carbon could be covered by a hardmask such as silicon nitride.
[0017] Each active region 202 may be used to form one or more FETs. The number of nanostructures 108 is variable and may be one or more. It will be understood that the more nanostructures 108 used to form a channel, the more current the FET will carry in the “on” state.
[0018] FIG. 3 shows the structure shown in FIG. 2 after a gate stack 302 has been formed over a portion of the active region 202 . The gate stack 302 includes a gate dielectric layer 304 . The dielectric layer 304 may be formed of any type of dielectric.
[0019] The gate stack 302 also includes a gate 306 . The gate may be formed of any appropriate gate material, including polysilicon (which can be doped and/or silicided) and metal.
[0020] The orientation of the gate stack 302 may be varied. However, in one embodiment, the gate stack 302 is not parallel to one or more of the nanostructures 108 . In one embodiment, the gate stack 302 has a length w and is disposed such that the l is substantially perpendicular to a nanostructure length l. The angle between w and l is not limited an may vary from 1 to 179 degrees. The gate stack 302 preferably causes the active region to be divided into at least a first portion 308 and a second portion 310 . It shall be understood that multiple gate stack 302 may be placed on a single active region 202 , forming stacked FETs, and that one gate stack 302 can run over multiple active regions 202 , forming multiple FETs with gates that are tied together.
[0021] In one embodiment, the exposed portions of the nanostructures 108 may be modified at this point in the production run. The modification may include, but is not limited to, chemical doping or implanting and may vary depending on the circumstances.
[0022] FIG. 4 shows the structure of FIG. 3 after spacers 402 have been formed on the sidewalls of the gate stack 302 . In FIG. 4 (and FIG. 5 below), the portion of the gate stack 302 (and the spacers 402 formed on its side) extending beyond the active region are not shown in order to illustrate the structure more clearly.
[0023] The spacers 402 may be formed, for example, by a conform material deposition followed by an anistropic etch. In one embodiment, the spacers 402 are formed of a silicon nitride material.
[0024] FIG. 5 shows the structure of FIG. 4 after the carbon first portion 308 and carbon second portion 310 have been converted to a metal carbide. The structure shown in FIG. 5 may be (with addition of one or more connectors) operated as a FET. The metal carbide first portion 308 ′ and the metal carbide second portion 310 ′ are separated by an insulating carbon portion 502 . The insulating carbon portion 502 is formed by the portion of the active region 202 that is covered by the gate stack 302 and spacers 402 .
[0025] The first portion 308 and carbon second portion 310 may be converted to the metal carbide first portion 308 ′ and the metal carbide second portion 310 ′ by depositing a metal over the structure of FIG. 4 , annealing to a temperature high enough to for the metal and carbon to react, and etching the remaining unreacted metal to form a metal carbide from the first portion 308 and the second portion 310 . To enable this process, the metal must not react with the spacers formed on the gate sidewall. The metal may or may not react with the exposed portions of the deposited nanostructures 108 . The metal may or may not react with the gate material. Removal of the un-reacted metal must be performed selectively to the gate metal, metal carbide, spacers, and any other expose material on the wafer.
[0026] The metal carbide first portion 308 ′ may form a source contact and the metal carbine second portion 310 ′ may form a drain contract, or vice versa, to the portion of the nanostructure 108 that is underneath the gate. Regardless, the source and drain are separated by insulating carbon portion 502 . Accordingly, in the absence of an external voltage applied to the gate 306 , the source and drain are electrically separated.
[0027] A portion of the nanostructure 108 is under the gate stack 302 . Application of a voltage to the gate 306 will cause that portion of the nanostructure 108 under the gate stack 302 to become conductive. Once conductive, the nanostructure 108 electrically couples the metal carbide first portion 308 ′ and the metal carbide second portion 310 ′ and allows for current to pass between them.
[0028] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
[0029] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the invention. The embodiment was chosen and described in order to best explain the principles of the invention and the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated
[0030] The flow diagrams depicted herein are just one example. There may be many variations to this diagram or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0031] While the preferred embodiment to the invention had been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described. | A field effect transistor includes a metal carbide source portion, a metal carbide drain portion, an insulating carbon portion separating the metal carbide source portion from the metal carbide portion, a nanostructure formed over the insulating and carbon portion and connecting the metal carbide source portion to the metal carbide drain portion, and a gate stack formed on over at least a portion of the insulating carbon portion and at least a portion of the nanostructure. | 1 |
BACKGROUND, BRIEF SUMMARY, AND OBJECTS OF THE INVENTION
This invention relates generally to rotary dyeing machines and more particularly to a new and improved dyeing system for effectively reducing the tangling of goods being dyed and retaining the goods in an oriented manner.
The invention will be described hereinbelow primarily with reference to the dyeing of hosiery. It is to be understood, however, that reference to hosiery or hosiery articles is not to be construed as an indication that the invention is so limited but is intended to include various articles and garments such as pantyhose, tights, socks, ladies conventional stockings, knee high garments and the like.
In conventional dyeing of hosiery, a series of bags are filled with light flexible articles, and the bags packed into the chamber of a rotary dyeing machine. The machine is filled with a dye bath and the bags moved in a generally circular path upon rotation of the machine cylinder. Wetting of the articles with the dye bath results in the articles becoming more compact, and coupled with the rotary displacement of the bags in the chamber, the bags and articles therein have room to move about resulting in tangling of the articles.
In the present invention, as the articles tend to be more compact and occupy less space due to being wet with the dye bath, means are provided for effectively selectively reducing the size of the chamber within which the bags are located thus maintaining the bags in close, compact association with each other and substantially eliminating tangling of the individual articles with each other. This, in turn, reduces product damage. Also, the articles are retained in an oriented, orderly fashion within the bags which facilitates handling of the articles in subsequent work operations. The chamber is divided into plural compartments by a partition means and each compartment is provided with a plate which normally abuts bags of articles within the compartment but which is capable of displacement for reducing the effective size of the compartment. The plate may be hinged adjacent one edge to the partition means with the opposite edge portion being permitted to swing in an arc in close proximity to the inner surface of the cylinder peripheral wall defining the compartment. The plate and bags are displaced as the cylinder rotates to reduce the amount of space within which the bags are retained, and a latch means may be provided to prevent the plate from returning back to its original position until completion of the dyeing cycle. A fluid means may be provided to urge the plate in a direction to reduce the effective size of the chamber upon shrinkage of the bags of articles. A stop mechanism may also be provided to limit the maximum extent that the plate may pivot so as not to over-compact the bags of hosiery.
The primary object of the invention is the provision of a new and improved dyeing system which significantly reduces tangling of the goods and retains them in an oriented manner during the dyeing process.
Another object of the invention is the provision of a means for, in effect, reducing the space occupied by the goods during the dyeing cycle to restrict movement of the bags and goods therein.
Still another object of the invention is the provision of a new and improved machine for dyeing delicate, flexible articles which results in less damage to the goods and reduced costs.
Other objects and advantages of the invention will be readily apparent to those skilled in the art during the course of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic, front elevational view, with portions broken away, of the dyeing machine.
FIG. 2 is an enlarged, schematic, sectional view taken from one end of the machine cylinder illustrating one embodiment of an assembly for variably reducing the amount of space within which bags of hosiery are located during the dyeing cycle.
FIG. 3 is a fragmentary, schematic, perspective view, with parts broken away, of the machine cylinder.
FIG. 4 is an enlarged view of a latching mechanism for the pivotable plate.
FIG. 5 illustrated another embodiment of an assembly for variably effectively reducing the size, during the dyeing cycle, of the compartment housing the goods being dyed.
DETAILED DESCRIPTION OF THE INVENTION
Referring initially to FIG. 1, number 10 generally represents the dye vat or dyeing machine which includes a stationary, generally cylindrical casing or housing 12 mounted upon standards 14 provided with conventional bearing members 16.
Referring to FIG. 3, a cylinder 20 is rotatably mounted upon a horizontal axis within the casing 12. The cylinder 20, having a perforated, peripheral wall 22, is provided with end heads 24 thus defining a chamber 25. The end heads 24 are provided with suitable shaft members 26 rotatably received in the bearing members 16, and variably driven through gearing or other suitable means from a drive motor 28.
A suitable dye bath and other liquids may be directed into the dye vat through inlet conduit 32 and removed from the vat via drain line 34. Conventional controls, pumps, control valves, etc. may be provided for the dyeing, rinsing, and finishing phases of the operation, including circulating of the liquids to and from the machine. The dye or dyes employed in a particular operation will vary depending upon the nature of the fibrous materials being dyed, i.e., whether synthetic or natural fibers, and a number of manufacturing variables and preferences.
In order to provide access to the cylinder 20, the casing 12, which is of conventional construction, includes a fixed lower portion 40 and an upper pivotable or slidable door or closure 42. As shown in FIG. 2, the cylinder 20 is provided with sets of diametrically opposed doors 44 for providing access to the chamber 25. In FIG. 2, one set of doors at the right are in the opened positions and the set of doors to the left are closed.
It is to be noted that a conventional perforated or otherwise open-work type construction partition 50 extends between end walls 24,24 and diametrically across the chamber 25 with opposite ends secured in a suitable manner to the peripheral wall 22 of the cylinder. The partition divides the chamber into two equal compartments 52 and 54. Note that one set of doors 44 provide access to compartment 52 while the diametrically opposite set of doors provide access to compartment 54.
Within each of the compartments 52 and 54 is a displaceable, generally rectangular plate 60. Each plate 60 extends generally from one end plate 24 to the other and is hinged along one edge portion in a conventional manner as at 62 to the partition 50 and in close proximity to the axis of rotation of the cylinder. The plates 60 may be of various types of open-work construction permitting fluids to pass freely therethrough.
In the embodiment of FIG. 2, upon rotation of the cylinder 20 in a counterclockwise direction, centrifugal force moves the plates 60 from the solid line positions along paths indicated by arrows P to, in effect, reduce the sizes of compartments 52 and 54. A latch mechanism 70 is provided for each plate 60 to prevent the plate from moving back to its original position. Also, an adjustable stop assembly 84 is provided to selectively vary the maximum extent of pivotable displacement of the plate.
As illustrated in FIGS. 2 and 4, each latch assembly includes a spring biased plunger mechanism 72 fixed to the plate 60 and a series of ratchet teeth 74 secured to the inner surfaces of the peripheral wall 22 of the cylinder 20. Member 76 is provided to be gripped by an operator to overcome the pressure of spring 78 acting on the plunger plate 80 to move the plunger to the right, FIG. 4, to disengage the teeth 74 and permit the plate 60 to be returned to the full line position, FIG. 2. Other types of latch assemblies could be employed equally well. Also, a latch assembly could be employed at each end of each pivotable plate 60.
Each adjustable stop assembly 84 includes an elongated member 86 suitably secured by welding or other fasteners to an end plate 24 and having a series of openings 88 therein for selectively, releasably receiving a stop element 90. The element 90 extends outwardly into the path of displacement of the moveable plate 60 for engagement thereby. Positioning the element 90 within a selected opening 88 serves to limit the extent of movement of plate 60 to a desired extent. A stop assembly 84 may be provided to limit the movement of each end of each plate.
FIG. 5 illustrates another embodiment of the invention for effectively reducing the size of a compartment, within which garments or hosiery articles are placed, during a dyeing operation by applying a biasing force to the hinged plate. As illustrated, a fluid mechanism 90a may be provided to act between a partion 50 and a hinged plate 60. A fluid under a predetermined, selected pressure may be directed from a suitable source 92 to an expandable bag 94 such that upon shrinking of the bags of hosiery articles due to the wetting by the dye bath and centrifugal force applied to the bags upon rotation of the cylinder, such pressure is sufficient to urge plate 60 away from partition 50 such that the plate is maintained in contact with the bags to apply pressure thereto.
The fluid assembly 90a urges the plate 60 in a direction to reduce the amount of space that the bags occupy. Maintaining pressure on the bags as taught by the embodiments of FIGS. 2 and 5 prevents the bags and delicate, flexible articles therein from moving with a compartment, thus reducing tangles and consequently picks, while maintaining the articles in an oriented manner within the bags.
The embodiment of FIG. 5 may also be provided with a latch assembly 70 and a stop assembly 84 if so desired.
Alternatively, rather than a bag 94, a fluid cylinder could be utilized to apply pressure to the plate 60. A spring assembly could also be employed to apply a biasing force to the plate.
While only one pressure applying means, that in compartment 52, has been shown on FIG. 5, it is to be understood that such means would also be provided in compartment 54. Further, while the chamber 25 of cylinder 20 has been shown as being divided into two compartments, it is to be understood that additional partitions 50 and sets of doors 44 could be provided to divide such cylinder chamber into three, four or more compartments.
In the operation of the machine, the door 42 is moved to the open position to provide access to the cylinder 20 and the cylinder is positioned with one set of doors 44 in the opening. The doors are opened providing access to a compartment and bags filled with dry hosiery articles are loaded to fill the compartment. The doors are closed, the cylinder is rotated to a predetermined position and bags are loaded into another compartment. Upon loading of all compartments, a dye bath is directed into the machine. Wetting of the bags and articles therein causes them to shrink or reduce in size, thus providing extra space within the compartment. Upon rotation of the machine cylinder centrifugal force tends to move the bags towards the rear of the compartments (in the direction of rotation of the cylinder) and a force is applied to the plates 60 to move them into engagement with the bags, reducing the sizes of the compartments and preventing excessive bag movement. The plungers 72 and ratchet teeth 74 prevent retractive movement of the plates until released by an operator after the dyeing operation.
It is to be understood that the invention is susceptible to various changes and modifications without departing from the scope of the invention as defined in the appended claims. | In a rotary dyeing system for dyeing hosiery articles, a rotary cylinder is divided into a plurality of compartments for receiving bundles of dry articles therein. Each compartment is provided with a pivotable plate means which, upon wetting of the articles and shrinkage thereof, is forced during the dyeing cycle against the articles to maintain them compact and stationary to prevent tangling thereof. | 3 |
FIELD OF THE INVENTION
[0001] The present invention is directed to a gene delta-6 desaturase isolated from Schizochytrium. It is further directed to the cloning of delta-6 desaturase derived from Schizochytrium in Yeast. The nucleic acid sequence and the amino acid sequences of the delta-6 desaturase are disclosed. Further disclosed are the constructs, vector comprising the gene encoding the enzyme delta-6 desaturase in functional combination with the heterologous regulatory sequences. The novel delta-6 desaturase can be used in a metabolic pathway to convert linoleic acid to gamma linolenic acid (omega-6 pathway). The invention provides the identification, isolation of these novel nucleic acids from Schizochytrium that encode the above-mentioned proteins. The invention specifically exemplifies recombinant yeast cells harboring the vector comprising the delta-6 desaturase gene and by the virtue of the enzyme produced shall be able to produce gamma-linolenic acid. The polyunsaturated fatty acids produced by use of the enzyme may be added to pharmaceutical compositions, nutritional compositions, animal feeds, as well as other products such as cosmetics.
BACKGROUND OF THE INVENTION
[0002] Delta-6 desaturases are the key enzymes required for the synthesis of highly unsaturated fatty acids such as Arachidonic acid, docosahexaenoic acid. The major metabolite product of the n-6 pathway is arachidonic acid (20:4n-6), whilst the major end products of the n-3 pathway are eicosapentanoic acid (EPA) (20:5n-3) and docosahexaenoic acid (DHA) (22:6n-3). The availability of 20- and 22-carbon (n-6) and (n-3) polyenoic fatty acids is greatly dependant upon the rate of desaturation of 18:2(n-6) and 18:3 (n-3) by delta-6 desaturase. Delta-6 desaturase is a microsomal enzyme and is thought to be component of a three-enzyme system that includes NADH-cytochrome b5 reductase, cytochrome b5 and delta-6 desaturase. Delta-6 desaturases catalyses the first and the rate limiting step of the PUFA synthesis. It acts as a gateway for the flow of fatty acids through the desaturation and the elongation pathway. Although it can act on any long chain fatty acid, the substrate binding affinity increases greatly with the number of double bonds already present. Recent identification of a human case of delta-6 desaturase deficiency underscores the importance of this pathway (Nakamura et al., 2003).
[0003] Unsaturated fatty acids such as linoleic acid and alpha-linoleic acid are essentially dietary constituents that cannot be synthesized by vertebrates since the vertebrate cells can introduce double bonds at the delta-9 position of the fatty acids but cannot introduce additional double bonds between the delta-9 and the methyl terminus of the fatty acid. Hence it is evident that animals cannot desaturate beyond the Delta-9 position and therefore cannot convert oleic acid to linoleic acid, likewise gamma-linolenic acid cannot be synthesized by mammals. Because they are precursors of other products, linoleic and alpha-linoleic acid are essential fatty acids (cannot be synthesized by the body and hence require to form a part of diet), and are usually obtained from plant sources. Linoleic acid can be converted by mammals into gamma-linolenic acid, which can in turn be converted to arachidonic acid (20:4), a critically important fatty acid since it is an essential precursor of most prostaglandins. Furthermore, animal bioconversions of high polyunsaturated fatty acids from linoleic, alpha-linolenic and oleic acids are mainly modulated by the delta6 and delta5 desaturases through dietary and hormonal stimulated mechanisms. ( Prostaglandins Leukot Essent Fatty Acids 68(2): 151-62.).
[0004] In view of the foregoing, there exists a definite need for the enzyme delta-6 desaturase, the respective genes for encoding this enzyme, including recombinant methods of producing this enzyme. The current requirement for these essential fatty acids have been satisfied through the dietary intake of plant sources rich in such PUFAs. But disadvantages do exist as these natural sources are always subjected to uncontrollable fluctuations in availability. Moreover, plant oils possess a highly heterogenous composition, requiring extensive purifications procedures to separate a particular polyunsaturated fatty acid of interest (US 20060035351). However, cost effective alternatives have to be explored for fulfilling the needs of the growing global populations.
[0005] The subject invention relates to the introduction of genes encoding the enzyme delta-6 desaturase isolated from the marine organism Schizochytrium in to yeast for the production of fatty acids such as gamma-linolenic acid, stearidonic acid and the other fatty acids resulting from the bioconversions of the respective substrates in the omega-3/omega-6 fatty acid biosynthetic pathway. Yeast provides numerous advantages as a favorable system for the expression of the fatty acid in a suitable medium. Yeast has long been recognized and used as a host for protein expression since it can offer the processing system along with the ease of use of microbial systems. As a host, it boasts of a number of benefits as it can be used for the production of both secreted and cytosolic proteins which may require post-translational modifications and its biosynthetic pathway resembles higher eukaryotic cells in many aspects. Moreover, in comparison to the other eukaryotic systems, there is considerably more advanced understanding of its genetics with an ease of manipulation similar to that of E. coli. The expression levels also range to several milligrams per liter of the culture.
[0006] A number of delta-6 desaturases have been identified. In plants such as the herb, borage ( Borago officianalis ), the delta-6 desaturase has been identified (Sayanova et al., 1997). The same has been identified in humans (Hyekyung et al., 1999), in animals such as nematode, Caenorhabditis elegans (Michaelson et al., 1998 and Napier et al., 1998) and in Eukaryotic microorganisms such as fungus Mortierella alpina (Hunag et al., 1999 and Knutzon et al., 1998). According to the aspects of the present invention there is provided an isolated nucleic acid molecule comprising the DNA sequence encoding for the enzyme delta-6 desaturase isolated from the marine organism Schizochytrium.
SUMMARY OF THE INVENTION
[0007] The present invention relates to an isolated nucleic acid sequence or fragment thereof encoding a polypeptide molecule possessing desaturase activity, the nucleic acid sequence of which has been represented in SEQ ID. No. 1 and amino acid sequence of which has been represented in SEQ ID. No. 2.
[0008] The present invention encompasses an isolated nucleic acid sequence or fragment thereof comprising, or complementary to, a nucleic acid sequence having at least 70%, preferably 80% and more preferably 90% nucleotide sequence identity to a nucleotide sequence represented in SEQ ID. No. 1.
[0009] The present invention also includes an isolated nucleic acid sequence or fragment thereof encoding a polypeptide having desaturase activity, wherein said polypeptide comprises an amino acid sequence having at least 70%, preferably 80% and more preferably 90% amino acid sequence identity to an amino acid sequence represented in SEQ ID. No. 2.
[0010] The nucleotide sequences described above encode a functionally active Delta-6-desaturase that utilizes a monounsaturated or polyunsaturated fatty acid as a substrate. The nucleotide sequences have be isolated from Schizochytrium SC-1.
[0011] Additionally, the present invention includes a method of identification, isolation and cloning of the nucleic acid sequence and amino acid sequence encoding delta-6 desaturase comprising the steps of (1) cDNA library screening with a partial delta-4 desaturase gene leading to the identification of a partial cDNA clone (2) Using the partial cDNA clone for screening the BAC library of Schizochytrium SC-1 for identification of a positive BAC clone (3) Identification and sequencing of the positive BAC clone and further identification of the delta-6 desaturase ORF within the full length sequence (4) constructing a vector comprising the at least 90% sequence identity to the sequence represented in SEQ ID 1 (5) Introducing the constructed vector via transformation into a host cell for a time and under conditions sufficient for the expression of the desaturase.
[0012] The host cell may be for example, a eukaryotic cell or a prokaryotic cell. A prokaryotic cells may be for example E. Coli and a prokaryotic cell may be for example a fungal cell, insect cell, mammalian cell or a plant cell but preferably a yeast cell such as Saccharomyces cerevisiae. Other suitable host cells may include Yarrowia lipolytica, Candida sp, Hansenula spp etc,
[0013] A particular embodiment of the invention describes the construction of the vector comprising the nucleotide sequence or fragment thereof encoding polypeptide having delta-6 desaturase activity, wherein the said polypeptide comprises an amino acid sequence having at least 70%, preferably 80% and more preferably 90% amino acid sequence identity to the sequence of SEQ ID. NO. 2, operably linked to a regulatory sequence (eg., promoter and terminator) under optimal conditions for the expression of the enzyme delta-6 desaturase.
[0014] Additionally, the invention includes a yeast cell comprising the above vector, wherein the expression of the enzyme delta-6 desaturase results in the production of gamma-linolenic acid.
[0015] Yet another aspect of the invention relates to induction of the yeast clone expressing delta-12 and delta-6 desaturases, showing the formation of linoleic acid and gamma linolenic acid. The in-vivo conversion of oleic acid to linoleic acid is carried out by Brassica juncae delta-12 desaturase. The subsequent desaturation of linoleic acid to gamma linolenic acid is catalyzed by the cloned SC-1 delta-6 desaturase. In the context of the said invention the experiment demonstrates the functional expression of SC-1 delta-6 desaturase in yeast.
DETAILED DESCRIPTION OF THE FIGURES AND SEQUENCES
[0016] FIG. 1 : Clustering of the Delta-6 desaturase of SC-1 with other known Delta-6 desaturases. (Note the presence of the Histidine motifs essential for the function of the desaturases in all species.)
[0017] FIG. 2 : Presence of fatty acid desaturase motif and Cytocrome B-5 domain in Delta-6 desaturase of SC-1.
[0018] FIG. 3 : Southern hybridization of Delta-6 desaturase (full length) to genomic DNA of SC1 digested with EcoRI(E) and PstI(P); M-1 kb Ladder. (The results of the hybridization clearly showed the presence of a single copy of the □-6 desaturase in SC-1.)
[0019] FIG. 4 : Map of the construct PET-SC-1-D6.
[0020] FIG. 5 : Amplification of the clones with Gal I primers. (Note: The amplification of Delta 6 desaturase gene. (1.5 Kb))
[0021] FIG. 6 : Map of the pESC-Trp construct containing Delta-6 desaturase in MCSI and Delta-12 desaturase in MCS II. The construct is called PET-D6SC1-D12BJ-CO.
[0022] FIG. 7 : Amplification of □-12 and □-6 desaturases from the PET-D12-D6 construct (Lanes: M; 1 KB ladder, 1: amplification of □-12 desaturase & 2: Amplification of □-6 desaturase.)
[0023] SEQ ID. No. 1: Nucleic Acid Sequence of Delta-6-desaturase isolated from Schizochytrium SC1
[0024] SEQ ID. No. 2: Amino Acid Sequence of Delta-6-saturase isolated from Schizochytrium SC1.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Linoleic acid is converted to gamma-linolenic acid by the enzyme delta-6 desaturase. The subject invention relates to an isolated nucleic acid sequence encoding delta-6 desaturase. It more specifically refers to the nucleotide and the corresponding amino acid sequences from the delta-6 desaturase genes derived from the marine organism Schizochytrium obtained through the screening of the BAC library of Schizochytrium.
[0026] The invention further relates to the transfer of the vector comprising the nucleic acid fragments of the invention or a part thereof that encodes a functional enzyme along with the suitable regulatory sequences that direct the transcription of their mRNA, into a living cell, which under the context of the present invention is a yeast cell thereby resulting in the production of the specified delta-6 desaturase leading to the conversion of linoleic acid to gamma-linolenic acid.
[0027] In the context of this disclosure, a number of terms shall be used. The following definitions are provided to better define the present invention and guide those of ordinary skill in the art in the practice of the present invention. Unless otherwise noted, terms are to be understood according to conventional usage by those of ordinary skill in the relevant art.
[0028] Desaturase: Desaturase is an enzyme that promotes the formation of a carbon-carbon double bonds in a hydrocarbon molecule.
[0029] Fatty acid desaturase: The term “fatty acid desaturase” used herein refers to an enzyme which catalyzes the breakage of a carbon-hydrogen bond and the introduction of a carbon-carbon double bond into a fatty acid molecule. The fatty acid may be free or esterified to another molecule including, but not limited to, acyl-carrier protein, co-enzyme A, sterols and the glycerol moiety of glycerolipids.
[0030] “Delta-6 desaturase” refers to a fatty acid desaturase that catalyzes the formation of a double bond between carbon positions 12 and 13 (numbered from the methyl end), i.e., those that correspond to carbon positions 6 and 7 (numbered from the carbonyl carbon) of an 18 carbon-long fatty acyl chain. As described herein and under the context of the present invention, delta-6 desaturase catalyses the conversion of linoleic acid to gamma-linolenic acid.
[0031] “Isolated nucleic acid fragment or sequence” is a polymer of RNA that is single- or double-stranded, may optionally contain synthetic, non-natural or altered nucleotide bases. An isolated nucleic acid fragment in the form of a polymer of DNA may be comprised of one or more segments of cDNA, genomic DNA or synthetic DNA.
[0032] Recombinant nucleic acid: A sequence that is not naturally occurring or has a sequence that is made by an artificial sequence that is made by an artificial combination of two otherwise separated segments of sequence. This artificial combination is often accomplished by chemical synthesis or, more commonly, by the artificial manipulation of isolated segments of nucleic acids eg., by the genetic engineering techniques such as those described in Sambrook et al. Molecular Cloning: A Laboratory Manual, 2rd Edition, Cold Spring Harbor Laboratory press, NY, 1989.
[0033] “Gene” refers to a nucleic acid fragment that expresses a specific protein, including regulatory sequences preceding (5′ non-coding sequences) and following (3′ non-coding sequences)
[0034] “Promoter” refers to a DNA sequence capable of controlling the expression of a coding sequence or functional RNA.
[0035] “Coding sequence” refers to a DNA sequence that codes for a specific protein and excludes the non-coding sequences. It may constitute an “uninterrupted coding sequence” i.e., lacking an intron or it may include one or more introns bounded by appropriate splice junctions.
[0036] “Initiation Codon” and “Termination Codon” refers to the unit of three adjacent nucleotides in a coding sequence that specifies initiation and chain termination respectively, of protein synthesis (mRNA translation).
[0037] “Open Reading Frame” (ORF) refers to the coding sequence uninterrupted by introns between initiation and termination codons that encodes an amino acid sequence.
[0038] “Operably linked” refers to the association of nucleic acid fragment so that the function of one is regulated by the other.
[0039] “Homologs” Two nucleotide or amino acid sequences that share a common ancestral sequence and diverged when a species carrying that ancestral sequence spilt into two species. Homologs frequently show a substantial degree of sequence identity.
[0040] “Transformation” herein refers to the transfer of a foreign gene into the genome of a host organism and its genetically stable inheritance.
[0041] “Expression”, as used herein refers to the transcription and stable accumulation of sense (mRNA) or antisense RNA derived from the nucleic acid fragments of the invention. Expression also refers to the translation of mRNA into a polypeptide.
[0042] The terms “plasmid”, “vector”, and “cassette” refers to an extra chromosomal element often carrying genes that are not part of the central metabolism of the cell, and usually in the form of circular double-stranded DNA fragments. Such elements may be autonomously replicating sequences, genome integrating sequences, phage or nucleotide sequences, linear or circular, of a single- or double stranded DNA or RNA, derived from any source, in which a number of nucleotide sequences have been joined or recombined into a unique construction that is capable of introducing a promoter fragment and DNA sequence for a selected gene product along with appropriate 3′ untranslated sequence into a cell. “Expression cassette” refers to a specific vector containing a foreign gene and having elements in addition to the foreign gene that allow for enhanced expression of that gene in a foreign host.
[0043] In accordance with one aspect of the present invention, the cDNA library of Schizochytrium (SC1) (herein after referred as “SC1”) has been screened with a partial delta-4 desaturase gene. This has lead to the identification of a clone of 617 base pair length homologous to the delta-6 desaturase gene of various other organisms. The identified clone is a partial cDNA clone.
[0044] In accordance with another aspect of the present invention, the partial clone identified was used to screen the BAC library of SC1. Screening the BAC library lead to the identification of a positive clone comprising the full length sequence of the delta-6 desaturase gene. The clone was further sequenced and the delta-6 desaturase ORF (open reading frame) was identified within the sequence.
[0045] The nucleic acid sequence of the delta-6 desaturase has been represented in SEQ ID 1. The nucleic acid sequence translates into a protein of 472 amino acids. The amino acid sequence of the delta-6 desaturase from SC-1 has been represented in SEQ ID 2. The invention encompasses other “obtainable” delta-6 desaturases from other organisms such as SC-1. “Obtainable” refers to those desaturases, which have sufficiently similar sequences to that of the sequences provided herein that encodes a biologically active protein.
[0046] In yet another aspect of the invention, the degree of homology of the isolated delta-6 desaturase is compared with the delta-6 desaturase of different species. The nucleic acid sequence of the isolated delta-6 desaturase is compared to “homologous” or “related” to DNA sequences encoding delta-6 desaturases from other organisms. “Homologous” or “related” includes those nucleic acid sequences, which are identical or conservatively substituted as compared to the exemplified organisms such as Borago officinalis, Echium gentianoides, Mortierella alpina, and Pythium irregulare. The similarity between two nucleic acids or two amino acid sequences is expressed in terms of percentage sequence identity. The higher the percentage sequence identity between the two sequences, the more similar the two sequences are. Sequences are aligned, with allowances for gaps in alignment, and regions of identity are quantified using a computerized algorithm. Default parameters of the computer programs are commonly used to set gaps allowances and other variables.
[0047] Methods of alignment of sequences are well known in art. Various programs and alignment algorithms are described by Pearson et. al., Methods in Molecular Biology 24:307-331, 1994 and in Altschul et al., Nature Genetics. 6:119-129, 1994. Altschul et al presents a detailed consideration of sequence alignment methods and homology calculations. The NCBI Basic Local Alignment Search Tool (BLAST) (Altschul et al., J. Mol. Biol. 215:403-410, 1990 is available from several sources, including the National Center of Biotechnological Information (NCBI, Bethesda, Md.) and on the internet, or use in connection with the sequence analysis programs blastp, blastn, blastx, tblastn, and tblastx etc.
[0048] Additionally, it will be appreciated by one skilled in art that polypeptides may have certain amino acids conservatively substituted in a manner such that the function of the polypeptide is not altered or comprised. It is very evident from the comparative homology conducted as represented in FIG. 1 that the histidine motifs have been conserved over the organisms compared.
[0049] In another aspect of the present invention, the delta-6 desaturase sequence was subjected to a motif search for confirmation of the presence of the desaturase domain. The results of motif search is represented in FIG. 2 . It was hence confirmed that the gene has the complete desaturase domain and the cytochrome b5 domain characteristic of the functional desaturases.
[0050] Recombinant nucleic acids, as mentioned for instance in SEQ ID: 1, containing all or a portion of the disclosed nucleic acid operably linked to another nucleic acid element such as promoter, for instance, as part of a clone designed to express a protein. Cloning and expression systems are commercially available for such purposes. Vectors containing DNA encoding the delta-6 desaturase are also provided by the present invention.
[0051] Various host cells can be used for expression of the protein. For example, various yeast strains and yeast-derived vectors are commonly used for expressing and purifying proteins. The current invention uses Saccharomyces cerevisiae as the host for the expression of the cloned gene. But also envisaged is the usage of other expression systems such as the Pichia pastoris expression systems.
[0052] Vectors or DNA cassettes useful for the transformation of suitable host cells are well known in art. Typically, however, the vector or cassette contains sequences directing transcription and translation of the relevant gene(s), a selectable marker Expression vectors such as pET systems can be used to express the gene of interest. The vector may be a plasmid, cosmid or bacteriophage preferably for the purposes of the invention a plasmid, may comprise the nucleotide sequence (eg. Promoter) which is functional in the host cell and is able to elicit expression of the desaturase encoded by the nucleotide sequence. (The promoter is “operably linked” with the coding sequence). Some suitable promoters include genes encoding T7, TPI, lactase, metallathionein or promoters activated in the presence of galactose such as GAL1 and GAL10. The kind of promoters used for expression shall depend upon the kind of expression product desired and also the nature of the host cell. For example in the current invention GAL1 or GAL10 promoters are used to control the expression of the delta-6 desaturase gene sequences. Any one of a number of regulatory sequences can be used, depending upon whether constitutive or induced transcription is desired, the efficiency of the promoter expressing the ORF of interest, the ease of construction and the like. Nucleotide sequences surrounding the translational initiation codon ‘ATG’ have been found to affect expression in yeast cells and certain nucleotide sequences of exogenous genes can be modified for desired expression levels. For expression in yeast, this can be done by site-directed mutagenesis of an inefficiently expressed gene by fusing it in-frame to an endogenous yeast gene, preferably a highly expressed gene.
[0053] Useful selectable markers can be used for the selection of the successfully transformed cells post transformation. Selectable markers for selection are not limited to streptomycin, Ampicillin etc.
[0054] The vector constructed may be then introduced into the host cell of choice by the methods known to those ordinary skilled in art such as transfection, electroporation or transformation. Such techniques of have been well illustrated in Molecular Cloning: A laboratory Manual. Vol 1-3 Sambrook et. al., Cold Spring Harbor Laboratory Press (1989). The host cell that has taken up the expression cassette that has been manipulated by any method to take up a DNA sequence will be herein referred to as “transformed” or “recombinant”.
[0055] The present invention is further illustrated in the following examples. It should be understood that these examples, while indicating preferred embodiments of the invention, are given by way of illustration only. From the above discussion and these examples, one skilled in the art can ascertain the essential characteristics of the invention and without departing from the spirit and scope thereof, can make variouis changes and modifications of the invention to adapt it to various usages and conditions.
EXAMPLES
Example 1
[0056] Screening of the cDNA Library of SC1 With Partial Delta-4-Desaturase Gene:
[0057] Screening of the cDNA library of SC-l with the partial A4 desaturase gene obtained from the sequencing of the SC-1 cDNA library led to the identification of a number of clones. One of these clones of 617 bp was found to be homologous to 6 desaturase of several organisms.
[0058] The sequence had an ORF running through till 273 bases. The 3′UTR is 401 bases A polyadenylation signal “AATAA” is seen towards the 3′ end of the sequence.
[0059] This sequence when subjected to homology search against the protein database of NCBI shows homology to −6 desaturases of Echium plantagina, Aragania spinosa and Echium pitardii v.
[0060] The protocols involved were
[0061] (A) Protocol for Plating of cDNA Library and Transfer to Membrane
[0062] Serial Dilutions
[0063] 1 μl of cDNA library clone mix and 9 μl of SOC were taken into an eppendorf (dilution factor 10-1), and the tube was labeled as A. From tube A, 1 μl of clone mix and add 9 μl of Soc was taken into another fresh tube, labeled as B (dilution factor 10-2). From tube B 1 μl of clone mix was taken and 9 μl of SOC was added into another fresh tube, labeled as C. 1 micro litre from tube A, B, & C was taken and 99 μl of SOC was added.
[0064] Plating
[0065] 1. 100 μl of final clones mix from each tube was plated to separate LB amp plates.
[0066] 2. The plates were incubated at 37° C. overnight.
[0067] 3. The plate that had 104 cells/plate or more was taken for transfer.
[0068] Transfer on to the Membrane
1. The plates were marked with Indian ink at four places, for proper orientation of the clones. 2. The nylon membrane was inverted on to the plate and allowed to soak for 1-2 min. 3. The membrane was lifted from one side with a sterile forceps and was then air-dried and further taken up for hybridization.
[0072] (B) Protocol for Preparation of Labeled Probes by Random Priming
1. The DNA for labeling was dissolved in either sterile water or 10 mMTris HCl (pH-8.0), 1 mM EDTA to a concentration of 10 μg/ml. 2. The DNA was denatured at 95° C. for 2 minutes (by keeping the vial containing the DNA in boiling water bath) & chilled immediately on ice. 3. Reagents were added in the following order in a small eppendorff vial kept on ice to label 50 ng of DNA: 5 μl of denatured DNA was taken in to the vial; to this 5 μl of random primer buffer was added, then 5 μl of random primer solution was added, further to which 12 μl of dNTP mix, 2 μl of klenow enzyme (1U/μl ), 18 μl of sterile water were added. 4. The tube was capped and mix gently either by slowly tapping at the bottom or by a ‘tap spin’, in a centrifuge. 5. 3 μl (30 μCi) of P32 labeled nucleotide was added to the above mix, by placing the tube behind the acrylic shield. 6. The tube was placed in a constant temperature at 37° C. in a PCR block. 7. The tube was then kept at 95° C. for 15 min in a PCR block and chilled immediately on ice. 8. The Random labeled fragment was ready for probing.
[0082] (C) Protocol for Hybridization
1. 25.0 ml of Pre-Hybridisation buffer was taken in the hybridization bottle and the membrane was immersed into it. 2. The bottle was then placed in the hybridization oven set at 65° C. for 2 hrs 3. The pre-hybridisation buffer was discarded and 25.0 ml of fresh pre-hybridisation buffer was added. 4. 50 μl of random labeled probe was added to the bottle behind the acrylic shield. 5. The bottle placed back in the hybridization oven set at 65° C. overnight. 6. The solution-containing probe was decanted into a labeled, radioactive discard can for disposal. 7. The membrane was rinsed with 2×SSC at room temperature to remove any unbound probe. 8. The membrane was further washed with 2×SSC+0.1% SDS at 650 C for 15 min on a rocker in the oven.
Example 2
[0091] Construction and Screening of BAC Library With the Delta-6 Desaturase Partial cDNA Clone of SC-1:
[0092] Screening of the BAC library of SC-1 with one of the partial clones led to the identification of a positive BAC clone. The BAC clone was sequenced and the −6 desaturase ORF identified within the sequence.
[0093] Protocols for BAC Library Construction:
[0094] DNA purified by Pulse field gel electrophoresis was digested with restriction enzyme 1 unit of Eco RI wherein fragments of 75-200 kb were maximally obtained. The size selected DNA was ligated (100 units of high concentration T4 DNA ligase (400 μ/microl; NEB biolabs) with 1:10::Insert:vector molar ratio) to the digested BAC vector (pIndigoBAC536) and transformed by electroporation in E. coli electrocompetant cells and plated on suitable medium. The recombinant clones would be picked and inoculated in SOB in a 96 well plate and the library is stored at −70° C. as glycerol stocks.
[0095] The protocols for screening of the BAC library are same as described in Example 1.
[0096] The sequence shows a high degree of homology to the −6 desaturase of different species.
[0097] The −6 desaturase sequence when subjected to a motif search, showed that the gene has the complete desaturase domain and the Cytochrome b5 domain characteristic of the functional desaturases.
Example 3
[0098] Determination of the Gene Copy No:
[0099] 10 μg of genomic DNA isolated from SC-1 was digested with Eco RI or Pst I, and was loaded on 0.8% agarose gel, electrophoresed at 30 volts overnight and the DNA was transferred to nylon N+ membrane (milipore). The SC-1 delta-6 desaturase gene labeled with 32 PdCTP by random priming was hybridized to the blot at 65° C. overnight. The blot was then washed with moderate stringency (2×SSC-15 min, 2×SSC+0.1%SDS-15 min, 0.5×SSC+0.1%SDS-15 min at 65° C.) and exposed to X-ray film.
[0100] The results of the hybridization have been represented in FIG. 3 and the results of the hybridization clearly showed the presence of a single copy of the delta-6 desaturase in SC-1. Cross hybridizing homologous sequences did not occur in the SC-1 genome.
Example 4
[0101] Construction of the Vector:
[0102] The delta-6 desaturase gene was cloned into the MCSII site under the GAL1 promoter between the BamHI and the SalI sites of pESC-Trp (PET-SC 1-D6). Primers used for the amplification are given below.
[0000]
D6 pES F
CGGGATCCTATGATCTGGCGGGAGG
D6 pES R
ACGCGTCGACTCAACCACGGAGGTTGAGAC
[0103] Table 1: Primers synthesized for the amplification and cloning of delta-6 desaturase from SC1 into the MCSII of pESC between BamHI and Sal I sites. The restriction sites in the primers are given in red.
[0000]
PCR components for 20 ul reaction
Milli-Q water upto
20, 1
10X reaction buffer
2.0, 1
dNTP mix (1OmM)
0.2, 1
Forward Primer (5.0 picomoles/ul)/
1.0, 1
Reverse Primer (5.0 picomoles/ul)/
1.0, 1
Genomic DNA of Sc-1 (100 ng)
1.0, 1
Taq polymerase (3 U/ul)
0.1, 1 (~0.3 U)
[0104] The cycling conditions are as follows:
[0000]
94° C.
94° C.
55° C.
72° C.
72° C.
3 minutes
30 seconds
30 seconds
1.3 minute
7 minutes
1 cycle
35 cycles
1 cycle
[0105] The ORF of the delta-6 desaturase has been amplified with the above primers, restricted with Bam HI and Sal I and directionally cloned into the corresponding sites of pESC-Trp. The construct has been named PET-SC-1-D6 and is represented in FIG. 4 .
Example 5
[0106] Transformation of Yeast:
[0107] The construct as represented in FIG. 4 was been transformed into Saccharomyces cerevicea YPH500 strain and the transformants were confirmed by PCRs. The PCR results are represented in FIG. 5 . Amplification of the clones (Kit used is from Stratagene, Yeast Epitope Tagging Vector) with Gal I primers indicated the Delta-6-desaturase gene.
[0108] Protocol for Preparation of Yeast Competent Cells:
[0109] All the steps are to be carried out in aseptic conditions. A single colony is inoculated into YPD and grown overnight at 30° C. Using 5% of inoculum a 50 ml culture was grown at 30° C. till the O.D reaches 1.0. The cells are left on ice for 10 min and centrifuged at 5000 rpm for 10 min at 4° C. and the media is discarded. The pellet is resuspended in equal volume of water (50 ml) and spun at 5000 rpm for 10 min at 4° C. The pellet was washed twice in equal volume of 1 M sorbitol and centrifuged at 5000 rpm for 10 min at 4° C. Finally the pellet was resuspended in 150 μl of 1 M sorbitol and stored at 4° C. The competent cells can be stored for a week.
[0110] Transformation of Yeast by Electroporation:
[0111] 60 μl of the competent cells and ˜1 μg of DNA were taken in a vial, mixed and kept on ice. This was further taken onto a 0.2 cm electroporation cuvette and given a pulse set at SC2 (1.7 kV and 5.8 ms). Immediately 600 μl of 1 M sorbitol was added and the cells were resuspended and transfered into a vial and stored at room temperature for 5 min. 200 μl of cells were spread on a suitable selection medium and incubated at 30° C. for 2 days. The number of colonies expected were 100 per 200 μl of culture spread.
[0112] The transformed yeast cells were selected by growing them in SD Dropout Media with. Tryptophan. (Sigma).
Example 6
[0113] In-Vivo Proof of Function
[0114] The in-vivo proof of function experiment was performed in yeast strain YPH 499 transformed with pESC-Trp construct containing Delta-6 desaturase and Brassica juncae delta-12 desaturase. Using this construct the in-vivo Delta-6 desaturase activity can be observed in absence of addition of precursor fatty acid in the media. The −6 desaturase cloned between the Eco RI and Spe I sites of MCS I of the pESC-Trp was restricted with Bam HI and Sal I. The PEH-D12-BJ-CO clone carrying Delta-12 desaturase was digested with BamHI and Sal I and the Delta-12 desaturase thus released was isolated. The latter was directionally cloned into the corresponding sites MCSII of the above construct. The construct thus obtained has delta-6 in MCSI and Delta-12 in MCS II. The above construct is called as PET-D6 SC1-D12BJ-CO ( FIG. 6 .)
[0115] The presence of both the genes in some of the selected clones was confirmed by PCR amplification and sequencing. ( FIG. 7 .)
[0116] The recombinant clones were grown overnight in SD medium without tryptophan (0.67% yeast N2 base W/O amino acids; 2% Dextrose; 0.13% amino acid drop out powder without tryptophan). The cells were pelleted at 5,000 rpm for 10 minutes, washed once with sterile water and resuspended in SG medium without tryptophan 0.67% yeast N2 base W/O amino acids; 2% galactose; 0.13% amino acid drop out powder without tryptophan). The cultures were incubated at 30 C for 1 day; the cells were pelleted, lyophilized. For fatty acid profiling, lipid extraction was performed and fatty acid methyl esters (FAME) were prepared and analyzed using GC-MS. The fatty acid profile of a typical recombinant yeast clone is given in the table below.
[0000]
TABLE
Fatty acid analysis of yeast expressing
Delta-12 and Delta-6 desaturases
Fatty acid composition (GC %)
Fatty acids
pESC
Delta-12 + Delta-6 desaturase
14:0
0.7
0.3
16:0
19.6
18.3
16:1
38.4
33.6
16:2
—
4.4
18:0
5.8
6.4
18:1
35.5
26.4
18:2
—
9.7
18:3*
—
0.8
*gamma linolenic acid
[0117] It is evident from the table above that upon induction, the yeast clone expressing delta-12 and delta-6 desaturases shows the formation of linoleic acid and gamma linolenic acid. The in-vivo conversion of oleic acid to linoleic acid is carried out by Brassica juncae delta-12 desaturase. The subsequent desaturation of linoleic acid to gamma linolenic acid is catalyzed by the cloned SC-1 delta-6 desaturase. This experiment demonstrates the functional expression of SC-1 delta-6 desaturase in yeast. | The present invention is directed to an isolated delta-6 desaturase gene from Schizochytrium. It is further directed to the cloning of delta-6 desaturase derived from Schizochytrium in Yeast. The nucleic acid sequence and the amino acid sequences of the delta-6 desaturase are disclosed. Further disclosed are the constructs, vector comprising the gene encoding the enzyme delta-6 desaturase in functional combination with the heterologous regulatory sequences. The novel delta-6 desaturase can be used in a metabolic pathway to convert linoleic acid to gamma linolenic acid (omega-6 pathway). The invention provides the identification, isolation of these novel nucleic acids from Schizochytrium that encode the above-mentioned proteins. The invention specifically exemplifies recombinant yeast cells harboring the vector comprising the delta-6 desaturase gene and by the virtue of the enzyme produced shall be able to produce gamnia-linolenic acid. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] An antimicrobial formulation containing a mixture of organic acids, aldehydes and organic acid esters, where such combination results in a synergistic response.
[0003] 2. Background
[0004] The Centers for Disease Control and Prevention (CDC) estimates that roughly one out of six Americans or 48 million people is sickened by food borne illnesses each year. Another 128,000 are hospitalized and approximately 3,000 die of food borne disease every year. In 2011, the CDC (http://www.cdc.gov/outbreaknet/foodborne-surveillance-questions-and-answers.html) estimated that salmonellosis resulted in 20,000 hospitalizations and 378 cases of death per year. It has also estimated that Escherichia coli O157:O7 causes approximately 62,000 cases of food borne disease and approximately 1,800 food borne illness-related hospitalizations in the United States annually. A study by the Pew Charitable Trusts of Georgetown University suggested that food borne illnesses cost the United States $152 billion in health-related expenses each year (Yeager, 2010).
[0005] A study commissioned by the UK Food Standard Agency (FSA) found that campylobacter was one of the main causes of Infectious Intestinal Diseases (IID) and was responsible for around 500,000 cases annually. The same agency also reported that two thirds of chicken samples on sale within the UK were contaminated with campylobacter (http://www.food.gov.uk/policy-advice/microbiologykampylobacterevidenceprogramme/campybackground).
[0006] The world's tendency to find more natural and/or organic antimicrobials has resulted in a great amount of research in identifying these type of products as well as an increased cost of new raw materials due to low commercial availability of natural/organic products. Currently many type of chemicals and their combinations are used as antimicrobials. These chemicals include organic acids, aldehydes, ester of organic acids, plant extracts and others.
[0007] One of the components of the present invention are organic acid esters. Several US patents and WO patents described the use of organic acid esters as flavorings, preservatives or antimicrobials. U.S. Pat. No. 7,652,067 and WO Patent #2009/037270 suggest of the use of a hydrophobic organic compound i.e. menthol, with a monoester of a saturated organic acid of C 6 -C 20 carbon length. This product is useful for flavoring food and perfumery. These patents do not suggest of a combination of organic acid esters combined with organic acids and aldehydes as antimicrobials. US Patent Application #2009/0082253, suggests of an antimicrobial comprising a mixture of organic acid esters of lactic acid (lactylate), a hydroxyl carboxylic acid and an antibacterial agent. They do not suggest that the mixture of esters of organic acids other than lactic acids ester and polylysine, a known antimicrobial, will result in an effective antimicrobial. U.S. Pat. No. 7,862,842 suggest the use of organic acid ethyl esters derived from lauric acid and arginine preservative for perishable food product not as animal feed preservative.
[0008] The present invention suggests the use of organic acid esters in combination with aldehydes and organic acids as an antimicrobial in feed ingredients, feed and water. Literature review has shown that organic acid esters have been studied as bactericides and fungicides against plant and human pathogens. Propyl, methyl and ethyl esters of ferulic acid were effective in inhibiting Saccharomyces cerevisiae, Aspergillus fumigatus and Aspergillus flavus (Beck, et. al, 2007). Organic acids esters prepared from mixing n-organic alcohols and dibasic acids were used as plasticizer and exhibited some benefits as a fungicide (Sadek, et. al., 1994). Six organic acid esters from soybean, including methyl and ethyl palmitates, methyl and ethyl oleates, methyl linoleate and methyl linolenate demonstrated curative and protective activities against powdery mildew in barley. Methyl laurate has also been reported to control the development of powdery mildew (Choi, et. al., 2010). Castor oil methyl ester can replace mineral oil to control the fungal disease, Black Sigatoka, in bananas (Madriz-Guzman, et. al., 2008). Organic acid methyl esters from linoleic, linolenic, arachidonic, palmitoleic and oleic acids were effective in inhibiting growth of Streptococcus mutans, Candida albicans, Aggregatibacter actinomycetemcomitans, Fusobacterium nucleatum and Porphyromonas gingivalis (Huang, et. al., 2010). The fungus Muscodor albus produces certain volatiles compounds that effectively inhibit and kill other fungi and bacteria. One of these volatile compounds is an ester of 1-butanol, 3-methyl acetate, which is 62% of the total esters that was effective in inhibit growth of several fungi (Strobel, et. al., 2001). The organic acid methyl ester profile from Sesuvium portulacastrum indicates the presence of palmitic, oleic, linoleic, linolenic, myristic and beheni acid esters, all of them effective against several human pathogenic microorganisms (Chandrasekaran, et. al., 2011). Organic acid methyl esters of dodecanoic and pentadecanoic acids found in carrots extract were effective against Leuconostoc mesenteroides, Listeria monocytogenes, Staphylococcus aureus, Pseudomonas fluorescens, Candida albicans and E. coli (Babic, et. al., 1994). The inhibitory activity against E. coli, L. monocytogenes, Fusarium culmorum, Bacillus cereus and Saccharomyces cerevisiae was higher when using phenolic acid butyl esters than methyl esters (Merkl, et. al., 2010).
[0009] Another compound of the present invention is an aldehyde. One of the most effective of these aldehydes, formaldehyde, has been used as an antiseptic for many years. Two U.S. Pat. Nos. 5,547,987 and 5,591,467 suggest the use of formaldehyde to control Salmonella spp. in animal feed. These patents do not suggest that the combination of formaldehyde or other aldehydes with organic acid esters provides a synergistic effect as described in the present invention.
[0010] An aldehyde used in the present invention is trans-2-hexenal, a six carbon, double bond aldehyde, C 6 H 10 O and MW=98.14. Trans-2-hexenal is present in many edible plants such as apples, pears, grapes, strawberries, kiwi, tomatoes, olives, etc. The use of plants and plant extracts have been successful in identifying new anti-microbials. For example, the extract from cashew apple was observed to effective against Helicobacter pylori and S. cholerasuis at concentrations of 50-100 ug/ml. The two main components were found to be anacardic acid and trans-2-hexenal. The minimum inhibitory and minimum biocidal activity of trans-2-hexenal were determined to be 400 and 800 ug/ml, respectively (Kubo, et. al., 1999; Kubo and Fujita, 2001). Kim and Shin (2004) found that trans-2-hexenal (247 mg/L) was effective against B. cereus, S. typhimurium, V. parahaemolyticus, L. monocytogenes, S. aureus and E. coli O157:H7. Nakamura and Hatanaka (2002) demonstrated that trans-3-hexenal was effective in controlling Staphylococcus aureus, E. coli and Salmonella typhimurium at a level of 3-30 ug/ml. Trans-2-hexenal completely inhibited proliferation of both P. syringae pathovars (570 μg/L of air) and E. coli (930 micrograms/L of air)(Deng, et. al., 1993). It was observed that trans-2-hexenal at 250 ug/ml was effective on inhibiting the growth of Phoma mycelium (Saniewska and Saniewski, 2007). In a study to control mold in fruits, it was found that trans-2-hexenal was not phytotoxic to apricots, but it was phytotoxic for peaches and nectarines at 40 μl/l (Neri, et. al., 2007). Trans-2-hexenal (12.5 μl/l) was effective on controlling Penicillium expansum that causes blue mold (Neri, et. al., 2006a and 2006b). Fallik et. al. (1998) and Hamilton-Kemp et. al. (1991), suggested that trans-2-hexenal vapors inhibited the germination of Botrytis spores and apple pollen.
[0011] USPTO Application #2007/0087094 suggests the use of at least two microbiocidally active GRAS compounds in combination with less than 50% alcohol (isopropanol or isopropanol/ethanol) as a microbicide. Trans-2-hexenal could be considered one of the GRAS compounds (USPTO Application No. 2007/0087094). Archbold, et. al. (1994) observed that the use of trans-2-hexenal at 0.86 or 1.71 mmol (100 or 200 microliters neat compound per 1.1 L container, respectively) for 2 weeks as for postharvest fumigation of seedless table showed promise for control of mold.
[0012] U.S. Pat. No. 5,698,599 suggests a method to inhibit mycotoxin production in a foodstuff by treating with trans-2-hexenal. Trans-2-hexenal completely inhibited the growth of A. flavus, P. notatum, A. alternate, F. oxysporum, Cladosporium spp., B. subtilis and A. tumerfaciens at a concentration of 8 ng/l air. When comparing trans-2-hexenal to citral for the control of yeast (10 5 CFU/bottle) in beverages it was found that 25 ppm of trans-2-hexenal and thermal treatment (56° C. for 20 min) was equivalent to 100-120 ppm citral. In beverages that were not thermally treated, 35 ppm of trans-2-hexenal was necessary to control microorganisms (Belleti, et. al., 2007). Trans-2-hexenal has also been reported to control insects, such as Tibolium castaneum, Rhyzopertha dominica, Sitophilus granaries, Sitophilus orazyzae and Cryptolestes perrugineus (Hubert, et. al., 2008). U.S. Pat. No. 6,201,026 suggests of an organic aldehyde of 3 or more carbons for the control of aphides.
[0013] Several patents suggest the use of trans-2-hexenal as a fragrance or perfume. U.S. Pat. No. 6,596,681 suggests the use of trans-2-hexenal as a fragrance in a wipe for surface cleaning. U.S. Pat. No. 6,387,866, U.S. Pat. No. 6,960,350 and U.S. Pat. No. 7,638,114 suggest the use of essential oil or terpenes (e.g. trans-2-hexenal) as perfume for antimicrobial products. U.S. Pat. No. 6,479,044 demonstrates an antibacterial solution comprising an anionic surfactant, a polycationic antibacterial and water, where an essential oil is added as perfume. This perfume could be a terpene such as trans-2-hexenal or other type of terpenes. U.S. Pat. No. 6,323,171, U.S. Pat. No. 6,121,224 and U.S. Pat. No. 5,911,915 demonstrate an antimicrobial purpose microemulsion containing a cationic surfactant where an essential oil is added as a perfume. This perfume can be various terpenes including i.e. trans-2-hexenal. U.S. Pat. No. 6,960,350 demonstrates an antifungal fragrance where a synergistic effect was found when different terpenes were used in combinations (for example trans-2-hexenal with benzaldehyde).
[0014] The mode of action of trans-2-hexenal is thought to be the alteration of the cell membrane due to the reaction of hexenal to the sulfhydryl moiety or cysteine residues or formation of Schiff bases with amino groups of peptides and proteins (Deng, et. al., 1993). Trans-2-hexenal is reported to act as a surfactant, but likely permeates by passive diffusion across the plasma membrane. Once inside cells, its α,β-unsaturated aldehyde moiety reacts with biologically important nucleophilic groups. This aldehyde moiety is known to react with sulphydryl groups mainly by 1,4-additions under physiological conditions (Patrignani, et. al., 2008).
[0015] Trans-2-hexenal is an inhibitor of phospholipase D, an enzyme that catalyses the hydrolysis of membrane phospholipids that occurs during the maturation and ripening of many types of fruits and vegetables. Therefore, it is suggested that trans-2-hexenal may inhibit ripening (USPTO Application No. 2005/0031744 A1). It is suggested that the inhibition of Salmonella typhimurium and Staphylococcus aureus by trans-2 hexenal is due to the hydrophobic and hydrogen bonding of its partition in the lipid bilayer. The destruction of electron transport systems and the perturbation of membrane permeability have been suggested as other modes of action (Gardine, et. al., 2001). The inhibition of P. expansum decay may be due to damage to fungal membranes of germinating conidia (Neri, et. al., 2006a and 2006b). Studies have been performed to compare trans-2-hexenal to other similar compounds. Deng, et. al. (1993) showed that unsaturated volatiles, trans-2-hexenal and trans-2-hexen-1-ol, exhibited a greater inhibitory effect than the saturated volatiles, hexanal and 1-hexanol. Trans-2-hexenal was more active than hexanal, nonanal and trans-2-octenal against all ATCC bacterial strains (Bisignano, et. al., 2001). Other have found that trans-2-hexenal had lower minimal fungal-growth-inhibiting concentrations than hexanal, 1-hexanol, trans-2-hexen-1-ol, and (Z)-3-hexen-1-ol (basically aldehydes>ketones>alcohols; Andersen, et. al., 1994). Hexenal and hexanoic acid have been reported to be more effective than hexanol in inhibiting Salmonella spp. (Patrignani, et. al., 2008).
[0016] Muroi, et. al., (1993) suggested that trans-2-hexenal exhibited broad antimicrobial activity but its biological activity (50 to 400 μg/ml) is usually not potent enough to be considered for practical applications. Studies have shown that trans-2-hexenal can potentiate the effectiveness of certain type of antimicrobials. Several patents suggest the use of potentiators for aminoglycoside antibiotics (U.S. Pat. No. 5,663,152), and potentiators for polymyxin antibiotic (U.S. Pat. No. 5,776,919 and U.S. Pat. No. 5,587,358). These potentiators can include indol, anethole, 3-methylindole, 2-hydroxy-6-R-benzoic acid or 2-hexenal. A strong synergic effect was observed when trans-2-eptenal, trans-2-nonenal, trans-2-decenal and (E,E)-2,4-decadienal were tested together (1:1:1:1 ratio) against ATCC and clinically isolated microbial strains (Bisignano et. al., 2001). The prior art has not suggested or observed that the use of trans-2-hexenal in combination with organic acids esters improved the antimicrobial activity of either of the components by themselves
[0017] Another component of the present invention are organic acids. Commercial mold inhibitors and bactericides are composed of single organic or a mixture of organic acids and/or formaldehyde. The most commonly used acids are propionic, benzoic acid, butyric acid, acetic, and formic acid. The mechanism by which small chain organic acids exert their antimicrobial activity is that undissociated (RCOOH=non ionized) acids are lipid permeable and in this way they can cross the microbial cell wall and dissociate in the more alkaline interior of the microorganism (RCOOH->RCOO − +H + ) making the cytoplasm unstable for survival (Van Immerseel, et. al., 2006; Paster, 1979).
[0018] Nonanoic acid (nonanoic acid) is a naturally occurring medium chain organic acid. It is oily, colorless fluid, which at lower temperature becomes solid. It has a faint odor compared to butyric acid and is almost insoluble in water. The primary use of nonanoic acid has been as a non-selective herbicide. Scythe (57% nonanoic acid, 3% related organic acids and 40% inert material) is a broad-spectrum post-emergence or burn-down herbicide produced by Mycogen/Dow Chemicals. The herbicidal mode of action of nonanoic acid is due first to membrane leakage during darkness and daylight and second to peroxidation driven by radicals originating during daylight by sensitized chlorophyll displaced from the thylakoid membrane (Lederer, et. al., 2004).
[0019] Chadeganipour and Haims (2001) showed that the minimum inhibitory concentration (MIC) of medium chain organic acids to prevent growth of M. gypseum was 0.02 mg/ml capric acid and for nonanoic acid 0.04 mg/ml on solid media and 0.075 mg/ml capric acid and 0.05 mg/ml nonanoic in liquid media. These acids were tested independently and not as a mixture. Hirazawa, et. al. (2001) reported that nonanoic acid as well as C 6 to C 10 organic acids were effective in controlling the growth of the parasite, C. irritans , and that C 8 , C 9 and C 19 organic acids were more potent. It was found that Trichoderma harzianum , a biocontrol for cacao plants, produces nonanoic acid as one of many chemicals, which was effective in controlling the germination and growth of cacao pathogens (Aneja, et. al., 2005).
[0020] Several US patents disclose the use of nonanoic acids as fungicides and bactericides: US Patent Application #2004/026685) discloses a fungicide for agricultural uses that is composed of one or more fatty acids and one or more organic acids different from the fatty acid. In the mixture of the organic acids and the fatty acids, the organic acid acts as a potent synergist for the fatty acid to function as a fungicide. U.S. Pat. No. 5,366,995 discloses a method to eradicate fungal and bacterial infections in plants and to enhance the activity of fungicides and bactericides in plants through the use of fatty acids and their derivatives. This formulation consists of 80% nonanoic acid or its salts for the control of fungi on plants. The fatty acids used are primarily C 9 to C 18 . U.S. Pat. No. 5,342,630 discloses a novel pesticide for plant use containing an inorganic salt that enhance the efficacy of C 8 to C 22 fatty acids. One of the examples shows a powdered product with 2% nonanoic acid, 2% capric acid, 80% talc, 10% sodium carbonate and 5% potassium carbonate. U.S. Pat. No. 5,093,124 discloses a fungicide and arthropodice for plants comprising of alpha mono carboxylic acids and their salts. The fungicide consists of the C 9 to C 10 fatty acids, partially neutralized by an active alkali metal such as potassium. The mixture described consists of 40% active ingredient dissolved in water and includes 10% nonanoic, 10% capric acid and 20% coconut fatty acids, all of which are neutralized with potassium hydroxide. U.S. Pat. No. 6,596,763 discloses a method to control skin infection comprised of C 6 to C 18 fatty acids or their derivatives. U.S. Pat. No. 6,103,768 and U.S. Pat. No. 6,136,856 discloses the unique utility of fatty acids and derivatives to eradicate existing fungal and bacterial infections in plants. This method is not preventive but showed effectiveness in already established infections. Sharpshooter, a commercially available product, with 80% nonanoic acid, 2% emulsifier and 18% surfactant, is effective against Penicillium and Botrytis spp. U.S. Pat. No. 6,638,978 discloses an antimicrobial preservative composed of a glycerol fatty acid ester, a binary mixture of fatty acids (C 6 to C 18 ) and a second fatty acid (C 6 to C 18 ) where the second fatty acid is different from the first fatty acid for preservation of food. WO 01/97799 discloses the use of medium chain fatty acids as antimicrobial agents. It shows that an increase of the pH from 6.5 to 7.5 increased the MIC of the short chain (C 6 to C 18 ) fatty acids.
[0021] Nonanoic acid is used as a component of a food contact surface sanitizing solution in food handling establishments. A product from EcoLab consists of 6.49% nonanoic acid as active ingredient to be use as a sanitizer for all food contact surfaces (12CFR178.1010 b). The FDA has cleared nonanoic acid as a synthetic food flavoring agent (21CFR172.515) as an adjuvant, production aid and sanitizer to be used in contact food (12CFR178.1010 b), and in washing or to assist in lye peeling of fruits and vegetables (12CFR173.315). Nonanoic acid is listed by the USDA under the USDA list of Authorized Substances, 1990, section 5.14, Fruit and Vegetable Washing Compounds.
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SUMMARY OF THE INVENTION
[0057] One object of the invention is to provide a chemical formulation that improves the microbicidal effect of organic acids. The composition can be a solution containing an organic acid, or a mixture of several organic acids, in combination with an aldehyde and an organic/fatty acid ester.
[0058] Another object is to provide an antimicrobial composition for extending the shelf-life of water, food/feed or food/feed ingredients, comprising:
5-25 wt. % nonanoic acid, 1-25 wt. % organic acid ester, 1-50 wt. % of a single or mixture of C 1 -C 24 aldehydes a mixture of C 1 -C 24 organic acids, and water.
[0065] Another object is to provide a method to preserve water, food/feed, and food/feed ingredients, comprising:
spray-treating, in-line mixing, in-line spraying or admixing to water, food/feed or food/feed ingredients, an effective amount of a composition comprising: 5-25 wt. % nonanoic acid, 1-25 wt. % organic acid ester, 1-50 wt. % of a single or mixture of C 1 -C 24 aldehydes, a mixture of C 1 -C 24 organic acids, and water.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0073] In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined to have the following meanings.
Definitions
[0074] A “weight percent” of a component is based on the total volume of the formulation or composition in which the component is included.
[0075] An organic acids of the composition can comprise formic, acetic, propionic, butyric, nonanoic, lactic and other C 2 to C 24 organic acid or mono-, di-, or triglycerides containing C 1 to C 24 fatty acids. These fatty acids comprising small chain, medium chain, long chain fatty acids or small chain, medium chain, long chain triglycerides.
[0076] A organic acid ester of the composition can comprise, methyl, ethyl, butyl and propyl organic acid esters or mixtures thereof.
[0077] By the term “effective amount” of a compound is meant such amount capable of performing the function of the compound or property for which an effective amount is expressed, such as a non-toxic but sufficient amount of the compound to provide the desired antimicrobial benefits. Thus an appropriate effective amount may be determined by one of ordinary skill in the art using only routine experimentation
[0078] Formulations can vary not only in the concentration of major components i.e. organic acids, but also in the type of aldehydes, organic acid ester and water concentration used. This invention can be modified in several ways by adding or deleting from the formulation one of the organic acids, aldehyde and type of organic acid ester.
[0079] By the terms “synergistic effect or synergy” of the composition is meant to the improved preservative and antimicrobial effect when the ingredients are added as a mixture rather than as individual components.
[0080] Composition (s)
[0081] A composition of the present invention contains an effective amount of organic acids having 1 to 24 carbons, an aldehyde and organic acid ester.
[0082] The organic acids of 1 to 24 carbon chain length may be saturated, unsaturated, cyclic or acyclic organic acids.
[0083] The effective mixture of the invention comprises 1 to 70% by volume organic acids,
[0084] The effective mixture of the invention comprises 1 to 70% by volume nonanoic acid.
[0085] The effective mixture of the invention comprises 1 to 50% aldehyde.
[0086] The effective mixture of the invention comprises 1 to 50% a organic acid ester.
[0087] The effective mixture of the invention comprises 0 to 70% by volume water.
[0088] The composition can further comprise a organic acid ester.
[0089] The composition can further comprise a organic acid methyl ester.
[0090] The composition can further comprise a organic acid ethyl ester.
[0091] The composition can further comprise a organic acid butyl ester.
[0092] The composition can further comprise a organic acid propyl ester.
[0093] The aldehydes of the composition comprise trans-2-pentenal, 2,4-hexadienal, 2,6-nonadienal, trans-2-nonenal, trans-2-hexenal, 10-undecenal, 2,4-decadienal, 2,6-dimethyl-5-heptanal, 2,6-dimethyloctanal, 2-decenal, 2-dodecenal, 2-ethylbutyraldehyde, 2-phenylpropionaldehyde, 2-tridecenal, 3-phenylpropionaldehyde, 9-undecenal, butyraldehyde, cinnamaldehyde, cis-4-heptenal, citral, Citronelloxyacetaldehyde, cuminaldehyde, decanal, furfural, heptanal, hexanal, hydroxycitronellal, Isobutyraldehyde, p-ethoxybenzaldehyde, phenylacetaldehyde, propionaldehyde, p-tolylacetaldehyde, pyruvaldehyde, salicylaldehyde, undecenal, valeraldehyde, veratraldehyde, α-amylcinnamaldehyde, α-butylcinnamaldehyde, α-hexylcinnamaldehyde or other similar aldehydes and their respective alcohol forms.
[0094] The composition is effective against various fungi present in food/feed and major food/feed ingredients.
[0095] The composition is effective against various bacteria present in food/feed and major food/feed ingredients.
[0096] The composition is effective against various bacteria and fungi present in water.
[0097] The composition is effective against microbes detrimental for the production of alcohol from fermentation of cellulose, starch or sugars.
Methods
[0098] The present invention is effective against bacteria and fungi.
[0099] The present invention is applied to water.
[0100] The present invention is applied to the food/feed ingredients before entering the mixer.
[0101] The present invention is applied to the unmixed food/feed ingredients in the mixer.
[0102] The present invention is applied during the mixing of the food/feed ingredients.
[0103] The present invention is applied by a spray nozzle.
[0104] The present invention is applied by a spray nozzle in an in-line application system.
[0105] The present invention is applied in liquid form or as a dry product when mixed with a carrier.
[0106] The present invention is applied is such a form that provides a uniform and homogeneous distribution of the mixture throughout the mixed ingredients.
[0107] One of the objectives of the present invention is to control the level of microorganisms in food/feed ingredients, food/feed and water. Several mixtures of organic acids, organic acid ester and aldehydes resulted in several formulations that showed effectiveness against bacteria in water and food/feed.
[0108] Other objective of the present invention is to formulate an antimicrobial with nature identical occurring compounds or safe to use compounds.
[0109] All of the chemicals used in the present invention are currently approved for human uses as antimicrobials, perfumery, flavorings and adjuvants enhancers.
[0110] There were unexpected results, i.e. synergism and additive effect, when the organic acids, organic acid ester and aldehydes were used in combination.
[0111] Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which this invention pertains.
Example 1
[0112] Methyl and ethyl esters of organic acids were added to test tubes at concentrations of 0.01% and 0.05%. Tubes were vortexed for 10 seconds to uniformly mix the solution. A suspension of Salmonella typhimurium (ATTC:14028) was added to each test tube to achieve a final concentration of 10 4 cfu/ml. The solutions were vortexed, incubated at room temperature for 24 hours and plated on XLT-4 agar. Plates were incubated for 48 hours at 37° C. before enumerating colonies. The effectiveness of each ester as percent reduction compared to the control value is shown in Table 1.
[0000]
TABLE 1
Effect of Organic acid Esters on Reduction (% Reduction)
of Salmonella typhimurium in vitro
0.01% Dilution
0.05% Dilution
Methyl
Ethyl
Methyl
Ethyl
Organic acid
Ester
Ester
Ester
Ester
Formic acid
0
67
5
27
Acetic acid
0
0
29
0
Propionic acid
9
0
19
40
Butyric acid
0
28
28
100
Valeric (pentanoic) acid
10
93
100
100
Caproic (hexanoic) acid
99
100
100
100
Caprylic (octanoic) acid
94
66
94
65
Lauric (dodecanoic) acid
1
0
0
0
Levulinic acid
0
0
12
8
Malonic acid
13
36
9
57
Benzoic acid
34
100
100
100
Capric (decanoic) acid
8
0
0
0
Myristic (tetradecanoic)
43
12
49
8
acid
Linoleic acid
14
0
0
0
Isobutyric acid
3
ND*
41
ND
Isovaleric acid
ND
61
ND
100
Isoamyl acetate
44
100
*ND not determined
[0113] Esters of organic acids with chain lengths of C 4 to C 8 were observed to be effective against Salmonella at the concentrations tested. Ethyl esters were generally more effective than methyl esters. The esters of benzoic acid (an aromatic ring acid) and isoamyl acetate (isoamyl ester of acetic acid) were also observed to have bactericidal activity.
Example 2
[0114] Eight organic acid esters (C 4 -C 8 organic acid esters and benzoic acid esters) were blended with trans-2-hexenal, nonanoic acid, propionic acid, acetic acid and water as presented in Table 2. A 25% hexanal: organic acid product (Formula 1) and a formic:propionic acid (90:10, F/P) product were included as positive controls. Formulations were added to test tubes at concentrations of 0.01% and 0.005%. Tubes were vortexed for 10 seconds to uniformly mix the solution.
[0000]
TABLE 2
Percentage of Ingredients in Test Formulas
Organic
Acetic
trans-2-
Acid
Formula
Nonanoic
Formic
(56%)
Propionic
Hexenal
Ester
Water
1
5
0
20
50
25
0
0
2
5
0
20
40
15
5
15
3
5
0
20
40
15
10
10
4
5
0
20
40
15
20
0
5
5
0
20
40
10
5
20
6
5
0
20
40
10
10
15
7
5
0
20
40
10
20
5
8
5
0
20
40
5
5
25
9
5
0
20
40
5
10
20
10
5
0
20
40
5
20
10
11
5
0
20
40
0
5
30
12
5
0
20
40
0
10
25
13
5
0
20
40
0
20
15
F/P
0
90
0
10
0
0
0
[0115] A suspension of Salmonella typhimurium (10 4 cfu/ml) was added to test tubes containing the different dilution of each formulation. The solutions were vortexed, incubated at room temperature for 24 hours and plated on XLT-4 agar. Plates were incubated for 48 hours at 37° C. before enumerating colonies.
[0116] The effectiveness of each formulation as percent reduction compared to the control value is shown in the Tables 3 to 10.
[0000]
TABLE 3
Effect of Methyl Benzoate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
64
100
2
37
95
3
58
98
4
59
100
5
57
93
6
55
96
7
34
95
8
48
76
9
42
77
10
40
88
11
33
4
12
39
0
13
24
0
F/P
1
90
[0000]
TABLE 4
Effect of Ethyl Benzoate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
64
100
2
86
99
3
57
100
4
68
100
5
55
98
6
46
98
7
71
100
8
51
88
9
66
89
10
67
99
11
40
7
12
44
6
13
40
50
F/P
1
90
[0000]
TABLE 5
Effect of Ethyl Butyrate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
50
100
2
39
99
3
20
99
4
1
100
5
0
97
6
7
97
7
4
95
8
0
70
9
0
73
10
0
86
11
0
0
12
0
0
13
0
0
F/P
0
51
[0000]
TABLE 6
Effect of Methyl Octanoate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
54
100
2
62
99
3
31
100
4
40
100
5
26
91
6
41
98
7
48
100
8
30
76
9
42
92
10
51
100
11
0
0
12
19
18
13
16
89
F/P
0
62
[0000]
TABLE 7
Effect of Methyl Hexanoate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
67
100
2
44
99
3
72
100
4
47
100
5
45
100
6
54
91
7
64
99
8
49
76
9
57
81
10
40
86
11
42
0
12
30
0
13
37
0
F/P
0
73
[0000]
TABLE 8
Effect of Ethyl Hexanoate Formulations on Reduction of
Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
54
99
2
15
95
3
41
95
4
21
05
5
10
86
6
20
87
7
14
97
8
0
56
9
9
58
10
5
88
11
0
0
12
0
0
13
6
0
F/P
0
71
[0000]
TABLE 9
Effect of Methyl Pentanoate Formulations on Reduction
of Salmonella typhimurium (% Reduction) in vitro
Formula
0.005%
0.01%
1
36
100
2
24
98
3
11
97
4
22
95
5
9
84
6
5
84
7
23
96
8
8
59
9
21
57
10
14
67
11
8
0
12
28
0
13
7
0
F/P
0
98
[0000]
TABLE 10
Effect of Ethyl Pentanoate Formulations on Reduction
of Salmonella typhimurium (% Reduction) in vitro
Formula
% 0.005%
0.01%
1
36
100
2
41
98
3
28
97
4
34
99
5
16
81
6
42
95
7
56
90
8
19
73
9
32
77
10
45
74
11
41
0
12
52
45
13
50
5
14
0
98
Conclusions: The addition of 5-20% of organic acid ester to an organic acid product containing 5-20% trans-2-hexenal improved the effectiveness of the trans-2-hexenal against Salmonella ..
Example 3
[0117] Eighteen formulations were prepared for in vitro studies as presented in Table 11. A 25% trans-2-hexanal: organic acid product (Formula 1) and a formic:propionic acid (90:10, F/P) product were included as positive controls. Formulations were added to test tube at concentrations of 0.005% and 0.01%. Tubes were vortexed for 10 seconds to uniformly mix the solution.
[0000]
TABLE 11
Percentage of Ingredients in Test Formulas (%)
Acetic
trans-2-
Ethyl
Ethyl
Ethyl
Ethyl
Formula
Nonanoic
Formic
Propionic
hexenal
hexanoate
butyrate
Water
1
5
0
20
50
25
0
0
0
0
0
2
5
0
20
40
5
20
0
0
0
10
3
5
0
20
40
10
15
0
0
0
10
4
5
0
20
40
15
10
0
0
0
10
5
5
0
20
40
20
5
0
0
0
10
6
5
0
20
40
5
0
20
0
0
10
7
5
0
20
40
10
0
15
0
0
10
8
5
0
20
40
15
0
10
0
0
10
9
5
0
20
40
20
0
5
0
0
10
10
5
0
20
40
5
0
0
20
0
10
11
5
0
20
40
10
0
0
15
0
10
12
5
0
20
40
15
0
0
10
0
10
13
5
0
20
40
20
0
0
5
0
10
14
5
0
20
40
5
0
0
0
20
10
15
5
0
20
40
10
0
0
0
15
10
16
5
0
20
40
15
0
0
0
10
10
17
5
0
20
40
20
0
0
0
5
10
F/P
0
90
0
10
0
0
0
0
0
0
indicates data missing or illegible when filed
[0118] A suspension of Salmonella typhimurium (10 4 cfu/ml) was added to test tubes containing the different dilution of each formulation. The solutions were vortexed, incubated at room temperature for 24 hours, and plated on XLT-4 agar. Plates were incubated for 48 hours at 37° C. before counting Salmonella colonies. The effectiveness of each formulation as percent reduction compared to the control value is shown in Table 12.
[0000]
TABLE 12
Effect of Formulations on Reduction of Salmonella typhimurium
(% Reduction) in Vitro
Formula
0.005%
0.01%
1
37
80
2
10
10
3
1
33
4
18
68
5
39
83
6
0
3
7
13
36
8
26
68
9
37
91
10
5
0
11
4
30
12
25
62
13
29
85
14
16
20
15
10
27
16
23
60
17
30
77
F/P
27
55
[0119] The addition of 5% of each ester to an organic acid product containing 20% trans-2-hexenal was equivalent in efficacy to the organic acid product containing 25% trans-2-hexenal.
[0120] Adding additional ester did not allow for the concentration of trans-2-hexenal to be further decreased.
Example 4
[0121] Sixteen formulations were prepared for in vitro studies as presented in Table 13. A formic:propionic acid (90:10, F/P) product was included as positive control. Formulations were added to test tubes at concentration of 0.005% and 0.01%. Tubes were vortexed for 10 seconds to uniformly mix the solution.
[0000]
TABLE 13
Percentage of Ingredients in Test Formulas
Acetic
Ethyl
Ethyl
Methyl
Ethyl
Methyl
Ethyl
Methyl
Formula
Nonanoic
Formic
Propionic
Trans-2-
Water
1
5
0
20
50
25
0
0
0
0
0
0
0
0
2
5
0
20
40
5
5
0
0
0
0
0
0
25
3
5
0
20
40
5
0
5
0
0
0
0
0
25
4
5
0
20
40
10
0
0
10
0
0
0
0
15
5
5
0
20
40
5
0
0
20
0
0
0
0
10
6
5
0
20
40
5
0
0
0
20
0
0
0
10
7
5
0
20
40
5
0
0
0
0
10
0
0
20
8
5
0
20
40
15
0
0
0
0
0
5
0
15
9
5
0
20
40
15
0
0
0
0
0
10
0
10
10
5
0
20
40
15
0
0
0
0
0
20
0
0
11
5
0
20
40
10
0
0
0
0
0
20
0
5
12
5
0
20
40
15
0
0
0
0
0
0
5
15
13
5
0
20
40
15
0
0
0
0
0
0
10
10
14
5
0
20
40
15
0
0
0
0
0
0
20
0
15
5
0
20
40
10
0
0
0
0
0
0
20
0
F/P
0
90
0
10
0
0
0
0
0
0
0
0
0
indicates data missing or illegible when filed
[0122] A suspension of Salmonella typhimurium (10 4 cfu/ml) was added to test tubes containing the different dilution of each formulation. The solutions were vortexed, incubated at room temperature for 24 hours and plated on XLT-4. Plates were incubated for 48 hours at 37° C. before enumerating colonies. The effectiveness of each formulation as percent reduction compared to the control value is shown in Table 14.
[0000]
TABLE 14
Effect of Formulations on Reduction of Salmonella typhimurium
(% Reduction) in vitro
Formula
0.005%
0.01%
1
73
100
2
29
78
3
33
90
4
39
94
5
17
84
6
27
93
7
44
98
8
57
100
9
57
100
10
45
99
11
33
97
12
43
98
13
37
98
14
37
95
15
41
95
F/P
0
96
[0123] The addition of organic acid ester to an organic acid product containing 5-15% trans-2-hexenal was equivalent or better in efficacy to the organic acid product.
Example 5
[0124] Nine formulations were prepared for in vitro studies as presented in Table 15. Formula 1 was used as a positive control. Formulations were added to test tube at concentration of 0.005% and 0.01%. Tubes were vortexed for 10 seconds to uniformly mix the solution.
[0000]
TABLE 15
Percentage of Ingredients in Test Formulas
Formulas
Ingredients
1
2
3
4
5
6
7
8
9
Nonanoic
5
5
5
5
5
5
5
5
5
Acetic (56%)
20
20
20
20
20
20
20
20
20
Propionic
50
40
40
40
40
40
40
40
10
trans 2-hexenal
25
15
15
15
15
15
15
15
15
Methyl octanoate
20
Methyl benzoate
20
Ethyl benzoate
20
Methyl hexanoate
20
Ethyl hexanoate
20
Ethyl butyrate
20
Ethyl pentanoate
20
Methyl
20
pentanoate
[0125] A suspension of Salmonella typhimurium (10 4 cfu/ml) was added to three test tubes containing the different dilution of each formulation. The solutions were vortexed, incubated at room temperature for 24 hours and plated on XLT-4. Plates were incubated for 48 hours at 37° C. before counting Salmonella colonies. The effectiveness of each formulation as percent reduction compared to the control value is shown in Table 16.
[0000]
TABLE 16
Effect of Adding Organic Acid Esters in the Formulation on the
Reduction of Salmonella typhimurium (% Reduction) in vitro
Formula
Organic ester added
0.005%
0.01%
1
None
59
100
2
Methyl octanoate
62
100
3
Methyl benzoate
64
100
4
Ethyl benzoate
51
100
5
Methyl hexanoate
55
100
6
Ethyl hexanoate
55
100
7
Ethyl butyrate
54
100
8
Ethyl pentanoate
46
100
9
Methyl pentanoate
46
100
[0126] The addition of 20% methyl or methyl ester to an organic acid product containing 15% trans-2-hexenal was equivalent in efficacy to the organic acid product containing 25% trans-2-hexenal.
Example 6
[0127] Six formulations were prepared for in vitro studies as presented in Table 17. A 25% trans-2-hexanal: organic acid product and formic:propionic (90:10) acid product were included as positive controls. Formulations were added to test tube at concentration of 0.01% and 0.005%. Solutions were vortexed for 10 seconds to uniformly mix the solution.
[0000]
TABLE 17
Percentage of Ingredients in Test Formulas
Formulas
Ingredients
1
2
3
4
5
6
Nonanoic
5
5
5
5
5
Formic
90
Acetic (56%)
20
20
20
20
20
Propionic
50
40
40
40
40
10
trans 2-hexenal
25
5
10
15
20
Ethyl pentanoate
20
20
20
20
[0128] A suspension of Salmonella typhimurium (10 4 cfu/ml) was added to test tubes containing the different dilution of each formulation. The solutions were vortexed, incubated at room temperature for 24 hours and plated on XLT-4. Plates were incubated for 48 hours at 37° C. before enumerating colonies. The effectiveness of each formulation as percent reduction compared to the control value is shown in Table 18.
[0000]
TABLE 18
Effect of Formulations on Reduction of Salmonella typhimurium
(% Reduction) in vitro
Formula
0.005%
0.01%
1
0
50
2
6
16
3
12
8
4
22
16
5
13
46
6
7
0
[0129] The addition of 20% ethyl pentanoate to an organic acid product containing 20% trans-2-hexenal was equivalent in efficacy to the organic acid product containing 25% trans-2-hexenal.
Example 7
[0130] In this study the effectiveness of several formulations containing organic acids ester against Salmonella spp. were tested in feed. A 90% formic: 10% propionic acid (F/P) product was included as positive control. A dry inoculum containing 10 5 cfu/g of Salmonella typhimurium was added to finely ground poultry feed. Contaminated feed was mixed in a lab mixer equipped with a liquid spray system for 5 minutes and then treated with the different formulations at 0, 1, 2, or 4 Kg/MT (Table 19). After treatment, the contents of the mixer were transferred to one-gallon glass jar, capped and allowed to sit overnight at room temperature (23-25° C.). Samples (four 10 g-subsamples/mixer load) were obtained at 24 hours and/or 7 days after treatment. The 10 g subsamples of feed were transferred to bottles containing 90 mL of Butterfields Phosphate. Dilutions were plated in triplicate on XLT-4 agar. Plates were incubated at 37° C. for 48 hours. After incubation, the level of the S. typhimurium on the agar plates was enumerated.
[0000]
TABLE 19
Percentage of Ingredients in Test Formulas
Ethyl
Methyl
pentanoat
butyrate
benzoate
benzoate
benzoate
hexanoate
hexanoate
octanoate
pentanoat
pentanoat
pentanoat
Ingredient
G
G
E
I
I
I
H
A
F
A
F
Propionic acid
40
40
40
40
40
40
40
40
40
40
40
Acetic acid (56%)
20
20
20
20
20
20
20
20
20
20
20
Nonanoic acid
5
5
5
5
5
5
5
5
5
5
5
trans-2-hexenal
5
5
10
5
5
5
5
15
10
15
10
Ethyl butyrate
5
0
0
0
0
0
0
0
0
0
0
Ethyl benzoate
0
5
0
0
0
0
0
0
0
0
0
Methyl benzoate
0
0
10
20
0
0
0
0
0
0
0
Ethyl hexanoate
0
0
0
0
20
0
0
0
0
0
0
Methyl
0
0
0
0
0
20
0
0
0
0
0
hexanoate
Methyl
0
0
0
0
0
0
10
0
0
0
0
octanoate
Ethyl pentanoate
0
0
0
0
0
0
0
5
20
0
0
Methyl
0
0
0
0
0
0
0
0
0
5
20
pentanoate
Water
25
25
15
10
10
10
20
15
5
15
5
Total
100
100
100
100
100
100
100
100
100
100
100
indicates data missing or illegible when filed
[0131] The effectiveness of each formulation as percent reduction compared to the control value is shown in Tables 20-30.
[0000]
TABLE 20
Effect of Ethyl Pentanoate Formulation “A” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Ethyl Pentanoate A
24 hours
Ethyl Pentanoate A - 1 kg/MT
77
Ethyl Pentanoate A - 2 kg/MT
92
Ethyl Pentanoate A - 4 kg/MT
100
F/P 1 kg/MT
0
F/P 2 kg/MT
59
F/P 4 kg/MT
83
[0000]
TABLE 21
Effect of Ethyl Pentanoate Formulation “F” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Ethyl Pentanoate F
24 hours
Ethyl Pentanoate F - 1 kg/MT
77
Ethyl Pentanoate F - 2 kg/MT
94
Ethyl Pentanoate F - 4 kg/MT
94
F/P 1 kg/MT
53
F/P 2 kg/MT
74
F/P 4 kg/MT
93
[0000]
TABLE 22
Effect of Ethyl Butyrate Formulation “G” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Ethyl Butyrate G
24 hours
Ethyl Butyrate G - 1 kg/MT
70
Ethyl Butyrate G - 2 kg/MT
85
Ethyl Butyrate G - 4 kg/MT
92
F/P 1 kg/MT
76
F/P 2 kg/MT
77
F/P 4 kg/MT
95
[0000]
TABLE 23
Effect of Methyl Benzoate Formulation “E” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Methyl Benzoate E
24 hours
Methyl Benzoate E - 1 kg/MT
52
Methyl Benzoate E - 2 kg/MT
65
Methyl Benzoate E - 4 kg/MT
80
F/P 1 kg/MT
32
F/P 2 kg/MT
65
F/P 4 kg/MT
89
[0000]
TABLE 24
Effect of Methyl Benzoate Formulation “I” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Methyl Benzoate I
24 hours
Methyl Benzoate I - 1 kg/MT
70
Methyl Benzoate I - 2 kg/MT
83
Methyl Benzoate I - 4 kg/MT
82
F/P 1 kg/MT
79
F/P 2 kg/MT
84
F/P 4 kg/MT
97
[0000]
TABLE 25
Effect of Ethyl Benzoate Formulation “G” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Ethyl Benzoate G
24 hours
Ethyl Benzoate G - 1 kg/MT
72
Ethyl Benzoate G - 2 kg/MT
85
Ethyl Benzoate G - 4 kg/MT
88
F/P 1 kg/MT
76
F/P 2 kg/MT
77
F/P 4 kg/MT
95
[0000]
TABLE 26
Effect of Methyl Pentanoate Formulation “A” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Methyl Pentanoate A
24 hours
Methyl Pentanoate A - 1 kg/MT
49
Methyl Pentanoate A - 2 kg/MT
50
Methyl Pentanoate A - 4 kg/MT
96
F/P 1 kg/MT
42
F/P 2 kg/MT
84
F/P 4 kg/MT
96
[0000]
TABLE 27
Effect of Methyl Pentanoate Formulation “F” on Reduction
of Salmonella typhimurium (% Reduction) in Feed
Methyl Pentanoate F
24 hours
Methyl Pentanoate F - 1 kg/MT
80
Methyl Pentanoate F - 2 kg/MT
91
Methyl Pentanoate F - 4 kg/MT
98
F/P 1 kg/MT
53
F/P 2 kg/MT
77
F/P 4 kg/MT
93
[0000]
TABLE 28
Effect of Ethyl Hexanoate Formulation “I”, Methyl Hexanoate
Formulation “I” and Methyl Octanoate Formulation “H”
on the Reduction of Salmonella typhimurium (% Reduction) in Feed
Ethyl Hexenoate I
7 days
Ethyl Hexenoate I 1 kg/MT
69
Ethyl Hexenoate I 2 kg/MT
79
Ethyl Hexenoate I 4 kg/MT
88
Methyl Hexenoate I 1 kg/MT
81
Methyl Hexenoate I 2 kg/MT
88
Methyl Hexenoate I 4 kg/MT
95
Methyl Octanoate H 1 kg/MT
73
Methyl Octanoate H 2 kg/MT
83
Methyl Octanoate H 4 kg/MT
92
F/P 1 kg/MT
81
F/P 2 kg/MT
91
F/P 4 kg/MT
98
[0132] Formulas containing ethyl or methyl pentanoate were as effective as the formic:propionic (F/P) based product. | An antimicrobial composition and method for extending the shelf-life of water, food/feed or food/feed ingredients, comprising: 5-25 wt. % nonanoic acid, 1-25 wt. % organic acid ester, 1-50 wt. % of a single or mixture of C 1 -C 24 aldehydes, a mixture of C 1 -C 24 organic acids, and water. | 0 |
BACKGROUND OF THE INVENTION
This present invention relates to a combustion and control system for increasing the productivity and energy efficiency of regenerative furnaces, such as those used in high temperature heating and melting applications.
The typical system used for the melting of glass in industry is the regenerative furnace (or "glass tank"), which is constructed largely of brick and other refractories. In this glass furnace, glass is melted in a large refractory lined tank which is maintained at temperatures above 2750° F. As the molten glass is withdrawn from the furnace, recycled glass and/or new raw material, depending on the desired quality of the product being produced, is added to make up the charge.
The glass bath is heated by a series of burners which can be fueled with natural gas, petroleum gas, fuel oil, or low BTU gas (such as coke oven gas). Each side of the furnace is equipped with a series of burner ports, each of which contains at least one burner which injects a stream of fuel into preheated air (1300°-2000° F.) introduced into the furnace through the port. This air is preheated in regenerators, which are usually constructed in brick.
The heat from the escaping flue gases is captured by regenerators and then recaptured by preheating combustion air, which is blown through the heated bricks of the regenerator and into the furnace. Every fifteen to twenty minutes these flows of exhaust gases and combustion air are alternated, thus drawing the combustion air up through the regenerator, which is now hot, and the exhaust gases up through the regenerator, which is cold. As the flows are alternated, the flame traverses the glass tank in opposite directions. This operation results in the recovery of heat from the exhaust gases which increases flame temperature beyond levels that can be achieved with ambient combustion air, increases furnace productivity (pull rate) and improves furnace thermal efficiency.
The fuel stream is mixed with the preheated combustion air to generate a high temperature flame. The hot products of combustion pass through the furnace, transferring heat to the load as well as to the furnace roof, which then radiates heat to the load. The exhaust gases are channelled through the opposite regenerator providing heat to the refractory brick. The flue gases then pass through a reversing valve to the furnace stack. The furnace production rate is typically limited by heat flux, which can be transferred from the flame to the load without overheating the furnace crown. An increase in flame luminosity is always desired to raise the radiative heat transfer from the flame to gain furnace throughput and thermal efficiency.
There are, however, problems encountered in using the standard-type regenerative furnace. Glass furnace "campaigns" (the time between major overhauls) can run for many months or even years. At the end of a campaign, much of the refractory in the furnace has deteriorated significantly and the regenerators in particular will need substantial rework. During the campaign the gradual deterioration of the refractory in the regenerator results in plugging of the regenerator, reducing the cross sectional area of the refractory brick exposed to the flow of exhaust gases and combustion air. The result is a reduction in heat recovery and therefore a decrease in the temperature of preheated combustion air delivered to the ports, which in turn decreases total heat input and furnace productivity.
Throughout the glass furnace campaign, various impurities and foreign matter will be carried out of the tank by the exhaust gases and deposited on the regenerators. This increased resistance to air and exhaust gases flows results in the deterioration of combustion air flow, so that the furnace will not be capable of maintaining the necessary maximum firing rate required for maximum production rates.
A number of problems arise as a result of the switching cycle used in regenerative furnaces. For example, a common problem with traditional regenerative furnaces is the undesirable cooling effect on the furnace interior of the incoming air stream used to purge combustible gases from the regenerator while switching from one regenerator to the other. During this switching cycle, which consumes at least 3-5% of an entire working campaign, the fuel stream is shutdown and combustion air at lower than furnace temperatures is delivered to the furnace from the process of purging the regenerators. This purging of flue gases from the regenerator is necessary during the switching cycle to establish proper air flow throughout the regenerator prior to restarting the fuel flow. The shut down of the burner and the purging of the regenerator negatively impacts furnace productivity. During the switching cycle, the purge air is taking heat from the load and furnace linings reducing production capacity and furnace efficiency.
Also, the switched bed nature of the regenerative air heaters results in less than optimum flame temperatures and reduced recaptured heat inputs during the latter portion of each firing cycle because of gradual cooling of the regenerators. At the beginning of a cycle the temperature of the combustion air supplied to the glass tank burner will be 1900° F.-2400° F. However, at the end of a cycle, this temperature may be down to 1600° F.-2100° F., which will result in lower flame temperatures and which will limit the amount of glass which can be melted.
There exists a need, therefore, for means for improving the heat transfer efficiency between the flame produced in the combustion air and the product to be heated or melted through improved flame luminosity.
There also exists a need for means for stabilizing the heat input at a maximum allowable level based upon the properties of the furnace refractory.
There exists another need for such means for improving heat transfer efficiency and for stabilizing the heat input at a maximum allowable level to overcome deterioration in heat input due to the regenerator plugging throughout the furnace campaign.
There also exists a further need for means for providing heat input by using an auxiliary fuel and oxidizing gas stream to prevent furnace cooling when the main fuel is shut down during the switching period.
SUMMARY
The present invention relates to a combustion and control system which provides a means for maintaining instant heat input at an optimal level while improving flame luminosity in a regenerative furnace. An auxiliary combustion chamber is placed in the furnace so that it provides a luminous stream of hot, pyrolyzed combustible products directed to mix with hot combustion air delivered from a regenerator to create a final flame directed in the furnace above the material to be heated or melted. An auxiliary combustion chamber utilizes a stream of auxiliary fuel and oxidizing gas to generate hot combustion products delivering additional heat to the furnace. Controlled amounts of main fuel is also directed through the combustion chamber, where it mixes with the hot combustion products, pyrolyzes, and produces a hot, luminous stream of pyrolyzed combustion products which is directed into the furnace to mix with hot comubstion air to form a final flame pattern. By controlling the rates of the main fuel, preheated combustion air, auxiliary fuel, and oxidizing gas, a final flame of desired characteristic can be achieved and maintained. This allows greater control over the temperature inside the furnace, including the ability to overcome decreases in heat input due to plugged regenerators. Increased flame luminosity allows the maintenance of heat input at the maximum rate without overheating the furnace refractories.
Also, during the switching of regenerators, during the period when the delivery of the main fuel to the combustion chamber is shut off, the flows of auxiliary fuel and oxidizing gas are increased to produce an auxiliary switching flame. This flame acts to maintain a furnace temperature which is sufficient to prevent loss of furnace productivity and efficiency and thermal shock damage to the refractory.
Means for sensing and controlling the instant flows of the main fuel, auxiliary fuel, oxidizing gas and air are provided, as is a thermocouple for detecting the temperature of the combustion air preheating. An electronic computing means is also provided for continually determining the setpoints for the flow controlling means based upon inputs from the sensing means, the thermocouple and preprogrammed information. Alternatively, the preprogrammed information may be based upon predetermined preheating characteristics such as combustion air temperature declining cycle.
It is an object of this invention, therefore, to provide means for maintaining the optimal instant heat input to a regenerative furnace.
It is also an object of this invention to provide means for improving the heat transfer efficiency between the flame produced in the combustion air and the glass to be melted through improving flame luminosity.
It is a further object of this invention to provide means for stabilizing the heat input at a maximum allowable level based upon the properties of the furnace refractory.
It is still another object of this invention to provide means for improving heat transfer efficiency and for stabilizing the heat input at a maximum allowable level to overcome deterioration in heat input due to the regenerator plugging throughout the furnace campaign.
It is also an object of this invention to set forth means for providing heat input by using auxiliary fuel and an oxidizing gas stream to prevent the furnace from cooling when the main fuel is shut down during the switching period.
It is also an object of this invention to set forth means for providing a high momentum flame to impinge into the load from melting operations to provide heat input by using auxiliary oxidizing stream as sole oxidizer without preheated combustion air.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial a cross-sectional view of the top of a regenerator and burner port with an auxiliary combustion chamber of the present invention.
FIG. 2 is a schematic diagram of the control system for the high temperature combustion system of the present invention.
FIG. 3 illustrates the heat inputs for a regenerative furnace over a campaign.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a partial cross section of a regenerative furnace having the high temperature combustion system of the present invention, and emphasizing the so called 'regenerator intake", or the transition from the regenerator section to the traditional burner section. The figure shows the addition of an auxiliary combustion chamber or "combustor" 10 to a regenerative furnace. The combustor 10 is used to pyrolyze the main fuel stream prior to its combustion with the air discharged from the brick checker 12 by mixing it with the products of combustion of auxiliary fuel and auxiliary oxidizing gas that have been burned in the auxiliary combustion chamber.
The combustor 10 has a main fuel inlet 14, an auxiliary fuel inlet 16, an oxidizing gas inlet 18, an air inlet 20, and a cooling water inlet 22. The main and auxiliary fuel are normally natural gas, and the oxidizing gas may be either oxygen, oxygen enriched air, or oxygen and air separately delivered into the combustion chamber.
The products of pyrolysis of main fuel from the combustor 10 are discharged as a hot luminous stream of combustible products directly into the hot air stream leaving the checker uptake 21 through the burner port 26. The preheated combustion air is mixed with hot luminous products of pyrolysis, thereby generating a final hot, luminous flame. The products of combustion of this final flame are passing over the molten glass in the glass tank 28 to maintain maximum glass production. Each burner part can be equipped with several such combustion chambers 10 directing a portion of the hot liminous pyrolytic product toward the stream of preheated combustion air delivered throughout the regenerator intake.
The flows of auxiliary fuel and oxidizing gas through these combustors 10 will be a function of the discharge temperature from the checker 12 measured continuously by the thermocouple 30, or predicted by the preprogrammed information of the predicted temperature decline.
FIG. 2 depicts the overall control system for the high temperature burner system of the present invention. The combustor 10 shown is typical of the burners installed in both right-hand and left-hand ports. The various fluid flows to the combustors 10 are shown. Overall control of the system is accomplished with a solid state programmable logic controller 32 which is interconnected to the existing glass furnace controls 34. Control of the fluids in the various circuits is accomplished through the manual shut off valves 36, the flow measuring orifices and differential pressure transduces 38, the motorized flow control valves 40 and solenoid on/off valves 42.
Necessary instrumentation may be included to monitor the flow rates and temperatures of the combustion air throughout the checkers 12. Flow rates can be measured through the use of pilot tubes 44 or other flow measuring devices. The position of an air reversing valve 46 may be monitored to indicate the direction of air flow. Discharge temperatures of the air from the checkers 12 are monitored via thermocouples 30. The monitoring of temperature and flow rate of combustion air, preferably by a computerized control means, enables the combustion system to determine instant heat input with preheated combustion air and to establish instant flow of auxiliary gas and oxygen needed to maintain the optimum temperature and heat input throughout the entire furnace campaign.
OPERATION
The present invention uses stages combustion of natural gas or other hydrocarbon fuels to provide an extremely hot luminous flame envelope structure to improve heat transfer efficiency between the flame and the load and to stabilize heat input at the maximum allowable level based upon the properties of the furnace refractory.
The ability to stabilize heat input into the furnace at maximum allowable levels is accomplished by dynamically introducing additional heat inputs from the auxiliary combustor 10 due to the periodical drop in the temperature of the combustion air during the firing cycle. This incremental heat input in response to the drop in heat input from the conventional system is illustrated in FIG. 3.
The main hydrocarbon fuel stream proportioned to the main air flow through the checker 12 is pyrolysized in the combustor 10 prior to mixing with the hot combustion air delivered from the checkers 12. This process involves directing the main fuel stream throughout at least one combustor 10 in order to mix this stream with the hot combustion products produced from the combustion of an auxiliary fuel stream with an auxiliary oxidizing gas. The oxidizing gas may be either oxygen, oxygen enriched air or a separately delivered stream of air and oxygen. This process results in the pyrolysis of the main fuel stream prior to its mixing with the main hot air stream delivered from the checker 12. When mixed with the heated combustion air this pyrolysized main fuel stream produces a hot, luminous flame, and enhances heat transfer from the flame to the glass.
The amount of auxiliary fuel introduced into the combustor 10 is controlled to produce the added heat necessary to keep the total heat input into the furnace 11 at maximum permissible levels. This is accomplished by monitoring the temperature of the preheated combustion air delivered into the furnace 11 environment. Therefore, as the combustion air temperature decreases the system will respond by increasing the flows of auxiliary gas and oxygen or auxiliary gas, oxygen and air to generate the additional heat necessary to make up for the heat input losses due to the reduction in the temperature of the combustion air during the cycle as the heat stored in the regenerator is recaptured by the flow of combustion air.
During the switching from one checker 12 to another, the main fuel flow is shut down. During the shutdown of the main fuel flow, the flows of auxiliary fuel and oxidizing gas which are directed toward the combustor 10 are increased to produce an "auxiliary switching flame". The auxiliary switching flame provides sufficient heat to the furnace 11 environment to prevent the cooling of the furnace 11, which normally results from either the shutdown of the main fuel flow or the introduction of purging combustion air from the checker 12, or both.
The invention further provides the capability to boost heat input to make up for the drop in the efficiency of the checker 12 over the period of the campaign due to refractory wearing and regenerator bed plugging. This invention provides the capability to make up for this loss in efficiency by providing additional heat input from the combustors 10, as obtained by the combustion of controlled amounts of auxiliary fuel and oxygen or auxiliary fuel, oxygen and air.
An additional application for this invention relates to providing a high momentum flame to impinge into a load during melting operations to provide heat input by using an auxiliary oxidizing stream without preheated combustion air. For example, if a large charge is provided, which interferes with combustion, the present invention allows the use of the auxiliary oxidizing stream as the sole oxidizer. The burner can be used to at least partially melt down the load, and the regenerative cycle can thereafter begin. | A method and apparatus for improving the performance of a regenerative burner has a combustion chamber which receives and combusts controllable amounts of auxiliary fuel, an oxidizing gas, and possibly air to form hot combustion products. A controllable amount of a main fuel is then delivered to the combustion chamber and is pyrolyzed by the hot combustion products to produce a hot flame. By controlling the flame, one can maintain optimal temperature of the combustion air passing through the flame. Sensing means and computing means allow for automatic adjustments of fuel, oxygen and air flow to further maintain optimal combustion air temperatures. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for the monitoring of one or more threads in a sewing machine with a number of sewing heads for at least one upper thread and one lower thread and with at least one signal emitter for generating an electric signal in correspondence to the movement of the lower thread during a certain period of time.
Apparatus for the monitoring and sensing of the upper and lower threads in sewing machines with one, and in many cases several, sewing heads are exposed to relatively great mechanical stresses and have failed, as a result of shortcomings in strength and unreliability, to reach any desired degree of use. However, it is an extremely urgent demand in this art to be able to monitor the threads in order to attain as faultless seams and sewing as possible. The quicker the machines work, the greater is the need of being able to monitor the threads. Moreover, it is, in many cases desirable to be able to stop the machine automatically in the event of thread breakage. Hence, there is a great need within this art for a reliable and mechanically durable signal emitter.
The task of satisfying the above-outlined needs forms the basis of the present invention.
SUMMARY OF THE INVENTION
This task is solved according to the present invention in that the apparatus disclosed by way of introduction is characterized in that the signal emitter includes a spring arm which is fixedly anchored at one end and, at the opposite end, supports a magnet, that this opposite end is located in the path of movement of the lower thread, in order to be influenced by the lower thread in at least a certain movement thereof, that an element sensitive to the position of the magnet is disposed so as, in correspondence to the change of position of the magnet as a result of the movement of the lower thread, to generate the electric signal, and that the element is coupled to a signal evaluation circuit for indicating the loss of the signal during at least a certain period of time and possibly stopping of the sewing machine.
By means of an apparatus according to the present invention, there will be realized an extremely reliable and trustworthy monitoring of a desired movement of the lower thread in one or more sewing heads of a sewing machine. The apparatus according to the present invention has proved to satisfy stringent mechanical strength requirements and to display a great degree of reliability.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be described in greater detail below with reference to the accompanying Drawings.
FIG. 1 is a schematic view of a signal emitter according to one embodiment of an apparatus according to the present invention.
FIG. 2 is a diagram of the signal emitter of FIG. 1.
FIG. 3 shows the diagram of FIG. 2 in greater detail.
FIG. 4 is a diagram of a part of a signal evaluation circuit according to the present invention.
FIG. 5 is a block diagram of a circuit for the evaluation of thread monitoring signals from both the upper thread signal emitter and the lower thread signal emitter.
FIG. 6 is a coupling diagram for the circuit illustrated in FIG. 5.
FIG. 7 is a block diagram of a circuit for the evaluation of thread monitoring signals from a number of lower thread signal emitters.
FIGS. 8a, 8b are a coupling diagram for the circuit illustrated in FIG. 7, a number of identical parts having been omitted.
FIG. 9 is a block diagram for a central unit for a sewing machine
FIGS. 10A, 10B, 10C and 10D are a coupling diagram for the central unit shown in FIG. 9.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The signal emitter shown in FIG. 1, according to one embodiment of the present invention, is built-up on a plate 1 which may suitably be cast in an appropriate plastic material. On the plate 1, there is fixedly disposed a spring thread arm 2 which is wound at least one turn about a pin 3 so that the arm 2 proper is pivotal about the pin 3. One end of the spring thread arm 2 is anchored in a hole 4 in the plate 1. The free end of the spring thread arm 2 is bent in U-shape so as to form two vertical prongs 5 and 6 and a web portion 7 or base prong uniting the vertical prongs. Between the vertical prongs 5 and 6, there is disposed a plate 8 which carries a magnet 9 which is located in the proximity of a generator element 10. The generator element 10 is, in the present embodiment, a Hall generator whose magnetic flux is influenceable by the magnet 9. When the magnet 9 is moved in relation to the generator 10, the magnetic flux in the circuit will be changed. In its turn, the change in the magnetic flux will result in a change of the output signal of generator 10, whereupon the changed output signal is amplified and evaluated. The generator 10 is coupled to an amplifier circuit 11 which is disposed on the plate 1. That thread 12 which is to be sensed is laid against the base prong 7 and, on tightening of the thread 12, the spring thread arm 2 will be bent in over the plate 1, which entails a change in the position of the magnet 9 and thereby a change in the magnetic flux in the generator 10.
FIG. 2 illustrates a block diagram of the Hall generator 10 and its amplifier 11, it being apparent that the Hall generator is impressed with a supply voltage via two conductors 13 and 14, which results in a magnetic flux in the Hall generator 10, which in turn gives rise to an output signal which is amplified in the amplifier 11. On a change of the position of the magnet 9, the output signal from the generator 10 will be changed and the changed output signal will be amplified by means of the amplifier 11 and will subsequently be evaluated with the help of the circuit shown in FIG. 4. FIG. 3 shows a coupling diagram for the block diagram shown in FIG. 2, and the components included in the circuit have been given values and designations which have proved to be suitable on final testing of the signal emitter. The signal from the amplifier 11 occurs on a conductor 15.
The signal on the conductor 15 is fed to the circuit illustrated in FIG. 4 and into its input 15. The signal is fed to a comparator 16 via a coupling capacitor 17. A sensitivity setting signal is fed to the second input of the comparator 16, this signal being variable and, when a large number of signal emitters are provided in one machine, the level of sensitivity can be centrally altered for all emitters. The signal on the input 15 must exceed the sensitivity setting signal in order that a signal be obtained on the output of the comparator 16. The signal obtained on the output of the comparator 16 is fed to a double flip-flop circuit 18 and 19. In the flip-flop circuit 18, 19, the signal is gated with a sensing signal. Using the sensing signal, that period of time when lower thread and upper thread move simultaneously is distinguished from that period of time when only lower threads are in motion and influence the signal emitter. The circuit illustrated in FIG. 4 may be considered as a signal evaluation circuit and is coupled to a central unit for sewing machines, the central unit being exemplified in FIGS. 9 and 10. The central unit is synchronised with the sewing machine so that a sensing pulse is obtained only during that period of time when solely the lower thread is to be in motion. Thus, on the output 20 from the flip-flops 18 and 19, there will be obtained a ready stop signal which can be used for indication and possible stopping of the sewing machine, if no signal is received from the comparator 16 during the sensing period.
In many cases, a sewing machine is fitted with several sewing heads and it is desirable, therein, to monitor both the upper threads and the lower threads. FIG. 5 shows a block diagram of an upper thread monitoring unit. Therein, there is to be found a number of per se conventional piezoelectric emitters P1, P2, P3, P4, P5 and P6. The signal from the emitters P1-6 is fed via an amplifier F to a comparator K whose input 8 serves as a time-lag activation and whose input 5 serves as a time-lag de-activation, while the input 7 is a sensitivity signal input. The output signal from the comparator is fed to a flank-forming circuit FF whose output is coupled to a flip-flop circuit V, whose input R is coupled to a synchronisation pulse input and whose input D is coupled to a blocking pulse input and whose output Q is coupled to a two-coloured LED D, the red color input of the LED being coupled to the flip-flop V and the green coloured input to the output 20 of the circuit illustrated in FIG. 4. This means that on the occurrence of a stopping signal from any of the emitters P1-P6, the LED will show a red light, while showing a green light on the occurrence of a stopping signal from any one of the lower thread signal emitters. The signal from the LED D is fed via a switch O for feeding the signal to the central unit of the sewing machine. Thus, it is possible, using the switch O, to select only indication of stopping signals or the relaying of stopping signals to the central unit of the sewing machine for stopping thereof.
FIG. 6 shows a coupling diagram for the circuit illustrated in FIG. 5, the circuit values being, naturally, disclosed by way of example.
FIG. 7 shows a block diagram for an amplifier circuit for twelve lower thread signal emitters, each signal emitter 1-12 being coupled via the circuit illustrated in FIG. 4 to their output 13-24. The sensitivity setting inputs of the circuits are interconnected, like their sensing pulse inputs, the S inputs constituting the beginning of the sensing period and the CL inputs constituting the end of the sensing period. The HP circuits are high frequency filters, while the LP circuits are low frequency filters. FIG. 8 shows a coupling diagram for the block diagram shown in FIG. 7, although the circuit leads 2-11 have been omitted for purposes of clarity, and also since they are identical to the two illustrated circuits. It should be furthermore observed that the component values disclosed are merely by way of exemplification and may be amended without departing from the spirit and scope of the present invention.
FIG. 9 shows a block diagram of a central unit according to the present invention and in FIG. 10 there is shown a coupling diagram for the central unit illustrated in FIG. 9, the component values disclosed therein being merely by way of exemplfication and being variable without departing from the spirit and scope of the present invention. The sensitivity signal for the lower thread guards is fed to the connection 29 and the sensitivity signal for the upper thread guards is fed to the input 31. The upper thread guard signal is fed to the input 30 and the lower thread guard signal is fed to the input 26, while the stopping signal occurs on the input 25. It is possible to feed a stopping signal to the input 14, and an operational signal to the input 18, while the synchronization pulse is fed to the input 19. A supply voltage of 220 V is impressed onto the inputs 4 and 8. | An apparatus for monitoring one or more threads in a sewing machine with a number of sewing heads, the signal emitter including a spring arm (2) which is fixedly anchored at its one end (3) and, at its opposite end, carries a magnet (9), this opposite end being moreover located in the path of movement of the lower thread (12) in order to be influenced by same and thereby change the position of the magnet (9) in relation to an element (10) sensitive to the position of the magnet (9) and generating an electric signal in dependence upon the position of the magnet (9), the signal change being sensed and evaluated. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a National Phase application of International Application No. PCT/AT2008/000469 filed Dec. 22, 2008 which claims priority to Austrian Patent Application No. A 7/2008, filed Jan. 3, 2008.
BACKGROUND OF THE INVENTION
The present invention relates to a heat engine, in particular for low-temperature operation for the utilisation of solar heat, waste heat from biological or industrial processes or the like, with at least two cylinder-piston units, each containing an expansion fluid, which stands under prestressing pressure and which changes its volume in the case of a change of temperature and thus moves the piston, elements for the individually controllable supply of heat to the expansion fluid of each cylinder-piston unit, and a control means controlling the heat supply elements to allow each expansion fluid to alternately heat up and cool down and thus move the pistons.
Such a heat engine is known from U.S. Pat. No. 5,916,140. Effective expansion fluids frequently require a specific prestressing pressure in order to show a significant coefficient of expansion in the desired operating temperature range. An example of this is liquid carbon dioxide, which changes its volume by about 2.2-fold when heated from 20° C. to 30° C. at a pressure of approx. 60-70 bar.
U.S. Pat. No. 5,916,140 discloses different variants to place the expansion fluid in the cylinder-piston units under the required prestressing pressure. On the one hand, metal or gas springs are proposed to prestressing the pistons in the direction of the expansion fluid. However, no prestressing pressure independent of the piston movement can be reached with such a distance-dependent spring force. On the other hand, a mechanical coupling of two cylinder-piston units by means of a crankshaft or by opposed cylinder assembly is described, so that the respectively extending piston maintains the prestressing pressure on the expansion fluid of the retracting piston. However, such a rigid coupling requires that the heating and cooling phases are about equal in length, since otherwise a piston that retracts too slowly will hinder the extending one, which is detrimental to efficiency, or a piston that extends too slowly will generate too little prestressing pressure to assure operation.
It is proposed in U.S. Pat. No. 5,916,140 as a solution to the last-mentioned problem to accelerate the cooling phase by removing heat as rapidly as possible, so that it is always shorter than the heating phase. However, this is scarcely realisable in practice, since highly variable heat supply is to be expected especially when using solar heat. Thus, for heating liquid carbon dioxide from 20° C. to 30° C. at midday, for example, a heat supply temperature of 70° C. and thus a temperature difference of 40-50° C. may be available, whereas for cooling from 30° C. to 20° C. there is only a temperature difference of 15-25° C.—even in the case of forced cooling with cold water at 5° C.—, and as a result a cooling phase that is about double the length of the heating phase is to be expected. On the other hand, in the morning and evening hours the temperature level of the solar plant may also only amount to 30°-40° C., for example, and as a result of which a heating phase that is longer than the cooling phase may even be expected.
SUMMARY OF THE INVENTION
Therefore, the aim set by the invention is to provide a heat engine of the aforementioned type, which always achieves a good efficiency even with highly fluctuating heat supply. This aim is achieved according to the invention in that a common prestressing fluid acts on the pistons of all cylinder-piston units in order to exert a common prestressing pressure on the expansion fluids, the control means is fitted with a pressure gauge for the prestressing pressure, and the control means controls the heating and cooling phases of the heat supply elements in dependence on the measured prestressing pressure in order to hold this within a predetermined range.
This enables a variable dynamic coupling of the cylinder-piston units to be achieved. Control of the piston movement dependent on the prestressing pressure prevents a deterioration in the efficiency of the engine as a result of an unnecessarily high prestressing pressure, while always assuring the necessary prestressing pressure for the expansion fluid. As a result, a constantly optimum operation is achieved even under changing ambient conditions.
A particularly advantageous embodiment of the heat engine according to the invention has at least three cylinder-piston units, and is distinguished in that the control means increases the number of cylinder-piston units, which are in the heating phase at a point in time, in relation to the number of cylinder-piston units, which are in the cooling phase at the same point in time, if the prestressing pressure drops below the predetermined range, and reduces same if the prestressing pressure exceeds the predetermined range. This allows the operation to be adapted to particularly highly fluctuating ambient conditions. For example, in the low-temperature morning or evening hours of a solar plant an about equal number of cylinder-piston units can be operated in the heating and cooling phases, while in the midday heat few rapidly heating cylinder-piston units are countered by many slowly cooling cylinder-piston units.
According to a further feature of the invention, the control means can also reduce or extend each individual heating and/or cooling phase for fine adjustment in order to hold the prestressing pressure within the predetermined range.
In principle, any fluid known in the art with an appropriately substantial coefficient of thermal expansion can be used as expansion fluid. It is particularly favourable if—as known from U.S. Pat. No. 5,916,140—the expansion fluid contains liquid carbon dioxide and the prestressing pressure is higher than or equal to the condensation pressure of carbon dioxide at the operating temperature. Because of its high coefficient of thermal expansion at room temperature, liquid carbon dioxide is particularly suitable for operation of the heat engine in the low-temperature range for the utilisation of solar heat, waste heat from biological or industrial processes or the like. Moreover, carbon dioxide formed from combustion processes can thus be fed to a beneficial secondary treatment process, in which it does not have any environmentally unfriendly greenhouse effect. The heat engine according to the invention therefore also makes a contribution to environmentally favourable CO 2 sequestration in the sense of a carbon dioxide capture and storage process (CSS).
The prestressing fluid can also be of any desired type, e.g. compressed air. However, it is particularly preferred if the prestressing fluid is hydraulic fluid, which provides a non-positive and reliable pressure coupling. In this case, the hydraulic circuit of the prestressing fluid is preferably fitted with a flexible intermediate reservoir, so that short-term pressure fluctuations during switchover operations or in the case of individual reductions or increases of the heating and cooling phases necessary for control can be temporarily absorbed.
The action of the prestressing fluid on the pistons can occur in a wide variety of ways, e.g. by mechanically coupling separate hydraulic prestressing cylinders to the cylinder-piston units. The pistons of the cylinder-piston units are preferably configured as double-action pistons, the expansion fluid acting on one side thereof and the prestressing fluid acting on the other side thereof, which results in a particularly simple structure.
The decoupling of the work performed by the cylinder-piston units can also be achieved in any desired manner known in the art, which takes into consideration the generally non-sinusoidal courses and different phase positions of the reciprocating movements of the individual pistons, e.g. by means of free-wheeling hubs, planetary gear trains, ratchet/pawl mechanisms etc. A hydraulic decoupling of the movement work, in which each cylinder-piston unit drives a working piston and all working pistons act on a common working fluid of a hydraulic load, is particularly favourable.
A preferred embodiment of the invention is distinguished in that the heat supply elements have a heat exchanger, through which a heat transfer medium flows and which is provided with a shut-off valve controlled by the control means. The time points and durations of the heating phases can be preset by simply opening and closing the shut-off valves, and the cooling phases then result between these.
The cooling phases can be accelerated if the heat supply elements preferably also comprise elements for forced cooling of the expansion fluids in the cooling phases. It is particularly favourable for this purpose if the heat transfer medium stands under pressure in the heating phase and the forced cooling elements have a controllable pressure release means for each heat exchanger. As a result, the heat transfer medium can be simultaneously used as coolant by it causing cooling as a result of pressure release.
The pressure release means preferably comprises a vacuum intermediate reservoir, which can be switched to the heat exchanger by means of a controllable switch valve, as a result of which a sudden release and therefore a particularly rapid cooling can be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention shall be explained in more detail below on the basis of exemplary embodiments illustrated in the attached drawings.
FIG. 1 is a basic circuit diagram of a heat engine of the invention with four cylinder-piston units;
FIGS. 2 a to 2 c are time diagrams relating to the control of the heat supply elements and the thus resulting piston movements of the engine of FIG. 1 ; and
FIG. 3 is a circuit diagram of a practical embodiment of a heat engine according to the invention with two exemplary cylinder-piston units.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a heat engine 1 with four cylinder-piston units 2 - 5 . Each cylinder-piston unit 2 - 5 has a cylinder 6 , in which a piston 7 can move between a retracted position (shown at 2 ) and an extended position (shown at 5 ).
The space in the cylinder 6 to the left side of the piston 7 is completely occupied by an expansion fluid 8 . The expansion fluid 8 has a high coefficient of thermal expansion and expands during heating in order to move the piston 7 from the retracted position into the extended position, or contracts during cooling to move the piston 7 back again.
In the shown example, the expansion fluid 8 is liquid carbon dioxide (CO 2 ), which has a condensation pressure of approx. 65 bar at room temperature. Liquid CO 2 has a thermal expansion of about 2.2-fold in the range from 20° C. to 30° C. Mixtures of liquid carbon dioxide with other substances could also be used as expansion fluid 8 instead of pure carbon dioxide.
To keep the CO 2 as expansion fluid 8 in its liquid state, the piston 7 is subjected to or prestressed in the direction of the expansion fluid 8 with a prestressing pressure p v higher than or equal to the condensation pressure.
As shown in FIG. 1 , the prestressing pressure p v is exerted by a prestressing fluid 9 , which directly acts on the side of each piston 7 remote from the expansion fluid 8 . The prestressing fluid 9 is preferably a hydraulic oil and circulates in a hydraulic circuit 10 common to all the cylinder-piston units 2 - 5 . The prestressing fluid 9 displaced when a piston 7 extends (arrow 11 ) thus maintains the prestressing pressure p v on the expansion fluids 8 of the retracting pistons 7 (arrows 12 ). The retraction movement of the pistons 7 is thus supported in the cooling phase and the pressure is prevented from dropping below the condensation pressure in the cooling phase.
The hydraulic circuit 10 is fitted with a flexible intermediate reservoir 13 , e.g. a pressure tank with gas filling means 14 and/or with a flexible membrane 15 in order to buffer short-term pressure fluctuations.
The heating of the expansion fluids 8 in the cylinder-piston units 2 - 5 is conducted by means of controllable heat supply elements 16 - 20 . In the shown example, the heat supply elements 16 - 19 comprise a heat exchanger 16 for each cylinder-piston unit 2 - 5 , which is in contact with the expansion fluid 8 in a thermally conductive manner and in which a heat transfer medium 17 circulates. The heat transfer medium 17 is heated by a solar panel 18 in a heat transfer circuit 19 (return pipes not shown in FIG. 1 for reasons of clarity).
The heat exchangers 16 can be of any type known in the art. They are preferably fitted with heat pipes to promote the heat exchange and for rapid and uniform distribution of the supplied heat in the expansion fluids 8 .
Each heat exchanger 16 is provided with a controllable shut-off valve 20 . The shut-off valves 20 are alternately and intermittently opened by a central control means 21 in order to alternately heat and cool each cylinder-piston unit 2 - 5 , and thus alternately expand and contract the expansion fluids 8 in the cylinders 6 and ultimately move the pistons 7 back and forth, wherein the piston movements are synchronised by means of the prestressing fluid 9 of the hydraulic circuit 10 .
The control means 21 , e.g. a microprocessor, operates the shut-off valves 20 in dependence on a measured value of the prestressing pressure p v , which it receives from a pressure gauge 22 connected to the hydraulic circuit 10 . In this case, the control target of the control means 21 is to keep the prestressing pressure p v in the hydraulic circuit 10 within the predetermined range. This is achieved primarily by controlling the number of the cylinder-piston units 2 - 5 currently in the heating phase at a specific time point in relation to the number of the other cylinder-piston units 2 - 5 that are currently in the cooling phase at this time point, as will now be explained in more detail on the basis of FIG. 2 .
The switching signals e 2 -e 5 of the control means 21 for opening the shut-off valves 20 are respectively recorded in the upper time diagrams of FIGS. 2 a - 2 c and the movements or paths s 2 -s 5 of the pistons 7 of the cylinder-piston units 2 - 5 resulting therefrom are plotted in relation to time t in the lower time diagrams.
FIG. 2 a shows a first operating state of the heat engine 1 for ambient conditions, in which the cooling phase of the expansion fluid 8 is about three times as long as the heating phase, e.g. because the temperature of the heat transfer medium 17 is high and causes a rapid heating. The shut-off valves 20 are respectively opened cyclically for about a quarter of the stroke periods. As may be seen, at a specific time point one cylinder-piston unit 2 - 5 is always located in the heating phase and three others are in the cooling phase, i.e. the ratio of expanding cylinder-piston units 2 - 5 to contracting cylinder-piston units 2 - 5 amounts to 1:3 here.
FIG. 2 b shows a second operating state of the heat engine 1 , in which the shut-off valves 20 are respectively opened cyclically for half a stroke period. The ratio of cylinder-piston unit 2 - 5 in the heating phase to cylinder-piston units 2 - 5 in the cooling phase amounts to 2:2 here, which takes into account heating and cooling phases of about equal length, e.g. because of reduced heat supply.
If, for example, the temperature of the heat transfer medium 17 decreases even further and the heating phase is thus extended even further, the control means 20 moves into the third operating state of FIG. 2 c , in which the ratio of cylinder-piston units 2 - 5 in the heating phase to cylinder-piston units 2 - 5 in the cooling phase amounts to 3:1.
The respective operating state of FIG. 2 a , FIG. 2 b or FIG. 2 c is set by the control means 21 in dependence on the prestressing pressure p v : if the prestressing pressure p v drops below a predetermined lower limit p min , in particular the condensation pressure of the expansion fluid 8 at the current operating temperature, the ratio of cylinder-piston units 2 - 5 in the heating phase to cylinder-piston units 2 - 5 in the cooling phase increases successively, e.g. 1:3→2:2→3:1; if the prestressing pressure p v exceeds a predetermined upper limit p max , in particular the condensation pressure plus a hysteresis threshold, then this ratio decreases successively, e.g. 3:1→2:2→1:3.
It is understood that the discussed control can be extended to any desired numbers of cylinder-piston units 2 - 5 , e.g. to 3, 5, 6, 7, 8, 12, 24 etc. cylinder-piston units. The more cylinder-piston units there are available, the more finely stepped the control can be.
For the fine control, the control means 21 can additionally reduce or extend each individual heating or cooling phase, e.g. by shifting the beginning t 1 of a heating phase and/or the beginning t 2 of a cooling phase or by changing the duration t 2 −t 1 . If heating or cooling phases of different cylinder-piston units 2 - 5 overlap one another briefly in this case to a higher or lower ratio than that selected by means of the primary control (1:3, 2:2, 3:1), corresponding short-term pressure fluctuations of the prestressing pressure p v can be temporarily absorbed by means of the intermediate reservoir 13 in the hydraulic circuit 10 .
It must be mentioned at this point that in a greatly simplified embodiment of the heat engine 1 , which only comprises two cylinder-piston units and thus only allows the single ratio 1:1, the control means 21 can also only perform the last-mentioned control with corresponding restriction with respect to the usable operating conditions.
FIG. 3 shows a specific configuration and further development of the heat engine 1 of FIG. 1 , wherein for reasons of clarity only two cylinder-piston units 2 , 3 are shown as representative and the control means 21 with its measurement and control lines is not shown. However, it is understood that the embodiment shown in FIG. 3 can be extended to any desired number of cylinder-piston units.
According to FIG. 3 a pump 23 pumps heat transfer medium 17 , e.g. refrigerant R 123 from Hoechst, from a reservoir 24 via a pipe 25 to the solar panel 18 , from there via pipe 19 and shut-off valves 20 to the heat exchangers 16 and from there back to the reservoir 24 via switch valves 26 and a return pipe 27 . In the operating state shown in FIG. 3 the right shut-off valve 20 is currently open and the left shut-off valve 20 is closed, so that the right cylinder-piston unit 3 is in the heating and expansion phase and the left cylinder-piston unit 2 is in the cooling and contraction phase.
For acceleration of the cooling phases the heat supply elements 16 - 20 also comprise elements for forced cooling of the expansion fluids 8 here. The forced cooling elements can be an optional feed path 28 for non-heated heat transfer medium 17 , for example, in order to feed this into the heat exchanger 16 in the cooling phases via shut-off valves 20 configured as multiple-way valves. Alternatively, separate heat exchangers could be used for a separate cooling medium (not shown).
The forced cooling elements preferably comprise a controllable pressure release means, as shown, which after the shut-off valve 20 closes relieves the heat transfer medium 17 that is still under the transport pressure of the pump 23 in a heat exchanger 16 via the shut-off valve 26 to a vacuum intermediate reservoir 29 . The vacuum in the vacuum intermediate reservoir 29 is created via a suction pipe 30 of a venturi ejector 31 , which is continuously fed with heat transfer medium 17 in the circuit by the pump 23 via a pipe 32 . As a result of the sudden expansion of the heat transfer medium 17 after the shut-off valve 26 is opened, the heat transfer medium 17 evaporates and thus cools the expansion fluid 8 via the heat exchanger 16 .
In the embodiment of FIG. 3 , the flexible intermediate reservoir 13 of the hydraulic circuit 10 can be selectively switched to the hydraulic circuit 10 via its own shut-off valve 33 . The power of the cylinder-piston units 2 , 3 is mechanically transferred via piston rods 34 to working pistons 35 , which act on a common working fluid 36 , e.g. hydraulic oil, that circulates in a hydraulic load circuit 37 via check valves 38 .
The working pistons 35 can be integrated into the cylinders 6 of the cylinder-piston units 2 , 3 , so that these have three operating zones: a reaction zone 39 , in which the expansion fluids 8 operate, a prestressing zone 40 , in which they are coupled via the prestressing fluids 9 , and a working zone 41 , in which the movement is decoupled via the working fluid 36 . The working pressure of the working fluid 36 substantially corresponds to the thermal expansion-related reaction pressure of the expansion fluid 8 minus the prestressing pressure p v of the prestressing fluid 9 .
The invention is not restricted to the represented embodiments, but covers all variants and modifications that fall within the framework of the attached claims. Thus, for example, a larger number of cylinder-piston units could also be actuated synchronously group by group in several groups to reduce the switching and control expenditure. In this case, the cylinders 6 of a synchronous group of cylinder-piston units could also share a common heat exchanger 16 and/or a common expansion fluid 8 . | Heat engine with at least two cylinder-piston units, each containing an expansion fluid, which stands under a prestressing pressure and which changes its volume in the case of a change of temperature and thus moves the piston, elements for the individually controllable supply of heat to the expansion fluid of each cylinder-piston unit, and a control means controlling the heat supply elements to allow each expansion fluid to alternately heat up and cool down and thus move the pistons, wherein a common prestressing fluid acts on the pistons of all cylinder-piston units in order to exert a common prestressing pressure on the expansion fluids, the control means is fitted with a pressure gauge for the prestressing pressure, and the control means controls the heating and cooling phases of the heat supply elements in dependence on the measured prestressing pressure in order to hold the prestressing pressure within a predetermined range. | 8 |
RELATED APPLICATIONS
This application is a continuation-in-part of:
(i) U.S. application Ser. No. 10/564,861, filed on Jan. 12, 2006, now U.S. Pat. No. 7,612,032, issued Nov. 3, 2009, which is a national phase application under 35 U.S.C. §371 of International Patent Application No. PCT/RU2004/00261, filed Jul. 1, 2004 (published in Russian on Jan. 20, 2005 as WO 2005/004903), which claims priority of Russian Federation Patent Application No. RU2004108061, filed Mar. 12, 2004 and International Patent Application No. PCT/RU2003/000304 filed Jul. 14, 2003; (ii) U.S. application Ser. No. 10/564,609 , filed on Jan. 12, 2006, which is a U.S. national phase application under 35 U.S.C. §371 of International Patent Application No. PCT/RU2004/00260, filed Jul. 1, 2004 (published in Russian on Jan. 20, 2005 as WO 2005/004789), which claims priority of Russian Federation Patent Application No. RU2004108057, filed Mar. 12, 2004 and International Patent Application No. PCT/RU2003/000304 filed Jul. 14, 2003; and (iii) U.S. application Ser. No. 11/919,141, filed on Oct. 23, 2007, which is a U.S. national phase application under 35 U.S.C. §371 of International Patent Application No. PCT/RU2005/000236, filed Apr. 25, 2005 (published in Russian on Dec. 7, 2006 as WO 2006/130034).
The contents of the above applications are incorporated by reference herein as if rewritten in their entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to a method for treating oncological diseases by administering an agent that destroys extracellular DNA in the blood of a cancer patient.
2. Description of the Background Art
Populations of tumor cells developing in patients have a very high genetic variability which exceeds a same for healthy cells. Genetic variability of cancer cell populations causes mutated cells to generate phenotypes that (1) are insensitive to immune and morphogenetic control, (2) have an ability to invade and metastasize, and (3) are desensitized to cancer therapies. Selection and clonal expansion of cancer cells are both considered to underlie a biological and a clinical progression of tumors. For this reason, an approach of modern cancer therapies is based on a destruction of cancer cell clones in patients by means of chemotherapy, immunotherapy, biotherapy, surgical methods, or a combination thereof.
Chemotherapy, radiotherapy, biotherapy and more recent immunotherapy are the most commonly used non-surgical methods of treating cancer diseases. These therapies are administered to destruct, to damage or to inactivate a cancer cell's intracellular DNA.
The chemotherapy approach is based on administration of well known compounds: platinum preparations, antracycline antibiotics, alkylating agents and podophyllotoxins. The radioimmunotherapy approach is based on irradiation of intracellular DNA of cancer cells' nuclei. Alpha particles from alpha emitters are specially delivered into the cancerous cells to increase effects on those cells' intracellular DNA. Biotherapeutic and immunotherapeutic approaches are based on an induction of apoptosis of cancer cells, which induces death of the cancer cell. Apoptosis starts with an activation of intracellular nucleuses and follows with a degradation of the tumor cell's intracellular DNA. This process is accomplished, for example, by means of administering genotherapeutic constructions that consist of genes that induce apoptosis or genes coding the factors which activate the nucleuses.
Aguilera. et al. discloses in U.S. Pat. No. 6,455,250 endonuclease Endo SR to treat cancer diseases by mode of its intracellular delivery into target cells. This method and chemotherapy, with Etopozide-4-Demetilpipodophylotoxe (4,6-O—R)-etiliden-b-D-glycopiranozid, were both selected for a prototype of the present invention.
Topoizomeraze II is an essential cell enzyme that regulates many aspects of DNA function. The enzyme is responsible for interconversion of different topological forms of intracellular DNA by means of a generation of transitory breaks of double-stranded DNA. Etopozide, as a Topoizomeraze II inhibitor, increases an intracellular level of “broken DNA-Topoizomeraze II” complexes.
The result of this drug's influence is an accumulation of double-stranded intracellular DNA breaks which lead to the cell's death. A drawback of this method prototype, along with well-known methods, is their low efficacy. These methods imply that mostly the cancer cells' intracellular DNA is the therapeutic target. Because of high genetic variability, these cancer cells become desensitized to the therapies before they are adequately eliminated. A further disadvantage is that the intracellular DNA is a difficult-to-approach target; it leads to necessary high-dosing antineoplastic chemotherapy and/or other complicated delivery systems. A final disadvantage to these methods is that they are highly toxic: their influence on cancerous cells' intracellular DNA also damages healthy cells' DNA.
SUMMARY OF THE INVENTION
An object of this invention is to develop a highly efficient cancer therapy having low toxicity. It is an object to resolve the foregoing drawbacks by administering into systemic circulation an agent which destroys blood extracellular DNA.
The agent is introduced in doses that alter an electrophoretic profile of blood extracellular DNA, which could be detectable by pulse-electrophoresis. Doses of the agent are introduced according to a regime schedule that provides for plasma hydrolytic activity exceeding 150 Kunitz units/liter of blood plasma. This level can be supported for more than 12 hours within a 24 hour period. The treatment is carried out continuously for no less than 48 hours. In particular, bovine pancreatic deoxyribonuclease (DNase) can be introduced parenterally in doses ranging from 50,000 Kunitz per day to 250,000,000 per day. DNase is an enzyme that catalyzes the hydrolytic cleavage of phosphodiester linkages in the DNA backbone. These doses of DNase are administered anywhere between five and 360 days. In particular, recombinant human DNase (dornase-alpha) can be parenterally introduced in doses ranging from 0.15 mg/day to 500 mg/day between a five-360 day period. The treatment may continue for a life of the patient. Additionally, an agent which bounds extracellular DNA, s.a., anti-DNA antibodies, can also be introduced to the systemic circulation. A modifying agent can further be introduced into the circulation, which modifies the chemical structure, the conformation, the degree of polymerization, or the association of proteins, lipids and/or ribonucleic acids of the blood's extracellular DNA. A preferred modifying agent may be a ribonuclease enzyme and, more particularly, Serratia Mercenses.
The present invention suggests that cancer can be treated by reducing circulating DNA levels. Circulating DNA levels are higher in the blood of cancer patients than in healthy controls. Stroun discloses in U.S. Pat. No. 5,952,170 a method of diagnosing cancers, wherein extracellular DNA in the blood is used for diagnostics and for a prognosis of a clinical course of a malignant disease. Hoon and Gocke disclose in U.S. Pat. Nos. 6,465,177 and 6,156,504, respectively, a use of blood's extracellular DNA to define mutations in oncogenes and microsatellic fragments of genes. These patents also disclose usages of blood's extracellular DNA for studying genome instability in tumors.
There is no systematic analysis of blood's extracellular DNA spectrum and its biological role prior to this invention. A search of the prior art reveals no published data concerning a research of blood's extracellular DNA performed without a polymerase chain reaction (“PCR”). Polymerase chain reactions can pervert a pattern of blood's extracellular DNA because of a specificity of primers which are used for amplification. Until recently, a genetic analysis of extracellular blood DNA was mainly carried out by PCR or by blot-hybridization and it was directed to a study of changes in certain fragments of a genome, s.a., e.g., microsatellites and separate genes during a malignant process.
There is thus no available knowledge about a genetic repertoire of blood's extracellular DNA in cancer patients, about a biological role of that blood's extracellular DNA in oncopatology, and about the potential therapeutic effects of a destruction, an inactivation or a treatment of these diseases.
The blood's extracellular DNA in cancer patients contains a unique quantitative and qualitative repertoire of genes and regulating genetic elements which greatly differ from that of DNA in a healthy human genome. In contrast to intracellular DNA, extracellular DNA in cancer patients mainly contains unique human genes, including genes which are involved in a development of and a maintenance of malignant behavior in cancer cells. Because blood's extracellular DNA contributes to malignant growth in cancer patients, a destruction of, a modification of, or a binding of blood's extracellular DNA is useful because it slows down that growth. These interventions are very useful in independent therapy and they also increase an effectiveness of traditional methods of treatment.
The aforesaid new characteristics of this invention are based on new ideas about mechanisms of oncological diseases.
BRIEF DESCRIPTION OF THE DRAWINGS
As set for below the invention has been explained by detailed description of embodiments without references to drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The inventive method is realized as followed:
1. Materials and Methods.
The following agents were used which destroy extracellular blood DNA: bovine pancreatic DNase (Sigma and Samson Med), recombinative human DNase 1 (Dornase alpha; Genetech), Serratia Mercenses extracellular nuclease. The solutions of DNase for administration were made by dissolving of mother solutions of DNase in sterile phosphate buffer just before administration.
Extracellular DNA from blood plasma was isolated as follows: fresh plasma (no more than 3-4 hours after sampling) was centrifuged on Ficoll-PlaquePlus (Amersham-Pharmacia) during 20 minutes at 1500 g at room temperature. ½ of plasma was detached, not affecting the rest of cells on the Ficoll pillow, and further centrifuged at 10000 g during 30 min for separation from cell fragments and debris. Supernatant was detached, without affecting the sediment, and was toped up to 1% of sarkosil, 50 mM tris-HCl, pH 7.6, 20 mM EDTA, 400 mM NaCl, and then mixed with equal volume of phenol-chloroform (1:1) mixture. The prepared emulsion was incubated during 2 hours at 65° C., then phenol-chloroform mixture was separated by centrifuging (500 g during 20 minutes, room temperature).
The procedure of deproteinisation with phenol-chlorophorm mixture was repeated 3 times, and then the water phase was processed with chloroform and diethyl ether. Separation from organic solvents was made by centrifugation at 5000 g during 15 minutes). Then equal volume of isopropanol was added to resulting aqueous phase and the mixture was incubated overnight at 0° C. After sedimentation the nucleic acids were separated by centrifugation at 10000 g during 30 minutes. The sediment of nucleic acids was dissolved in 10 mM tris-HCl buffer, pH 7.6 with 5 mM EDTA, and inflicted to the CsCl gradient (1 M, 2.5 M, 5.7 M) in test-tube for rotor SW60Ti. The volume of DNA solution was 2 ml, volume of each step of CsCl was 1 ml. Ultracentrifugation was conducted in L80-80 (Beckman) centrifuge during 3 hours at 250000 g. DNA was collected from the surface of each gradient step into fractions. These fractions were dialyzed during 12 hours (4° C.). Presence of DNA in fractions was determined by agarose electrophoresis and DNA was visualized by ethidium bromide staining. The amount of DNA was determined with specrophotometer (Beckman DU70) in cuvette (100 mkl) at wavelength of 220-230 nm.
Mice Lewis lung carcinoma and Erlich carcinoma were used in experiments. Cells were cultivated in RPMI-1640 medium with 10% calf serum and 1% penicillin-streptomycin in atmosphere of 5% CO2.
For tumor inoculation in mice the cells were cultivated till monolayer is formed, then detached with tripsin-EDTA buffer. The cells were washed 3 times by centrifuging in phosphate buffer and then resuspended up to 0.5×10 7 /ml concentration in the same buffer. The cell viability was determined with methylene blue staining in hemocytometer. Cells suspensions with no less than 95% of living cell were used for transplantation.
C57B1 mice and white randomly bred mice from “Rappolovo” animal house were used. Weight of animals was 24-26 g. 6-7 animals were kept in one cage on a standard diet without limitation of water. LLC cells in dose 5×10 5 per mice in 0.1 ml of phosphate buffer were transplanted into thigh soft tissues. Erlich tumors were transplanted by administration of 0.2 ml of 10% cell suspension in physiological solution.
In some experiments level of extracellular DNA in blood plasma was quantified. DNA was isolated according to the aforesaid protocol. The DNA level was measured with PicoGreen kit. Electrophoresis of extracellular blood DNA was performed with 1% agarose gel. DNA was visualized with ethidium bromide solution. The levels of high molecular weight DNA fraction (more than 300 base pairs) were determined by densitometry. Lambda phage DNA, digested with EcoRI and HindIII was used as electrophoresis marker.
EXAMPLE 1
Inhibition of Erlich Carcinoma Growth
Recombinant human DNase 1 (Genentech) was used.
1 group: 10 mice bearing Erlich carcinoma were used as control. The mice were injected with 0.2 ml of phosphate buffer intraperitoneally twice a day every day from day 3 to day 7 after the tumor cell transplantation.
2 group: 10 mice bearing Erlich carcinoma were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight in 0.2 ml of phosphate buffer four times daily every day from day 3 to day 7 after the tumor cell transplantation.
3 group: 10 mice bearing Erlich carcinoma were administered intraperitoneal injections of DNase in dose of 0.5 mg/kg of body weight in 0.2 ml of phosphate buffer four times daily every day from day 3 to day 7 after the tumor cell transplantation.
4 group: 10 mice bearing Erlich carcinoma were administered intraperitoneal injections of DNase in dose of 0.1 mg/kg of body weight in 0.2 ml of phosphate buffer four times daily every day from day 3 to day 7 after the tumor cell transplantation.
5 group: 10 mice bearing Erlich carcinoma were administered intraperitoneal injections of DNase in dose of 0.05 mg/kg of body weight in 0.2 ml of phosphate buffer four times daily every day from day 3 to day 7 after the tumor cell transplantation. The results were evaluated as tumor Growth Inhibitory Index (GII) (%) at the last day of DNase injections. The quantification of blood plasma extracellular DNA and its electrophoretic qualification were also performed.
The results are presented in Table 1.
Tumor size, extracellular DNA level and extracellular DNA electrophoresis profile on day 7 after tumor transplantation.
TABLE 1
Presence of high
Inhibi-
Extracellular
molecular
Tum or
tion
DNA level,
fractions of
Group
volume
(%)
(ng/ml)
extracellular DNA
Control
98 +/− 14
—
104.8
100%*
1
mg/kg
23 +/− 6
76%
38.3
0
0.5
mg/kg
32 +/− 6
67%
55.1
25%
0.1
mg/kg
58 +/− 12
37%
78.0
70%
0.05
mg/kg
87 +/− 11
10%
98.7
100%
*The control group electrophoretic density were considered as 100%.
The presented data demonstrated that sufficiently high doses of DNase 1 are needed to achieve the better therapeutic effect.
EXAMPLE 2
Inhibition of Erlich Carcinoma Growth
Recombinant human DNase I (Genentech) was used.
5 groups of mice bearing LLC were used.
1 group—7 mice—the control.
2 group—6 mice were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight twice a day every day from day 3 to day 5 after the tumor cell transplantation.
3 group—6 mice were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight twice a day every day from day 3 to day 10 after the tumor cell transplantation.
4 group—6 mice were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight twice a day every day from day 3 to day 15 after the tumor cell transplantation.
5 group—6 mice were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight twice a day every day from day 3 to day 18 after the tumor cell transplantation.
6 group—6 mice were administered intraperitoneal injections of DNase in dose of 1 mg/kg of body weight twice a day every day on 3,5,7,9,11,13,15 and 17 day after the tumor cell transplantation.
7 group—6 mice were administered intraperitoneal injections of DNase in dose of 0.5 mg/kg of body weight four times daily every day from day 3 to day 10 after the tumor cell transplantation. The results were evaluated as animal survival on day 30 and day 50 after the tumor cell transplantation. The results are presented in Table 2.
Animal survival on day 30 and day 50 after the tumor cell transplantation.
TABLE 2
day 30
day 50
(amount of alive/dead
(amount of alive/dead
Group
animals in group)
animals in group)
1
0-7
0-7
2
0-6
0-6
3
3-3
0-6
4
5-1
3-3
5
6-0
6-0
6
0-6
0-6
7
4-2
1-5
The presented data demonstrated that the therapy efficacy increases as the treatment time extends. The therapy efficacy is decreased if it is interrupted. Multiple-dose administration is preferred.
EXAMPLE 3
Lung Carcinoma Treatment
54-years-old man has been admitted to the hospital with diagnosis of lung carcinoma.
By patient's agreement, due to lack of any available treatment modality, subcutaneous injections of dornase-alpha were prescribed. The treatment began with administration of daily dose of 50 mkg/kg. Every consecutive day blood extracellular DNA level was measured and blood extracellular DNA was fractioned by electrophoresis. Once a week the primary tumor site and metastases were checked with X-rays and NMR-tomography. After initial 7 day period the dornase-alpha daily dose has been increased up to 100 mkg/kg because of no changes in level and electrophoresis pattern of blood extracellular DNA and no reactions from primary site of the tumor and the metastases. Because of no changes after another 7 days the dosing has been increased up to 150 mkg/kg. Two days after the first injection of the preparation in dose 150 mkg/kg the material recession (more than 50%) of the blood extracellular DNA fraction with the size more than 300 base pairs has been observed although total amount of extracellular DNA has not been greatly decreased (less than 20%). During the next 4 days the patient's general condition has noticeably improved and on day 7 of this cycle of therapy 25%-decreasing of primary tumor lesion size and signs of regression of two bone metastases have been shown by NMR-scanning and X-ray examination. The probes of patient's extracellular DNA taken before the treatment started and 21 days after the beginning the therapy were cloned by means a method which allowed to construct non-amplified plasmid libraries of blood extracellular DNA with representativeness up to one million of clones with the average size of 300-500 base pairs. The DNA which had been isolated with aforesaid protocol was additionally deproteinized with proteinase K (Sigma) at 65° C. for the removal of tightly bound proteins. After the deproteinization and single-stage treatment of phenol-chloroform mixture (65° C.) DNA was precipitated overnight with 2.5 volumes of ethanol. Then DNA was treated by Eco RI restrictase during 3 hours or by Pfu polymerase (Stratagene) in presence of 300 mkM of all desoxynucleotidtriphosphates for sticky-ends elimination. The completed DNA was phosphorylated by polynucleotidkinase T4 (30 U, 2 h.). The preparations were ligated to pBluescript plasmide (Stratagene), which has been digested with EcoRI or PvuII and dephosphorylated by phosphatase CIP (Fermentas) during 1 hour. 1 mkg of vector and 0.1-0.5 mkg of serum DNA were used. The process of ligation was conducted with Rapid Legation Kit (Roche) during 10 hours at 16° C. The volume of this mixture was 50 mkl. The ligated library was transformed into DH12S cells (Life Technologies) by means of electroporator E. Coli porator (BioRad). 12-20 electroporation cuvettes were used for the transformation of one library. The library serial dilutions of 10 −4 , 10 −5 and 10 −6 were cloned on 1.5% agar and LB media supplemented with 100 mkg/ml of ampicilline. In both cases the libraries represented 2-3×10 6 clones.
Analysis of 96 randomly selected clones with the size 300-1000 base pairs from the “before treatment” library showed that 55 from 96 clones were the unique sequences of human DNA. For the 15 sequences from 55 the gene function or corresponding gene product were identified with HumanGeneBank.
Gene or corresponding
Reported role in cancerogenesis and cancer
protein product
progression
G-protein coupled
Key role in neoplastic transformation, apoptosis
receptor protein
receptor protein inhibition, hormone independence
and metastasis
Snf2 coupled CBP
Transcription activator, reported in synovial sarcoma
activator (SCARP)
and leukemia.
SRY-box containing
Transcription modulator expressed in embryogenesis.
gene
Reported in medulloblastoma, gonadal tumors, highly
metastatic melanoma.
Tyrosine kinase
Key role in cancer cell regulation network. Some
class homologues are the products of cellular
oncogenes.
Fibroblast activation
Involved into cancer invasion and metastasis.
protein, cell surface
protease
Brain testican
Reported in embryonic rhabdomyosarcoma.
KRAB domain, Zn-
Reported in early embryogenesis, neuroblastoma,
finger protein.
Ewing sarcoma, T-cell lymphoma, linked with
acquisition of drug resistance in lung cancer.
Melanoma associated
Antigen expressed in melanoma cells.
antigen
N-cadherin
Involved into cancer invasion and metastasis.
Interleukin 7
Proposed essential autocrine -paracrine growth factor
for many cancers
DEAD Box RNA
Expressed in highly proliferating and cancer cells.
helicase-like protein
Lipin-1
Involved into cancer cell response to cytotoxic drugs.
Dynein
Participate in p53 intracellular traffic, reported in
prostate cancer and hepatocellular carcinoma.
Ramp protein
Reported in human embryonic carcinoma
Analysis of 100 clones selected randomly from the “21 day after treatment” library showed that more than 90% sequences of clones represented short fragments of repetitive DNA of human genome with dominance of alpha-satellite DNA.
Hence the use of DNAase in doses which are sufficient for destroying extracellular blood DNA with size higher than 300 base pairs leads to disappearing of unique fragments of human genome from extracellular blood DNA, including those involved in development and maintenance of cancer cells malignant behavior. At the same time the tumor responded to applied therapy.
EXAMPLE 4
The Treatment of Malignant Low Differentiated Lymphoma Invading the Spleen and Portal Vien and Metastases in the Liver
49-years-old woman has been admitted to the hospital with the fever (39° C.), progressive jaundice, liver failure and being under suspicion of acute hepatitis suffering. During the inspection malignant lymphoma with the diffusely defeats of spleen and gates of liver and multiply metastases in liver were revealed. By patient's agreement, due to the lack of any specific treatment and because of progression of the disease, intravenous injections of bovine pancreatic DNase were prescribed. Twice a day measuring of level of blood extracellular DNA and its electrophoretic fractioning were conducted. During the first day 500000 units of enzyme were administered as 2 6-hour infusions. Later this dose was increased by 1 000 000 units per day. When the dose was 5500000 units daily the 50% decrease of blood extracellular DNA and disappearance of fraction of DNA with size more than 300 base pairs were noted. As the continued DNA infusions at 5500000 units per day were being performed the patient's general condition was being improved, fever and jaundice disappeared, biochemical indexes of blood taken a turn to the better. Control Doppler examination which has been made at day 20 after the beginning of the treatment showed significant reduction (more than 40%) of lesion in the spleen and disappearance of more than half of all metastatic sites in the liver. The woman was moved to another hospital for conducting chemotherapy.
Hence the use of DNase in doses which are sufficient for destroying extracellular DNA of blood with size higher than 300 base pairs leads to tumor regression according to the inventive method.
EXAMPLE 5
The Study of Influence of Polyclonal Serum Containing the Antibodies Against DNA on the Growth of Erlich Carcinoma of in Mice Treating with DNAase
Antibodies against DNA were isolated from the blood of patients with systemic lupus erythematosus according to method of Shuster. A. M. (Shuster A. M. et. al., Science, v.256, 1992, pp. 665-667). Such anti-DNA antibodies could not only bind DNA but also hydrolyze it. Human recombinant DNase 1 (Genetech) was used.
1 group—7 mice bearing Erlich carcinoma—control.
2 group—6 mice bearing Erlich carcinoma received intravenous injection of human anti-DNA antibodies (Ig G) in dose of 200 mkg per animal on day 3 after the carcinoma transpalantation. Mice also have been administered with DNase in dose 0.5 mg/kg 4 times intraperitonealy a day from day 3 to day 7 after the tumor transplantation.
3 group—6 mice bearing Erlich carcinoma received intravenous injection of human non-specific immunoglobulin (IgG) in dose of 200 mkg per animal on day 3 after the carcinoma transpalantation. Mice also have been administered with DNAase in dose 0.5 mg/kg 4 times intraperitonealy a day from day 3 to day 7 after the tumor transplantation.
4 group—6 mice bearing Erlich carcinoma received intravenous injection of human DNase in dose of 0.5 mg/kg 4 times intraperitonealy a day from day 3 to day 7 after the tumor transplantation.
The effect was evaluated as the tumor growth inhibition on day 7 after the tumor cell transplantation (TGI, evaluated in percent). The results are presented in Table 3.
The tumor volume on day 7 after tumor transplantation.
TABLE 3
Group
Tumor volume
T %
1
105 +/− 12
—
2
25 +/− 5
~75%
3
37 +/− 6
~66%
4
35 +/− 7
~67%
The presented data demonstrated that the combined therapy with DNase and the agent binding blood exracellular DNA has more noticeable antitumor effect.
EXAMPLE 6
The Study of Degradation Kinetics of High Molecular Weight Fraction (Size more than 300 Pairs of Bases) of Blood Extracellular DNA of Breast Cancer Patient in the Presence of Bovine Pancreatic DNase, Proteinase K and Bovine Pancreatic DNase, Lipase and Bovine Pancreatic DNase and Extracellular Desoxyrybonuclease Serratia Mercenses , which has Ribonuclease Activity and is as Destroyed and Modifying Agent at the Same Time
The respective enzyme was added to a sample of patient's plasma and incubated for 45 minutes at 37° C. 45 minutes later the reaction has being stopped and isolation and electrophoretic fractioning with densitometry of blood extracellular DNA have being performed.
The results are presented in Table 4.
Degradation kinetics of high molecular fraction.
TABLE 4
Degradation of high
molecular fraction,
The way of working
%
Intact control
0
Proteinase K (0.1 mkg/ml)
0
Pancreatic lipase (0.1 mkg/ml)
0
Bovine pancreatic DNAase
25
(1 Kuntz Units/ml)
Bovine pancreatic DNAase
35
(1 Kuntz Units\ml) + proteinase K (0.1 mkg\ml)
Bovine pancreatic DNAase
40
(1 Kuntz Units/ml) + pancreatic lipase (0.1 mkg/ml)
Extracellular desoxyribonuclease of
45
Serratia Mercenses (1 Kuntz Units/ml)
The presented data demonstrated that the combined therapy with DNase and the agent modifying blood exracellular DNA binding with proteins, lipids and ribonucleic acids leads to more effective degradation of high molecular fraction (size more than 300 pairs of bases) of blood extracellular DNA.
EXAMPLE 7
The Study of the Influence of Different Methods of Destroying Extracellular DNA on its Pathogenic Properties
C57B1 mice have been inoculated with high metastatic or low metastatic strain of LLC tumor. On the 9th day after the inoculation animals were euthanized and pool of their blood plasma was collected. The summary fraction of extracellular blood plasma DNA was kept in phosphate butler at −20° C.
7 groups of mice inoculated with low metastatic strain of LLC were included in the experiment.
1 group—6 mice grafted by low metastatic LLC strain.
2 group—6 mice grafted by low metastatic LLC strain and were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA from mice grafted by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood).
3 group—6 mice grafted by low metastatic LLC strain and were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA from mice grafted by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood). Before the administration the sample with DNA has been disinfected photochemically (by adding 1 mkM of methylene blue stain and exposure of red light during 10 min (˜60 000 lux).
4 group—6 mice grafted by low metastatic LLC strain and were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA from mice grafted by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood). Before the administration the sample with DNA has been mixed with 10 mkg of hydrolytic anti-DNA antibodies.
5 group—6 mice grafted by low metastatic LLC strain and were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA of mice graft by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood). Before the administration 1 mkg of the fragment A of the plant toxin Ricin was added to the sample and the mixture was incubated during 1 hour at 37° C. Ricin is the representative of RIP-toxins family (proteins inactivating ribosomes) which widely used for immunotoxins' development. In addition to its capability to inactivate ribosomes these proteins also can deadenilate and hydrolyze DNA. To realize the toxic effect the unit A of the type II RIP toxin should be delivered into cell by unit B. In the absence of subunit B chain A is not toxic, however polyadeninglicosidase activity of chain A can be used for destruction of DNA circulating in blood.
6 group—6 mice grafted by low metastatic LLC strain were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA from mice grafted by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood). The DNA sample was enzymatically methylated before the administration. (I. Muiznieks et. al., FEBS Letters, 1994, v. 344,pp.251-254).
7 group—6 mice grafted by low metastatic LLC strain were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA of mice graft by low metastatic strain
8 group—6 mice grafted by low metastatic LLC strain were subjected to twice repeated intravenous administration (on 7 and 8 day after inoculation) of summary fraction of extracellular DNA of mice grafted by high metastatic strain (before the administration 0.05 mkg of DNA have been dissolved in 500 mkl of fresh heparinized blood). The sample with DNA was incubated with 200 ng/ml of dornase alpha during 30 minutes at 37° C. before the administration.
The number of lung metastases (N cp) was evaluated on day 15 after the inoculation.
The results are presented in Table 5.
The number of lung metastases on day 15 after the tumor inoculation subject to the extracellular DNA destruction method.
TABLE 5
Group
N cp
1
12.0
2
22.5
3
14.1
4
15.5
5
15.1
6
12.3
7
13.3
8
13.5
Hence blood extracellular DNA of mice bearing highly malignant tumor strain increases metastasis of less malignant tumor. Destruction, binding and modification of blood extracellular DNA suppress that process according to the inventive method.
EXAMPLE 8
Pilot Clinical Trials of DNase Enzyme Monotherapy in Patients with Advanced Cancer of Different Origin
The trials were performed in St. Petersburg Academy of Advanced Medical Education; Department of Thoracic Surgery. Total 12 patients were included according to following inclusion criteria:
Men and women 18 y. or older
T4M+ advanced cancer of any orign
Diagnosis proved by clinical, instrumental and laboratory assessment
Absence of any alternative treatment modality
CT (Spiral Computer Tomography) or clinical evidence of rapidly progressing disease
Karnofsky performance score >40
The following patients were included:
MOI—Malignant Melanoma. Multiple lung and liver metastasis.
GEF—Breast cancer. Disseminated bone metastasis.
FVV—Breast cancer. Disseminated lung and liver metastasis.
KNP—Gastric cancer. Disseminated lymphatic and liver metastasis.
PGP—Colon cancer. Disseminated lung and liver metastasis.
MCF—Colon cancer. Local reappearance. Disseminated lymphatic and liver metastasis.
MVI—Pancreatic adenocarcinoma. Disseminated lymphatic metastasis.
SSA—Lung cancer. Disseminated lung and lymphatic metastasis.
ISP—Colon cancer. Liver metastasis.
BVI—Recurrent Renal cancer. Multiply bone metastasis.
CLV—Recurrent rectal carcinoma. Multiply bone and lung metastasis.
BAI—Lung cancer. Disseminated lung and lymphatic metastasis
The patients received one course of monotherapy with bovine pancreatic DNase enzyme according following regimen:
Treatment duration—21 day.
DNase delivery—20 min. intravenous infusion in isotonic sodium chloride.
Number of daily infusions—6.
Day 1-8: 50 mg per infusion (510 000 Kunitz units per day)
Day 8-12: 75 mg per infusion (765 000 Kunitz units per day)
Day 12-21: 100 mg per infusion (1 020 000 Kunitz units per day)
The efficacy was assessed on day 30 after start of therapy. All patients demonstrated stabilization of the disease. (Spiral CT scan; RECIST criteria). All patients demonstrated significant increase in Karnofsky performance score; some patients showed shrinkage of metastatic nodules. It can be therefore concluded that DNase therapy is effective in treatment of malignant tumors of different origin. In Terms of Different DNase Enzymes:
EXAMPLE 9
Inhibition of Growth of Human Tumors in Nude Mice Under Treatment with Different High-dose DNase Enzymes
DNase IIβ DLAD is an enzyme that degrades DNA during lens cell differentiation and was purchased from Abnova Corporation. DNase 1L1 is a member of deoxyribonuclease family showing high sequence similarity to lysosomal DNase I (Abnova Corporation). TURBO™ DNase is genetically reengineered form of bovine DNase I for greater catalytic efficiency than conventional DNase I at higher salt concentrations and lower DNA concentrations. The enzyme was purchased from Ambion.
All experiments were performed in 6-8 week old female nu/nu mice. Eighty eight nude mice were randomly divided into control and experimental groups as follows:
%% of Tumor
Animals
growth
Group
per group
Tumor
DNASE enzyme
Dosage
inhibition
1
8
COLO205
Saline
—
0%
2
6
COLO205
DNASE DLAD
5
mkg\kg
0%
3
6
COLO205
DNASE DLAD
250
mkg\kg
60%
4
6
COLO205
TURBO DNASE
5
U\kg
5%
5
6
COLO205
TURBO DNASE
500
U\kg
75%
6
6
COLO205
DNASE 1L1
5
mkg\kg
0%
7
6
COLO205
DNASE 1L1
250
mkg\kg
100%
8
8
NCI-H82
Saline
—
0%
9
6
NCI-H82
DNASE DLAD
5
mkg\kg
0%
10
6
NCI-H82
DNASE DLAD
250
mkg\kg
50%
11
6
NCI-H82
TURBO DNASE
5
U\kg
10%
12
6
NCI-H82
TURBO DNASE
500
U\kg
75%
13
6
NCI-H82
DNASE 1L1
5
mkg\kg
10%
14
6
NCI-H82
DNASE 1L1
250
mkg\kg
90%
COLO205 (Human colon cancer) and NC1-H82 (Human lung cancer) cells (10-to-12 million) were injected s.c. in the left flank of animals. Once a palpable tumor was observed seven daily intramuscular injections of DNase enzyme or saline were given as indicated in the table above. The anti-tumor activity following DNase treatment was assessed by measuring the tumor dimensions at the day following the day of last injection in the control (PBS) and DNase-treated groups. The apparent tumor volume was calculated using the formula [tumor volume (mm 3 )=(Length×Width 2 )/2]. The results of treatment expressed as % % of tumor growth inhibition in DNase-treated animals in comparison with controls arc presented in the above table. Thus, different DNase enzymes possess anti-cancer activity at doses used.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are neither intended to be exhaustive nor to limit the invention to the precise forms disclosed and, obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, to thereby enable others skilled in the art to best utilize the invention and its various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the Claims appended hereto and their equivalents. Therefore, the scope of the invention is to be limited only by the following claims. | A method to treat cancer and other malignant diseases, said method comprising parenterally administering an agent which destroys blood extracellular DNA into the systemic circulation of a cancer patient to slow down cancer growth. The agent is embodied in the form of a DNase enzyme and, more particularly, as a DNase I enzyme. Doses from 50,000-250,000,000 Kunitz units/day are administered for 5-360 days. | 2 |
FIELD OF THE INVENTION
[0001] The invention relates to the field of decorative trim strips for automobiles made of aluminum alloy for use primarily on the outside of bodywork, such as in particular window surrounds, side moldings on body shells or doors, trim for tailgates, hubcaps and bumper trim strips.
[0002] The invention relates more particularly to aluminum alloy plates of the AA5xxx series with a composition and heat treatment that are particularly suitable for this type of application and offering, after shaping and brightening, excellent resistance to corrosion in particular to the increasingly alkaline solutions that make up the detergents that are used particularly in automatic carwashes.
STATE OF THE ART
[0003] Aluminum alloys are commonly used in the manufacture of bright decorative parts for the automotive industry in competition with steel and plastics.
[0004] Such is the case in particular for trim strips for the outside of bodywork, such as window surrounds, side moldings on body shells or doors, trim for tailgates, grilles and bumper trim strips.
[0005] All aluminum alloys discussed in the following are designated, unless otherwise stated, according to the designations defined by the “Aluminum Association” in the “Registration Record Series” that it publishes regularly.
[0006] Two types of products are currently available on the market: extruded profiles and shaped plates, before the anodizing/brightening treatment.
[0007] For the first, so-called high purity AA6xxx series alloys are mainly used, and particularly type AA6401.
[0008] For the second, in North America, the predominant types are AA3xxx and 8xxx alloys, while in Europe, high purity alloy of the AA5xxx series are mainly used.
[0009] However, these are judged by motor vehicle manufacturers to be less efficient than products made from profiles of the AA6xxx series, particularly in terms of corrosion resistance in strongly alkaline media.
[0010] Among the main parameters of the specification of this type of bright plate are a certain mechanical strength, good formability, and especially a good capability for brightening and anodizing, and maintaining the appearance obtained without deterioration throughout the life of the vehicle.
[0011] This parameter has become particularly important with the recent developments in automatic carwash detergents, with a move to more alkaline solutions, i.e. above the pH at which the final anodic layer is stable and which can lead to a loss of brightness that is ultimately prohibitive.
[0012] For this reason, qualification tests have been developed by motor vehicle manufacturers to differentiate between the different products (alloys, processing mode and surface treatment).
[0013] The most widespread, known as the “carwash test” involves partially immersing a sample of the final product in a highly alkaline solution, i.e. a pH of 11 to 14, for 10 minutes, then visually determining the loss or otherwise of brightness after cleaning of etching products.
[0014] The exact experimental procedure is described below in the section “subject of the invention”. The aqueous alkaline solution most recently used consists of 12.5 g/l of NaOH, 4.64 g/l of Na 3 PO 4 —12H 2 O and 0.33 g/l of NaCl. Its pH measured as during the tests reported in the section “Examples” was 13.5.
[0015] In order to quantify the results, one may, in addition, measure the weight loss of samples during the operation.
[0016] The main work on this topic has focused primarily on the conditions of brightening surface treatment and especially final anodization to increase the resistance of the anodic layer to these very aggressive solutions. This is particularly true of the study by L. E. Cohen and J. A. Hook reported in “Corrosion of anodized aluminum by alkaline cleaners: Causes and cures”, Plat. Surf. Finish, 74(2), 1987, p. 73-76.
[0017] The effectiveness of the addition of silicate or transition metal salts during the sealing step has been demonstrated in particular by S. Jolivet in “Colmatage résistant aux milieux alcalins” ( Sealing resistant to alkaline media ), Symposium on the Surface Treatment of Aluminum Alloys, CETIM/CERTEC, 2008. It was also the subject of application EP 1873278 A1 “Silicate treatment of sealed anodised aluminium” filed in 2006 by Henkel KGAA.
[0018] Other studies have also focused on the influence of the geometry of the oxide layer, such as those of R. Steins et al. reported in “High performance anodized layers”, European Aluminium Congress, 2009.
[0019] Finally, the latest solutions focus on the application of a layer of silane-based sol-gel on the anodic layer, which greatly increases the resistance of the final product. They were the subject of request WO 2009/068168 “Component made of Al alloy having very high corrosion resistance and method for the production thereof”, filed in 2008 by Erbslöh AG.
[0020] In fact, little research focuses on the metallurgical influence of the substrate, although differences have been observed, as mentioned above, between alloys of series AA5xxx and AA6xxx. The alloys used to date in Europe come generally from very pure bases (A199.9Mg or A199.7Mg and A199.9MgSi) such as alloys of types AA5657 or even AA5505 or AA5210 for plates of the AA5xxx series and type AA6401 for profiles of the AA6xxx series.
[0021] The rolled product or plate is usually supplied in the annealed condition, known by the name of “H2x” in order to guarantee minimum strength but still with sufficient formability for the forming step, followed by the steps of brightening and anodizing.
[0022] The extruded product is usually delivered in metallurgical temper T4 (solution heat-treated and quenched) or T6 (solution heat-treated, quenched and aged) in a form similar to that of the final product.
THE PROBLEM
[0023] The invention aims to provide a laminated product of the AA5xxx series which, when developed and transformed under certain conditions, achieves a performance similar to an extruded product of the AA6xxx series in terms of conservation of its brightness in contact with a strongly alkaline solution, or one at pH values from 11 to 14, while maintaining satisfactory mechanical strength and sufficient formability of the plate or strip used to prepare the final product.
SUBJECT OF THE INVENTION
[0024] The invention relates to a method of manufacturing an outside decorative trim strip of motor vehicles, such as window surrounds or body shell trim, made of aluminum alloy by shaping and brightening of a plate or strip made according to the following successive steps:
[0025] Direct Chill (DC) casting of a slab made of an alloy of the AA5xxx series of high purity, i.e. a composition such that (as a percentage by weight): Mg≦1.1, Cu≦0.10, other elements≦0.30, the rest aluminum.
[0026] Heating the plate to a temperature of 480 to 530° C. for at least 1 h, hot rolling to a thickness of typically 5 to 30 mm, and cooling followed by cold rolling including intermediate annealing in a continuous tunnel furnace, or holding between the solvus temperature and the alloy incipient melting temperature typically for 3 seconds to 5 minutes, followed by quenching in air or water prior to final cold rolling with a reduction rate of 15 to 70% to a thickness of 0.4 to 1.5 mm
[0027] To facilitate the subsequent shaping of the plate or strip, annealing at a temperature of 100 to 200° C. for a time ranging from 3 to 15 h at 170° C. may be performed. According to a preferred embodiment, the composition of the plate is of the AA5657 type or (as a percentage by weight):
Si:≦0.08, Fe:≦0.10, Cu:≦0.10, Mn:≦0.03, Mg: 0.6-1.0, Zn:≦0.05, Ti:≦0.020, other elements <0.05 each, and <0.15 in total, the rest aluminum.
[0029] In another embodiment of the invention, the composition of the plate is the AA5205 type, or (as a percentage by weight):
Si:≦0.15, Fe:≦0.7, Cu: 0.03-0.10, Mn:≦0.10, Mg: 0.6-1.0, Zn:≦0.05, Ti:≦0.05, other elements <0.05 each, and <0.15 in total, the rest aluminum.
[0031] In another embodiment, the alloy plate is a high-purity alloy of the AA5xxx series, with a composition such that (as a percentage by weight): Mg≦1.1, other elements≦0.10, the rest aluminum.
[0032] According to this embodiment, the composition of the plate is of the AA5505 type or (as a percentage by weight):
Si:≦0.06, Fe:≦0.04, Cu≦0.01, Mn:≦0.03, Mg: 0.8-1.1, Zn:≦0.03, Ti:≦0.010, other elements <0.05 each, and <0.10 in total, the rest aluminum.
[0034] Still according to this embodiment, the composition of the plate is of the AA5210 type or (as a percentage by weight):
Si:≦0.06, Fe:≦0.04, Cu:≦0.01, Mn:≦0.03, Mg: 0.35-0.60, Zn:≦0.03, Ti:≦0.020, other elements <0.05 each, and <0.10 in total, the rest aluminum.
[0036] The duration of the intermediate annealing, i.e. holding between the solvus temperature and the incipient melting temperature of the alloy is preferably between 5 s and 2 min and in an advantageous embodiment, the temperature of the intermediate annealing is between 450 and 550° C.
[0037] The invention also comprises a decorative trim strip made according to a method such as described above and chosen among the group comprising window surrounds, side moldings on body shells or trim for tailgates, decorative trims for grilles and bumper trim strips.
[0038] It also relates a decorative trim strip manufactured by a method according to one or more of the embodiments mentioned above, characterized in that:
after brightening of the plate or strip, comprising the steps of conventional degreasing, electro-brightening in a phospho-sulfuric acid medium, typically at 75° C. and with a DC voltage of 25V, rinsing, alkaline etching typically at 50° C., desmutting at ambient temperature, rinsing, anodizing in a sulfuric acid medium in direct current, typically at 21° C., sealing pores in two steps: cold with nickel then in hot water, (i.e. pre-sealing in a solution of nickel acetate at ambient temperature and followed by boehmitage in boiling water), followed by a test known to experts in the field as the “carwash test”, namely: acid etching for 10 min. in a solution of pH 1, or an aqueous solution containing 0.1 mol HCl/liter, rinsing, drying by holding for 1 h at 40° C., immersing for 10 minutes in an alkaline solution at pH 11 to 14, typically as described above, rinsing, drying and wiping with a polishing cloth, no loss of brightness is observed visually.
[0041] According to another advantageous feature, said decorative trim strip manufactured by a method according to one or more of the embodiments mentioned previously is characterized in that:
after brightening of the plate or trim comprising the steps of conventional degreasing, electro-brightening in a phospho-sulfuric acid medium, typically at 75° C. and with a DC voltage of 25V, rinsing, alkaline etching typically at 50° C., desmutting at ambient temperature, rinsing, anodizing in a sulfuric acid medium in direct current, typically at 21° C., sealing pores in two steps: cold with nickel then in hot water, followed by a test known to experts in the field as the “carwash test”, namely: acid pickling for 10 min in a solution of pH 1, rinsing, drying by holding for 1 h at 40° C., keeping immersed for 10 min in an alkaline solution at pH 11 to 14, rinsing, drying and wiping with a polishing cloth, the weight loss measured on specimens cut from said plate or strip does not exceed 40 mg/dm 2 of immersed surface.
DESCRIPTION OF THE FIGURES
[0045] FIG. 1 is a diagram representing a cross-sectional observation of the anodic layer of a sample of aluminum after immersing for 10 min. in an alkaline solution at pH 11 to 14, as described above. The anodic layer (1+2) has a standard thickness of 5-6 μm.
[0046] Approximately 1μm (1) is attacked by chemical dissolution after the 10 min. test. The rest of the anodic layer (2) has attack channels throughout the thickness of the layer and etching of the underlying metal is sometimes observed (3). Channel size is about one hundred nm.
[0047] FIG. 2 is a diagram representing the surface of the sample observed in a scanning electron microscope after 10 min of alkaline attack for samples 5505 H22 on the left and 6401 T6 on the right. The diagram shows an identical observation surface for both samples. The density of defects can therefore be compared directly. It is clear from this diagram that a poor reaction to the alkaline test leads to higher density of defects as shown for sample 5505 H22 compared to sample 6401 T6.
DESCRIPTION OF THE INVENTION
[0048] The invention consists in a judicious choice of alloy and heat treatment, together with fabrication process parameters, of the plate or strip used for making trim strips for the outside of motor vehicles subjected to a severely corrosive environment such as that of detergents in carwashes, consisting of highly alkaline solutions at a pH of 11 to 14, in any case above the pH for stability of the anodic layer, which allows it to preserve its brightness throughout the life of the vehicle, while maintaining satisfactory mechanical strength and adequate formability.
[0049] It is based on the observation by the applicant that in contact with a strongly alkaline solution, i.e. a pH of 11 to 14, such as that commonly used by motor vehicle manufacturers in their qualification tests, etching of the anode layer takes place according to two distinct modes. This is evident in FIG. 1 , a view taken with a scanning electron microscope of a section of the anode layer with a thickness of 5 to 6 μm, after immersion for ten minutes in such an alkaline solution:
[0050] The first mode (1) is a relatively slow and uniform chemical dissolution of the sealed oxide film, while the second (2) corresponds to a rapid and localized attack of the anodic layer and the underlying metal and results in the formation of narrow tunnels through the oxide layer.
[0051] The applicant also noted that the homogeneous attack of the oxide layer according to the first mode was relatively independent of the type of alloy and its metallurgical temper; on the contrary: the degree of localized attack through the oxide layer does greatly depend on the alloy and its metallurgical temper.
[0052] This has a pronounced effect in the case of different alloys of series AA5xxx tested, whereas this effect does not appear to be significant in the case of alloys of series AA6xxx.
[0053] This difference in behavior is attributed to a localized attack density that is significantly lower in favorable cases compared to the worst cases. It is illustrated in FIG. 2 which shows images obtained by scanning electron microscopy at the same magnification for both samples after immersion for ten minutes in the alkaline solution at pH 11 to 14: The left-hand image is an AA5505 type alloy after cold rolling and final annealing at a temperature of 250° C. for 1 h (temper H22) leading to a poor behavior, while the right-hand image is an extruded AA6401 alloy, temper T6 (quenched and aged) leading to favorable behavior.
[0054] To date, no industrial solution is known to improve the behavior of AA5xxx series alloy plates as compared with profiles made with AA6xxx series alloys.
[0055] As the applicant had noted this difference in behavior between alloys of series 5xxx and series 6xxx during qualification tests known as “carwash tests”, including the one described in the examples, and because of the above observations, he saw it not as behavior intrinsic to a type of alloy, but as being related to the method of manufacture of the product.
[0056] More specifically, the poor behavior of AA5xxx series alloys was attributed to the precipitation of the Mg 2 Si phase during the final annealing treatment. The applicant therefore sought the solution to the problem in a more appropriate method of production that would take into account the influence of the precipitation of fine particles of the Mg 2 Si phase during the final annealing treatment, but also in all intermediate annealing, particularly during cold rolling.
[0057] It turned out that the solution lay in intermediate annealing during cold rolling, of the “flash” type: in a continuous tunnel furnace at a temperature between the solvus temperature and the incipient melting temperature of the alloy, typically for 3 seconds to 5 minutes, followed by quenching in air or water, before final cold rolling, during which the mechanical strength is improved by work-hardening.
[0058] Moderate additional annealing, i.e. at a temperature of 100 to 200° C. for a time equivalent to 3 to 15 h at 170° C. may be performed if necessary to facilitate the subsequent shaping of the plate or strip.
[0059] Equivalent time t(eq) is defined by the formula:
[0000]
t
(
eq
)
=
tref
*
exp
(
-
15692
/
Tref
)
exp
(
-
15692
/
T
eq
)
[0000] where T (in K) is the temperature and t the annealing time, T ref being a reference temperature of 443K or 170° C. and tref being the said reference time between 3 h and 15 h.
[0060] The alloys of the invention are so-called high purity alloys of the AA5xxx series, such as those used for the development of bright plates (called “high gloss” alloys), and obtained from very pure bases (A199.9Mg or A199.7Mg) or the 5xxx series alloys of chemical composition expressed in percentages by weight such that: Mg<1.1, Cu<0.10, other elements <0.30, the remainder being aluminum, or, even purer, of chemical composition such that: Mg≦1.1, other elements≦0.10, the rest aluminum.
[0061] In the first case, mention may be made of the AA5657 type alloy, of chemical composition, expressed as percentages by weight: Si:≦0.08, Fe:≦0.10, Cu:≦0.10, Mn:≦0.03, Mg: 0.6-1.0, Zn:≦0.05, Ti:≦0020, other elements <0.05 each and <0.15 total, the rest aluminum, or the alloy of type AA5205, of chemical composition, expressed percentages by weight: Si:≦0.15, Fe:≦0.7, Cu: 0.03-0.10, Mn:≦0.10, Mg: 0.6-1.0, Zn:≦0.05, Ti:≦0.05, other elements <0.05 each, and <0.15 in total, the rest aluminum.
[0062] In the latter case mention may particularly be made of the AA5505 alloys, of composition (as a percentage by weight): Si:≦0.06, Fe:≦0.04, Cu≦0.01, Mn:≦0.03, Mg: 0.8-1.1, Zn:≦0.03, Ti:≦0010, other elements <0.05 each and <0.10 in total, the rest aluminum, or the alloy of type AA5210, of chemical composition, as a percentage by weight: Si:≦0.06, Fe:≦0.04, Cu:≦0.01, Mn:≦0.03, Mg: 0.35 - 0.60, Zn:≦0.03, Ti:≦0.020, other elements <0.05 each, and <0.10 in total, the rest aluminum.
[0063] The manufacture of plates according to the invention mainly comprises casting, typically DC casting of plates and scalping them.
[0064] The scalped plates are then subjected to heating for more than one hour at a temperature of 480 to 530° C. and then hot rolling to a thickness of typically 5 to 30 mm, before cooling.
[0065] It then undergoes cold rolling as mentioned above in which the product undergoes intermediate annealing at a temperature between the solvus temperature and the alloy incipient melting temperature, or typically between 450 and 550° C.
[0066] After this annealing, cold rolling is resumed with a reduction rate of 15-70% to a final thickness of 0.4 to 1.5 mm
[0067] Finally, the plates or strips obtained are subjected, if necessary, to the final annealing mentioned above.
[0068] The details of the invention will be understood better with the help of the examples below, which are not, however, restrictive in their scope.
EXAMPLES
[0069] Example 1
[0070] An AA5657 alloy plate was cast by Direct Chill (DC) casting. Its composition (as a percentage by weight) was:
Si: 0.06, Fe: 0.06, Cu: 0.04, Mg: 0.76, Mn:≦0.03, Zn:≦0.05, Ti:≦0.020, other elements <0.05 each, and <0.15 in total, the rest aluminum.
[0072] The plate was heated for 1 hour at a temperature of 490° C. and then hot rolled to a thickness of 7.5 mm, and cooled before cold rolling without intermediate annealing to a thickness of 0.7 mm
[0073] Finally, the resulting plate was subjected to final annealing for 1 h at a temperature of 260° C.
[0074] Two samples of the coil (A and B in summary Table 1 at the end of the “Examples” section) were collected to undergo brightening and anodizing treatment followed by the qualification test of the “carwash test” type, both as mentioned above.
[0075] The amount of weight lost during the test expressed in mg/dm 2 of immersed surface for an immersion time of 10 minutes are given in Table 1 below. Both samples A and B lead to a similar result: values of 54 and 58 mg/dm 2 .
[0076] To evaluate the idea underlying the invention, namely that the negative behavior of the AA5xxx series alloys was due to the precipitation of the Mg 2 Si phase during the final annealing heat treatment, heat treatment (called “Simulation” in table 1) was performed on a 0.7 mm thick laboratory sample C in the final annealed state to dissolve any Mg 2 Si particle which might have precipitated during the transformation range by conventional solution heat treatment.
[0077] It was assumed in this example (and this is validated by the following examples) that the cold strain hardening and final annealing of the invention did not lead to the precipitation of Mg 2 Si.
[0078] Sample C treated in this way underwent the full cycle of brightening/anodizing and the alkaline test of the “carwash test” type, both as mentioned above.
[0079] The weight loss after an immersion time of 10 minutes is 24 mg/dm 2 , which is consistent with the claimed characteristic.
[0080] Samples A, B, outside the invention, and C, simulating the invention were also evaluated visually and no loss of brightness was found on sample C, unlike the two samples A and B.
[0081] This example validates the positive effect of intermediate annealing according to the invention.
Example 2
[0082] An AA5657 alloy plate was cast by Direct Chill (DC) casting. Its composition (as a percentage by weight) was identical to that of example 1.
[0083] The plate was also heated for 1 hour at a temperature of 490° C. and then hot rolled to a thickness of 6.5 mm, and cooled before cold rolling to a thickness of 1.09 mm
[0084] The coil was then subjected to intermediate annealing in a batch type furnace for 8 hours at a temperature of 360° C.
[0085] Cold rolling was then resumed down to the final thickness of 0.42 mm
[0086] Finally, the resulting coil was subjected to final annealing for 2.5 h at a temperature of 170° C.
[0087] This is a range with intermediate annealing outside the invention.
[0088] A sample (D in Table 1) was then taken to undergo brightening and anodizing treatment followed by a qualifying test of the “carwash test” type, again as mentioned above. The weight loss after an immersion time of 10 minutes is 75 mg/dm 2 , which is well above the claimed value of 40 mg/dm 2 .
[0089] Sample D was also assessed visually and showed significant loss of brightness after the test.
Example 3
[0090] An AA5505 alloy plate was cast by Direct Chill (DC) casting. Its composition (as a percentage by weight) was:
Si: 0.03, Fe: 0.03, Cu:≦0.01, Mg: 0.88, Mn:≦0.03, Zn:≦0.03, Ti:≦0.010, other elements <0.05 each, and <0.10 in total, the rest aluminum.
[0092] The plate was also heated for 1 hour at a temperature of 490° C. and then hot rolled to a thickness of 0.30 in, and cooled before cold rolling to a thickness of 0.09 in.
[0093] The coil was then subjected, according to the invention, to intermediate annealing in a continuous furnace at 500° C. with a holding time of 23 s above the solvus temperature of the alloy, followed by air quenching.
[0094] Cold rolling was then resumed to give the final thickness of 1.6 mm Another coil, of the same alloy and processed identically but without intermediate annealing, was also produced. The latter underwent final annealing at a temperature of 250° C. for 1 h.
[0095] Samples (F and G for the first and for the second E) were taken from each coil, to undergo brightening and anodizing treatment followed by qualifying test of the “carwash test” type, again as mentioned above.
[0096] The weight losses after an immersion time of 10 minutes are presented in table 1 below.
[0097] These results demonstrate the improved behavior of the metal produced with intermediate annealing according to the invention, here without final annealing (F at 30 and G at 29 mg/dm 2 ), relative to the one, outside the invention, produced without intermediate annealing (E at 58 mg/dm 2 ).
[0098] Samples F, G, with intermediate annealing and according to the invention, here without final annealing, and E, outside the invention, produced without intermediate annealing, were also assessed visually and no loss of brightness was observed on samples F and G unlike sample E, which showed a significant loss of brightness.
Example 4
[0099] An AA5505 alloy plate was cast by Direct Chill (DC) casting. Its composition (as a percentage by weight) was identical to that of example 3.
[0100] The plate was also heated for 1 hour at a temperature of 490° C. and then hot rolled to a thickness of 0.30 in, and cooled before cold rolling to a thickness of 0.07 in.
[0101] The coil was then subjected, according to the invention, to intermediate annealing in a continuous furnace at 520° C. with a holding time of 1 min above the solvus temperature of the alloy, followed by air quenching.
[0102] Cold rolling was then resumed down to the final thickness of 1.2 mm
[0103] Finally, the resulting coil was subjected to final annealing for 3 h at a temperature of 170° C.
[0104] Samples were then taken before (H) and after (I) final annealing, to undergo brightening and anodizing treatment followed by a qualifying test of the “carwash test” type, again as mentioned above.
[0105] The weight losses after an immersion time of 10 minutes are similar: 26 and 27 mg/dm 2 . Samples H and I, according to the invention, were also assessed visually and no loss of brightness was observed after the test.
[0000]
TABLE 1
Ex-
Wt. loss
am-
Sam-
Intermediate
Final
(mg/
ple
ple
Alloy
annealing
annealing
dm 2 )
1
A
AA5657
Non
1 h - 260° C.
58
1
B
AA5657
Non
1 h - 260° C.
54
1
C
AA5657
Non
Simulation
24
2
D
AA5657
8 h - 360° C.
2.5 h - 170° C.
75
3
E
AA5505
Non
1 h - 250° C.
58
3
F
AA5505
23 s - 500° C.
Non
30
3
G
AA5505
23 s - 500° C.
Non
29
4
H
AA5505
1 min. - 520° C.
Non
26
4
I
AA5505
1 min. - 520° C.
3 h - 170° C.
27 | The invention relates to a method of manufacturing an outside decorative trim strip of a motor vehicle, such as window surrounds or body shell trim, made of aluminum alloy, by shaping and brightening of a plate or strip made by vertical continuous casting of an alloy slab of series AA5xxx of high purity, homogenization-heating of the slab, hot rolling, cooling, cold rolling with intermediate annealing in a continuous tunnel furnace, or holding between the solvus temperature and the alloy burning temperature typically for 3 seconds to 5 minutes, quenching in air or water, possible annealing at a temperature of 100 to 200° C.
The invention also relates to a decorative trim strip of motor vehicle manufactured using such a method. | 2 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is the U.S. National Stage of International Application No. PCT/EP2009/008731, filed Dec. 8, 2009, which designated the United States and has been published as International Publication No. WO 2010/075935 and which claims the priority of German Patent Application, Serial No. 10 2008 061 057.7, filed Dec. 8, 2008, pursuant to 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The invention relates to a method for operating an internal combustion engine with a crankcase, a crankcase vent and an intake system.
Vehicles with modern internal combustion engines have a crankcase vent which prevents leakage of lubricants, preferably oil or lubricant vapors, into the environment. In the simplest case, the crankcase vent consists only of a tube or hose connection between the crankcase and an intake tube of the internal combustion engine, wherein the vacuum in the intake tube suctions lubricant vapors in the crankcase. Depending on the construction of the internal combustion engine and the lubricant circulation, the intake system constructed in this manner may also include a pressure control valve, a throttle or an auxiliary branch, for example disposed upstream of a damper flap of the internal combustion engine and/or a check valve which prevents an undesirable flow direction. It is known from online oil consumption measurement that internal combustion engines have high oil consumption in operating phases with low absolute intake tube pressure, corresponding to a very high intake tube vacuum. Such operating phases occur, for example, during deceleration, i.e., when the vehicle speed is reduced by way of the engine brake, for example when driving downhill. The increase of the oil consumption in these operating phases is mainly influenced by the large differential pressure between the intake tube pressure, i.e., the pressure in the intake system, and the pressure in the crankcase. For example, if a differential pressure of about 650 mbar is exceeded, a large increase in the oil consumption is observed. The oil consumption in the aforedescribed operating phases is typically optimized through improvements of piston rings and pistons, i.e., by improving the sealing of movable parts. However, this entails significantly more stringent requirements for precision and significant additional costs as well as increased friction losses of the sealing piston rings and pistons.
It is an object of the invention to provide a method for operating an internal combustion engine having a crankcase, a crankcase vent and an intake system, which obviates the aforementioned disadvantages and which significantly reduces the oil consumption in the aforementioned operating phases with zero load or in a deceleration phase without requiring modification of the pistons and/or the piston rings.
SUMMARY OF THE INVENTION
To this end, a method for operating an internal combustion engine is proposed, wherein the internal combustion engine has a crankcase, a crankcase vent and an intake system. To reduce the lubricant consumption of the internal combustion engine, the pressure in the crankcase should be reduced from a differential pressure between the intake system and the crankcase to maximally −500 mbar, in particular maximally −300 mbar, with respect to ambient pressure. According to the invention, the crankcase pressure is reduced to maximally −500 mbar, in particular maximally −300 mbar, with respect to ambient pressure during the operation of the internal combustion engine, preferably in operating state with zero load or in a deceleration phase. The crankcase is therefore under reduced pressure such that the differential pressure to the pressure in the intake manifold is smaller in order to prevent a critical differential pressure. The intake manifold pressure corresponds approximately to the pressure in the combustion chamber above the piston when the intake valves are open.
In a preferred embodiment of the method, the pressure in the crankcase is reduced when the differential pressure between the intake manifold and the crankcase exceeds at least a predetermined threshold value. If the differential pressure between the intake system, in the simplest case between the intake manifold and the crankcase, becomes too large because the vacuum of the intake system is too high in relation to the crankcase, then the pressure in the crankcase is also reduced, thereby reducing the differential pressure.
In one embodiment of the method, the differential pressure between the intake system and the crankcase and hence between the crankcase and the environment is adjusted with at least one pressure control valve and/or at least one throttle. The pressure control valve and the throttle, respectively, are constructed such that the differential pressure in the aforementioned operating states can be suitably adjusted or is adjusted automatically; for this purpose, a switching valves or a pressure control valve with a correspondingly matched spring or mimic can be used.
In a preferred embodiment of the method, the pressure in the crankcase is adjusted in a range from −50 mbar to −500 mbar, in particular in a range from −100 mbar to −300 mbar with respect to the environment. This setting of the crankcase pressure relative to the ambient pressure enables operation in a safe range with respect to lubricant consumption for known pressures of the intake system, in particular intake manifold pressures. The crankcase pressure relative to the ambient pressure can be relatively easily adjusted. This produces a differential pressure to the intake system, in particular to the intake manifold, in a certain interval relative to the respective operating pressure of the intake system and the intake manifold, respectively.
In another embodiment of the method, at least one pressure control valve and/or at least one throttle for adjusting the crankcase pressure is arranged in a ventilation line running to the crankcase. Such embodiments are useful, in particular, with internal combustion engines that are operated with dry sump lubrication. In these engines, unlike in engines with sump pressure lubrication circuits, the lubricant is stored in a separate lubricant reservoir and suctioned out of the crankcase, namely from a reservoir arranged in or on the crankcase, preferably arranged below the crankcase, by way of a lubricant pump. Ventilation must therefore be provided to adjust the desired pressure level in the crankcase. A gas flow is hereby also transported through the oil pump; the gas flow is used to ventilate the crankcase. By arranging a pressure control valve or a throttle in the ventilation line, the following air, preferably the gas flow transported in the oil flow by the oil pump, can be adjusted for attaining the desired pressure level in the crankcase.
The invention will now be described in more detail with reference to exemplary embodiments of different internal combustion engine designs, but is not limited thereto.
BRIEF DESCRIPTION OF THE DRAWING
It is shown in:
FIGS. 1 and 2 exemplary embodiments of naturally-aspirated wet sump engines;
FIGS. 3 and 4 exemplary embodiments of turbocharged wet sump engines; and
FIGS. 5 and 6 exemplary embodiments of dry sump engines.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows schematically an internal combustion engine 1 with a crankcase 2 and an intake manifold 3 forming an intake system 24 , through which combustion air is supplied to the internal combustion engine 1 . The crankcase 2 and the intake manifold 3 are connected with each other by a crankcase vent 4 . In the illustrated embodiment, the internal combustion engine 1 is constructed as a naturally-aspirated wet sump engine 5 . The crankcase vent 4 includes a pressure control valve 6 which allows adjustment of the vacuum pressure P KR in the crankcase 2 by applying to the crankcase 2 an intake manifold vacuum P SR , which can be adjusted with the pressure control valve 6 in the intake manifold 3 , thereby evacuating lubricant vapors 7 residing in the crankcase 2 . The pressure control valve 6 is hereby configured such that a differential pressure Δ p between the crankcase vacuum P KR and the ambient pressure P UG can be adjusted to be between 100 mbar in 300 mbar. The crankcase therefore has with respect to the ambient pressure P UG a differential pressure Δ P of preferably −100 mbar to −300 mbar.
FIG. 2 shows an internal combustion engine 1 which is also constructed as a naturally-aspirated wet sump engine 5 , with the crankcase 2 , the intake manifold 3 and a damper flap 8 located upstream of the intake manifold 3 for supplying combustion air to the internal combustion engine 1 . In this embodiment, the crankcase vent 4 has a branch 9 originating at the crankcase 2 . The branch 9 branches, on one hand, via a throttle 10 to the intake manifold 3 and, on the other hand, via a check valve 11 to an inlet location 12 before the damper flap 8 (meaning upstream of the damper flap 8 ). The crankcase vacuum P KR is adjusted by way of a matched throttle bore of the throttle 10 so as to produce a differential pressure Δ P of about −100 mbar to −300 mbar with respect to ambient air pressure P UG .
FIG. 3 shows an internal combustion engine 1 which is implemented as a turbocharged wet sump engine 13 . The internal combustion engine 1 has an intake manifold 3 and a turbocharger 14 disposed in the air flow upstream of the intake manifold 3 for supplying combustion air to the intake manifold 3 for combustion in the internal combustion engine 1 . The crankcase vent 4 is, on one hand, connected via the branch 9 to the intake manifold 3 through the pressure control valve 6 and a downstream check valve 11 and is, on the other hand, connected via the branch 9 to the inlet location 12 upstream of the turbocharger 14 through a check valve 11 . In this case, too, the crankcase vacuum pressure P KR can be adjusted with the pressure control valve by using a preferably matched spring so as to produce a differential pressure Δ P of about −100 mbar to −300 mbar with respect to ambient air pressure P UG .
FIG. 4 shows the internal combustion engine 1 implemented as turbocharged wet sump engine 13 , as described above with reference to FIG. 3 . Instead of the pressure control valve 6 described in FIG. 3 , in the present embodiment a throttle 10 with a matched throttle bore is provided in the crankcase vent 4 , namely upstream of the branch 9 and downstream of the check valve 11 , downstream of the intake manifold 3 . In the other branch which originates from the branch 9 and terminates upstream of the turbocharger 14 at the inlet location 12 , a check valve 11 is likewise provided. In this embodiment, too, a crankcase vacuum pressure P KR of about −100 mbar to −300 mbar with respect to ambient pressure P UG can be adjusted with the matched throttle bore.
FIG. 5 shows an internal combustion engine 1 in an embodiment as a dry sump engine 15 , wherein a lubricant circuit 16 embodied as a dry sump lubricant circuit 25 includes, inter alia, a dry sump 17 with an oil pump 18 . The dry sump lubricant circuit 25 is hereby formed between the crankcase 2 , the dry sump 17 with oil pump 18 , a lubricant reservoir 19 and a pressure controller 20 with a return from the pressure controller 20 to the crankcase 2 , with a gas flow coexisting with the lubricant flow. A vent line 21 , which terminates in the intake manifold 3 via a pressure control valve 6 , branches off from the lubricant reservoir 19 ; this arrangement represents the crankcase vent 4 . Accordingly, crankcase ventilation 22 , with which the desired pressure conditions in the crankcase 2 can be adjusted, is provided from the lubricant reservoir 19 via the pressure controller 20 , namely by way of a gas flow transported by the oil pump 18 along the oil flow. A crankcase vacuum pressure P KR is hereby also adjusted to a value of about −100 mbar to −300 mbar with respect to ambient pressure P UG .
FIG. 6 shows the internal combustion engine 1 , namely the dry sump engine 15 as described in FIG. 5 . This dry sump engine 15 has, unlike in the exemplary embodiment described in FIG. 5 , no pressure regulator 20 in the crankcase ventilation 22 ; the crankcase ventilation 22 is implemented as a direct conduit 23 from the lubricant reservoir 19 to the crankcase 2 . The crankcase vent 4 , starting from the lubricant reservoir 19 and terminating in the intake manifold 3 , includes downstream of the lubricant reservoir 19 the pressure control valve 6 which is modified so as to allow adjustment, for example via a matched spring, of the crankcase vacuum pressure P KR in the crankcase 2 from about −100 mbar to −300 mbar with respect to ambient pressure P UG .
In all illustrated exemplary embodiments, an undesirably high differential pressure between the crankcase 2 and the ambient pressure P UG , and between the crankcase vacuum pressure P KR and the intake manifold pressure P SR can thus be prevented. Increased oil consumption observed during deceleration and turnoff operation can then advantageously be reduced without requiring alteration of, for example, piston rings of the pistons of the internal combustion engine 1 to improve sealing. | The invention relates to a method for operating an internal combustion engine with a crankcase, a crankcase vent and an intake system. According to the invention, the pressure in the crankcase can be reduced, depending on a differential pressure between the intake system and the crankcase, to maximally −500 mbar, in particular maximally −300 mbar, with respect to ambient pressure for reducing lubricant consumption of the internal combustion engine. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to beach gear transporters, and more particularly, to a wheeled beach gear transporter that converts to provide storage, chairs, table and shade.
2. Description of the Related Art
Several designs for wheeled beach gear transporters have been designed in the past. None of them, however, provide for a device that provides all necessary beachgoer accessories comprising, inter alia, chairs, a table, storage and shade that assemble together in a compact manner to form a wheeled package for easy transport to and from the beach or other recreational site.
Applicant believes that the closest reference corresponds to U.S. Pat. No. 6,131,925 issued to Weldon. However, it differs from the present invention because the Weldon invention requires straps to hold the components of the device together during transport, only provides a single chair and does not provide a table surface. Furthermore, the Weldon invention is not readily compatible with larger diameter wheel as is beneficial for mobility on soft ground such as sand. The Weldon invention also does not provide for a stable mounting feature for a sunshade which is desirable for use on firmer ground or in windy conditions.
The present invention solves these problems by providing in a preferred version a compact and large wheeled device that easily converts to provide two chairs a table, an umbrella stand and storage container. Additionally, the configuration of the present invention does not require the use of straps while in its transport mode but instead relies on gravity to hold the storage container securely on the device.
In U.S. Pat. No. 5,269,157, Ciminelli describes an insulated beach box which is adapted to be wheeled or slid over terrain to reach a desired beach location. The beach box has a pivotally connected back which may be used as a handle when moving the box and as a seat back when sitting upon the box. The back includes a flexible member with pockets for storing personal items. While Ciminelli suggests that there is a need for a device to facilitate carrying utilitarian items to and from the beach, his invention provides for an insulated box and a seat/chair only. Ciminelli suggests that a beach umbrella may be stuck into the sand and clamped to the seat back to shade the seat's occupant. However, Ciminelli does not disclose how the umbrella is carried to the beach and no provision for attachment to the beach box is described. During transit, Ciminelli suggests that miscellaneous beach items which can fit between the back and top of the beach box may be held on with a flexible strap.
Carlile, in U.S. Pat. No. 4,865,346, describes a collapsible cart, held together by the frictional engagement of its components and quickly disassembled, which may be used to carry articles to the beach. The cart has a pivotally attached bottom shelf, which may be locked into position with a set of folding braces, for carrying a cooler chest. The cart is supported in an upright position by a rest attached to the edge of the shelf when the shelf is in its locked position. A picnic basket with folding shelf is attached to the cart above the cooler chest. Carlile provides for a single umbrella holder on one of the cart's side arms and beverage holders on the other side arm. Additional bracket arms support one or more folding chairs. On the rear of the cart, a auxiliary storage bag is removably attached.
A beach caddie is described by Higson in U.S. Pat. No. 4,703,944 which incorporates a chair rack and platform assembly, and, when used in a horizontal position at the beach, provides a beach table. The beach caddie apparently provides for the transportation of an umbrella and fishing poles as well as for their storage once at the beach. A topmost hinged section attached to the vertical members may be rotated at a right angle to the vertical members so that shafts of umbrellas and fishing poles may be placed through orifices therein. Such shafts rest upon the “upper cross-member 6 ” of the caddie although it is not clear whether the shafts engage the holes in the cross-member. It is also not clear what keeps the topmost hinged section from working against and flexing the fishing poles and/or umbrella shaft. The table surface of the caddie has orifices sized to hold umbrella and fishing pole shafts (presumably in an upright position for use) and orifices to hold drinks. Hook and loop fasteners secure the movable members when the caddie is used as a table at the beach.
Bonewicz, in U.S. Pat. No. 4,887,837, describes a carrier for transporting objects to the beach. Bonewicz describes a relatively straight-forward hand cart having a platform which either folds up parallel to the main frame or rotates perpendicularly to form a carrying surface. The platform has locking braces on its underside which engage the side rails to support the weight of the items being transported. In one embodiment the cart has a “cup-like” member located near the lower end of a side frame and a hook-like clasping member mounted higher on the same side frame. An umbrella may be attached with its top end in the cup-like receptacle and the hook-like element encircling its lower end. It is not clear what happens when the umbrella diameter exceeds the size of the hook-like member. The cart is further provided with a picnic basket or bag which may be mounted between the two frame members to carry additional articles. In a preferred embodiment, a hollow bag may be slipped over the upright frame and held by a strap to the handle. In this embodiment, the hook-like member and the cup-like member are not used and an umbrella can not be carried on the cart. Like Ciminelli an elastic cord may be stretch between the upright frame and the platform to restrain items placed on the platform.
While these devices of the prior art address some of the needs of a typical beachgoer, none of the devices address the problems which are solved by the present invention and, in particular, perhaps the most frequently encountered problem of beach activity is not met. No known prior art provide for a beach transport device that works well on both hard and soft surfaces, holds a storage element by gravity reducing the need for straps while imparting stability to the device, provides multiple seats and a table and can hold an umbrella in impenetrable soil.
Other patents describing the closest subject matter provide for a number of more or less complicated features that fail to solve the problem in an efficient and economical way. None of these patents suggest the novel features of the present invention.
SUMMARY OF THE INVENTION
It is one of the main objects of the present invention to provide a device that increases the ease of transporting essential gear to the beach or other recreational area and then converts to provide two chairs, a table, a shade mount and storage.
It is another object of this invention to provide a device that can easily transport desirable beach gear for at least two people by a single person.
It is still another object of the present invention to provide a device that can easily be transported over soft ground such as sand yet allows for the mounting of a shade umbrella over firm ground.
It is an object of this invention to provide a gravity roller with an insulated cooler or wet-bag and a dry storage upper bag in combination to pack anything into it as may seen fit by the consumer, resulting in ease of transportation when pulled or pushed.
Another object of the invention is to convert into two comfortable chairs.
Another object of this invention is to provide a means to securely erect and transport an umbrella.
An additional purpose of the invention is to provide a lightweight and easy rollable device that is easy to maneuver.
Another object of this invention is to provide a compact device that can be assembled or dissembled easily and quickly.
It is yet another object of this invention to provide such a device that is inexpensive to manufacture and maintain while retaining its effectiveness.
Further objects of the invention will be brought out in the following part of the specification, wherein detailed description is for the purpose of fully disclosing the invention without placing limitations thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
With the above and other related objects in view, the invention consists in the details of construction and combination of parts as will be more fully understood from the following description, when read in conjunction with the accompanying drawings in which:
FIG. 1 represents a perspective view of an embodiment of the device in a transport mode.
FIG. 2 shows an exploded perspective view of the embodiment shown in FIG. 1 more clearly showing the component parts.
FIG. 3 illustrates an example of an embodiment of the device as it would be assembled in a stationary mode ready for use.
FIG. 4 is a representation of an exploded perspective view of an embodiment of the device demonstrating in more detail the component elements.
FIG. 5 is a perspective view of a version of a chair configured in its stationary mode ready for use.
FIG. 6 shows a perspective view of axle elements comprising a portion of a version of a wheel assembly.
FIG. 7 represents a perspective cross section of the axle elements shown in FIG. 6 .
FIG. 8 illustrates an elevation cross section of the axle elements shown in FIG. 6 .
FIG. 9 is a perspective view of elements of a yoke assembly.
FIG. 10 shows a perspective view of the topside of a table.
FIG. 11 is a perspective view of the underside of the table shown in FIG. 10 .
FIG. 12 is a perspective view of a version of a case assembly showing the upper compartment of the case assembly open.
FIG. 13 is a perspective view of the case assembly shown in FIG. 12 with the lower compartment of the case assembly open.
FIG. 14 shows a perspective view of a variation of the device in a transport mode.
FIG. 15 is a perspective view of a chair as shown in FIG. 14 in stationary mode.
FIGS. 16-19 illustrate the various adjustments of a chair as shown in FIG. 15 .
FIG. 20 is a perspective view of a version of the device in a transport mode.
FIG. 21 is a perspective view of a chair as shown in FIG. 20 in a stationary mode.
FIGS. 22-24 demonstrate a perspective view of the various stages of converting a chair as shown in FIG. 21 from a transport mode to a stationary mode.
FIG. 25 shows perspective view of a variation of the device in transport mode.
FIG. 26 is an exploded perspective view of various components of the device as shown in FIG. 25 .
FIG. 27 is a perspective view of a chair as shown in FIG. 25 in a stationary mode.
FIG. 28 is a plan view of a chair as shown in FIG. 25 in a stationary mode.
FIGS. 29-31 show an elevation cross section of the various adjustments of a chair as shown in FIG. 28 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, where a version the present invention is generally referred to with numeral 10 in FIG. 1 (sometimes referred to as the device), it can be observed that it basically includes a wheel assembly 100 , a yoke assembly 200 , a chair assembly 300 , a case assembly 400 and optionally an umbrella 216 .
Two wheel assemblies 100 are preferably present, one on each side of the yoke assembly 200 . A case assembly 400 is supported by the yoke assembly 200 and situated between said wheel assemblies 100 . Each wheel assembly 100 has affixed to it a chair assembly 300 .
The device 10 as shown in FIG. 1 is in transport mode. In transport mode generally each of the two chair assemblies 300 are affixed to one of each of the two wheel assemblies 100 . Each of the two wheel assemblies 100 are rotatably attached to the yoke assembly 200 . The case assembly 400 rests in place by gravity over the yoke assembly 200 . An umbrella 216 rests atop the case assembly 400 and the yoke assembly 200 . When the device is in transport mode it can be easily moved or stored.
Now referring to FIG. 2 where an exploded perspective view of the version of the invention demonstrated in FIG. 1 is shown to comprise, inter alia, the wheel assembly 100 , the yoke assembly 200 , the chair assembly 300 and the case assembly 400 .
Each of said wheel assemblies 100 is further comprised of, inter alia, a wheel 102 , an axle 104 , a disk 106 , a bore 108 , a rib 110 , a cup holder 112 , a fastener 114 , a seat 116 , a flange 118 and a seat 136 .
Said yoke assembly 200 is further comprised of, inter alia, a yoke 202 , a receiver 204 , a receiver 206 , a shaft 208 , a rest 210 , a handle 212 and a fork 214 .
Each of said chair assemblies 300 is further comprised of, inter alia, a back 302 , a hinge 304 , a hinge 306 and a support 308 .
Said case assembly 400 is further comprised of, inter alia, a strap 402 , a panel 404 , a frame 406 , a case 408 , a seam 410 , a seam 412 , a saddle 414 and a panel 416 .
Still referring to FIG. 2 where the invention is shown in an exploded view it can be understood that one each of said wheels 102 are positioned on each side of said yoke 202 . Between each of said wheels 102 and said yoke 202 is a disk 106 . Said disk 106 optionally has a multiplicity of cup holders 112 around the periphery of the disk 106 that are dimensioned to accept standard sized drinking cups. Said disk 106 optionally has a rib 110 integrally formed or affixed to the underside of the disk 106 to lend structural rigidity to the disk 106 .
When the device 10 is in a transport mode the disk 106 is nested onto the bottom side of the wheel assembly 100 . The chair assembly 300 is nested onto the top side of the wheel assembly 100 . The bore 108 through the disk 106 is rotatably and removably affixed to the axle 104 on seat 136 . A fastener 114 attaches each wheel assembly 100 , chair assembly 300 and disk 106 to the axle 104 . The yoke assembly 200 at each of the forks 214 is held by gravity onto the axle 104 between flange 118 and seat 136 . A handle 212 is connected to the yoke 202 via a shaft 208 that connects to the yoke 202 at receiver 206 . A rest 210 is positioned along the shaft 208 and holds one end of an umbrella 216 (not shown in FIG. 2 ) while the strap 402 fastens the opposite end. The saddle 414 of the case assembly 400 straddles the axle 104 between each arm of the yoke 202 and is held in place by gravity.
Now referring to FIG. 3 where a variation of the device 10 is shown in a stationary mode. The variation in FIG. 3 is principally different from that shown in FIG. 1 in regard to the Chair assembly 301 . Chair assembly 301 is shown in include, inter alia, a frame 310 , a support 312 , a hinge 314 , a hinge 316 , a seat 318 , a back 320 and a wheel 162 .
The device 10 is generally in its stationary mode when the wheel assemblies 100 are disengaged from the axle 104 , the axle 104 is oriented vertical to act as a pedestal for the disk 106 . For stability of the disk 106 in stationary mode the opposing disk 106 corresponding to the opposite wheel assembly 100 can be used as a base member in contact with the ground. The fastener 114 may be stored for later use when converting the device 10 into transport mode by placing the fastener 114 in the middle of the upper disk 106 .
Further characterizing stationary mode, chair assemblies 301 are erected to form a chair by laying the wheel 162 onto the ground with the seat 318 side up then raising the frame 310 about hinge 316 . The support 312 then rotates away from the frame 310 about hinge 314 . The end of the support 312 opposite hinge 314 is place in ground contact to provide a stable place for a person to sit. The back 320 spans between the frame 310 to provide a comfortable back rest.
Yet describing the stationary mode of the device as depicted in FIG. 3 the case assembly 400 is removed from over the axle 104 . In an embodiment of the device 10 the case assembly 400 may be an insulated cooler to keep cool beverages cool or hot food hot. Preferably the case assembly 400 is openable and sealable at seam 410 . Seam 410 may be zipper, hook and loop fastener or any other type of fastener commonly available and known in the art.
Still referring to FIG. 3 the yoke assembly 200 is separated from the wheel assembly 100 , chair assembly 300 and case assembly 400 and placed flat onto the ground. The umbrella 216 may then be erected and set into receiver 204 to support the umbrella 216 . This is of particular benefit where the umbrella 216 cannot be driven into the ground, for example, in a paved lot while tailgating.
Now referring to FIG. 4 where an exploded view of a variation of the device 10 is shown with a chair assembly 100 similar to that demonstrated in FIG. 1 , an alternate yoke assembly 201 and an alternate handle 218 .
The chair assembly 300 in FIG. 4 is further shown to include a hinge 305 , a hinge 307 a hinge pin 322 , pins 324 , hinge pins 326 and a port 328 . For ease of manufacture wheel 102 may be manufactured in two mirror image halves. When assembling the two halves of the wheel 102 , hinge pin 326 is inserted through hinge 306 and into hinges 307 on the wheel 102 before the halves of the wheel 102 are permanently secured to each other. Hinge pin 326 permits the radial movement of the back 302 relative to the seat 116 . Hinge 305 on the support 308 corresponds with hinge 304 on the back 302 by means of hingepin 322 secured into hinge 305 with pins 324 to permit radial articulation of the support 308 relative to the back 302 .
Still referring to FIG. 4 said alternate yoke assembly 201 receives the axle 104 into forks 220 . Handle 218 is dimensioned to be used by a human hand to pull the device 10 while in transport mode. A spindle 128 and a spindle 130 join together inside the axle 104 . Said wheel assemblies 100 are removably affixed to the respective spindle 128 and spindle 130 by means of fasteners 114 . Spindle 128 and spindle 130 both freely rotate inside of axle 104 thereby permitting said wheel assemblies 100 to rotate to facilitate moving the device 10 when in transport mode.
Now referring to FIG. 5 where element of the wheel assembly 100 and chair assembly 300 are shown in stationary mode forming a chair suitable for a human to sit. The elements of the chair variation shown in FIG. 5 is materially similar to the chair assembly 300 and wheel assembly shown in FIG. 4 . The support 308 is hingedly affixed to back 302 . Back 302 is hingedly affixed to seat 116 . Seat 116 is preferably formed integral to wheel 102 . When the chair shown in FIG. 5 is in use in stationary mode as a chair a person can comfortably sit on seat 116 and lean back onto back 302 . Back 302 may be adjusted to varying degrees of reclination by moving support 308 nearer to or farther from the edge of the wheel 102 . A port 328 is positioned near the center of the back 302 that overlays a hub 132 to permit a fastener 114 to attach the wheel assembly 100 and chair assembly 300 to the spindle 128 (as shown in FIG. 4 ).
FIGS. 6-8 show the same variation of an axle assembly 166 in more detail that includes, inter alia, a fastener 114 , a flange 118 , a cord 120 , a thread 122 , a fastener 124 , a seam 126 , a spindle 128 , a spindle 130 , a cavity 134 , seats 136 and an axle 164 . FIG. 7 is a cross section of the view shown in FIG. 6 at section line 7 . The axle assembly 166 shown in FIGS. 6 and 7 is configured as it would be used in transport mode as contrasted to stationary mode.
Cord 120 spans through the cavity 134 inside of spindle 128 and spindle 130 and terminates on each end with a fastener 114 . The cord 120 is ideally made of an elastic cord but could also be effective if made from an inelastic material such as rope or cable. The function of the cord 120 is to prevent the loss of the fasteners 114 when transitioning the device between stationary mode and transport mode.
Yet referring to FIGS. 6-8 , seat 136 is dimensioned to mate with a hub 132 (as shown in FIG. 5 ) of a wheel assembly 100 to attach the wheel assembly 100 to the axle assembly 166 for transport mode. A wheel assembly 100 is then secured one each to the spindle 128 and spindle 130 by fastener 114 screwed into threads 122 . Spindle 128 and spindle 130 are fixed to each other at fastener 124 . Wheel assembly 100 may be attached to seat 136 . Spindle 128 and spindle 130 may then freely rotate inside of axle 164 to permit the rotation of each wheel assembly 100 when in transport mode. Flange 118 aids in positioning the axle assembly 166 onto the fork 214 of a yoke assembly 200 such as demonstrated in FIG. 2 .
Optionally, the axle 164 may be manufactured in two pieces. The axle 164 would then have a seam 126 . If present, seam 126 preferably would be permanent.
Referring now to FIG. 9 where a yoke assembly 200 is shown isolated from the other elements of the device 10 to reveal more detail and is shown to include, inter alia, a yoke 202 , a receiver 204 , a receiver 206 , a shaft 208 , a rest 210 , a handle 212 and forks 214 .
Said yoke 202 is generally semi-circular in shape and has on each end a fork 214 dimensioned to accept an axle such as axle assembly 166 as shown in FIG. 6 . Equidistant from said forks 214 is receiver 204 dimensioned to accept an umbrella such as umbrella 216 shown in FIG. 1 when the device 10 is in stationary mode. Adjacent to receiver 204 is receiver 206 dimensioned to accept shaft 208 which in turn terminates with a handle 212 . Near the handle 212 end of the shaft 208 is the rest 210 that holds the umbrella 216 while the device 10 is in transport mode.
FIGS. 10 and 11 demonstrate in more detail the disk 106 and its components that include, inter alia, a bore 108 , a rib 110 and several cup holders 112 . The disk 106 in FIGS. 10 and 11 is similar to the disk 106 shown in FIGS. 2 and 3 . Disk 106 is fit inside the wheel assembly 100 and axle seat 136 fits into bore 108 when in transport mode as shown in FIG. 2 . Preferably when in transport mode the edge of the disk 106 is not in ground contact to avoid unnecessary wear on the disk 106 . When in stationary mode, as depicted in FIG. 3 , the disk 106 is removed from the wheel 102 and erected to form a table with the corresponding disk 106 of the pair acting as a base when in ground contact. One or more cup holders 112 are optionally positioned around the periphery of the disk 106 that are dimensioned to facilitate the insertion and support of a common beverage container. Optionally, a rib 110 is present on one side of the wheel 106 to stiffen and strengthen the disk 106 .
FIGS. 12 and 13 show in more detail the case assembly 400 separated from the other various elements of the invention. Said case assembly 400 is shown to include, inter alia, a strap 402 , a panel 404 , a frame 406 , a case 408 , a seam 410 , a seam 412 , a saddle 414 , a panel 416 , a panel 417 , a handle 418 and a hinge 420 . The case assembly 400 shown in FIGS. 12 and 13 is similar to the case assembly 400 shown in FIG. 2 .
The case assembly 400 is generally forms two hollow interior volumes, a first volume bounded by case 408 and a second volume bounded by panel 416 and panel 417 . Said first volume accessible by unsealing seam 410 and raising panel 417 by pivoting about hinge 420 . Said seam 410 may include a closure means such as a zipper, straps, hook and loop fasteners, snaps, buttons or other commonly available means to reversibly seal the seam 410 . Said second volume is generally bounded by panel 417 and panel 416 . The interior of said second volume is opened and closed at seam 412 . Said seam 412 may include a closure means such as a zipper, straps, hook and loop fasteners, snaps, buttons or other commonly available means to reversibly seal the seam 412 . In one contemplated use of the case assembly 400 said first volume may be insulated and used as a cooler for food and beverages while said second volume may be used to store items preferably kept dry such as a phone, keys, camera and clothes. It would be obvious to one knowledgeable in the art that anything that would fit inside either of said first or second volumes may be placed inside for storage or transport.
Said saddle 414 bisects the case and provides a means to support the case assembly 400 over the axle 104 (shown in FIG. 2 ) while the device is in transport mode. When in transport mode the case assembly 400 need not be secured with any fastening device to the axle 104 because gravity holds the case assembly 400 securely in place over the axle.
Yet referring to FIGS. 12 and 13 it is shown that a frame 406 may optionally be present to form a cage around the exterior of the case 408 to lend strength and rigidity to the case 408 . The frame 406 is increasingly preferred when the case 408 is less rigid, for example when the case 408 is constructed of an insulated soft-sided fabric system.
In the embodiment of the case assembly 400 demonstrated in FIGS. 12 and 13 a strap 402 is present to aid in securing an umbrella to the panel 416 while in transport mode. Handles 418 are present on opposite sides of the case 408 to aid in moving the case assembly 400 when unmounted from the yoke assembly 200 (shown in FIG. 2 ).
FIG. 14 shows a variation of the invention particularly emphasizing a variation of a chair assembly 303 and shown in transport mode. This variation of the chair assembly 303 is shown to include, inter alia, a hinge 138 , a seat 140 , a back 142 , a frame 144 , a frame 146 , a bar 148 , notches 150 , a clip 152 , a clip 154 , a wheel 156 , a hinge 158 , a hinge 159 and a bar 160 . The case assembly 400 and yoke assembly 200 are similar to those shown in FIG. 2 .
FIGS. 15 through 19 show the same chair assembly 303 in stationary mode as depicted in FIG. 14 . When transforming from transport mode to stationary mode the wheel 156 and chair assembly 303 are removed from the yoke assembly 200 and case assembly 400 (shown in FIG. 14 ). The wheel 156 is placed onto the ground or other suitable surface with the seat 140 facing up. Clip 154 is snapped out of clip 152 and the frame 144 is raised about hinge 138 . Frame 146 is rotated away from frame 144 about hinge 159 and the edge of the frame 146 opposite that of hinge 159 is brought into ground contact to support the frame 144 .
To secure the angle between the frame 144 and frame 146 the bar 148 is extended straight by means of hinge 158 . As shown in more detail in FIGS. 16 through 19 the angle of the frame 144 relative to the seat 140 can be securely adjusted by fitting any of the several notches 150 over the bar 160 (shown in FIG. 15 ). A user of the chair assembly 303 may desire to adjust the angle of the frame 144 relative to the seat 140 to increase comfort by reclining to a lesser or greater degree.
Back 142 is disposed between the edges of frame 144 to provide a soft and resilient surface upon which a user of the chair assembly 303 may rest their back. Back 142 may be constructed of a fabric, plastic, natural fiber or other material suitable for a user to rest against while sitting in the chair assembly 303 while in stationary mode.
FIG. 20 shows another variation of the invention particularly demonstrating a variation of a chair assembly 301 that is shown to include, inter alia, a wheel 162 , a frame 310 , a support 312 , a hinge 314 , a seat 318 , a back 320 and a clip 330 . The yoke assembly 200 and case assembly 400 remain similar to those shown in FIG. 2 . FIG. 20 shows the chair assembly 301 in transport mode, ready to travel to the beach.
A user of the chair assembly 301 in stationary mode places the wheel 162 in ground contact with the seat 318 side up. The user is able to sit on seat 318 cleanly off the ground and recline her body onto back 320 . Back 320 is preferably a durable material such as fabric, plastic, natural fiber or other material suitable for a user to rest against while sitting in the chair assembly 301 . The back 320 is supported on its edges by frame 310 .
FIG. 21 represents the chair assembly 301 removed from the other components of the invention shown in FIG. 20 and erected into the stationary mode of the chair assembly 301 . FIGS. 22 through 24 illustrate the sequence of steps of transforming the chair assembly 301 from transport mode as best shown in FIG. 22 into stationary mode as depicted in FIGS. 21 and 24 .
Generally to transform the chair assembly 301 into it stationary mode the wheel 162 is placed on a surface (i.e. ground, sand, pavement, bleacher, etc. . . . ) and frame 310 is raised from against the wheel 162 about hinge 316 to form a seat back as shown in FIG. 23 . The support 312 is then rotated away from frame 310 about hinge 314 . The end of frame 312 opposite that of hinge 314 is placed in ground contact to act as a brace to maintain the angle between the frame 310 and the seat 318 .
Optionally, the length of support 312 may be adjustable to better support the frame 310 at the desired angle relative to the seat. The adjustability can be achieved by forming the support 312 from concentric tubes. An outer tube having a series of holes may be provided to accept a snap clip inside of an inner tube. The snap clip may then be selectively engaged into any of the holes on said outer tube to achieve the appropriate length of the frame. Said tubes that comprise the frame 312 may effectively have round, square, oval or other suitable cross section profile. Said frame 312 and frame 310 is optimally constructed of aluminum, plastic or any other light weight and rigid material known in the art.
FIGS. 25 and 26 show a variation of the present invention in transport mode and particularly emphasizes alternate chair assembly 309 and alternate case assembly 401 while the yoke assembly 200 remains similar to the yoke assembly 200 shown in FIG. 2 . Said alternate chair assembly 309 is shown to include, inter alia, a wheel 222 , a back 224 , a clip 226 , a frame 228 , a seat 230 , a disk 232 , a bore 234 , cup holders 235 and a fastener 236 . Said alternate case assembly 401 is shown to include, inter alia, a bore 422 . Other elements of FIGS. 25 and 26 include a fork 214 , an umbrella 216 , threads 122 and an axle 164 .
Said case assembly 401 utilizes the axle 164 penetrated through bore 422 to support the case assembly 401 . Said axle 164 is set into said fork 214 of the yoke assembly 200 so that the case assembly 401 is suspended above the ground when transporting the invention on its wheels 222 . In other regards the case assembly 401 is similar to the case assembly 400 shown in FIGS. 12 and 13 .
Yet referring to FIG. 26 the disk 232 has a multiplicity of cop holders 235 arranged in a predetermined pattern around the periphery of the table and are dimensioned to accept commonly sized beverage containers. The disk 232 and axle 164 may be erected into a table when converted into stationary mode similar to the disk 106 and axle 104 as shown in FIG. 3 and described above.
When assembled into transport mode the axle 164 passes through the bore 422 in the case assembly 401 . The axle 164 then rests one end on each of the forks of the yoke assembly 200 . One each of said disks 232 is nested against the edge of each wheel 222 opposite the seat 230 . For each of said wheel assemblies 309 of the pair, said bore 234 and a bore 336 (shown best in FIG. 27 ) on the center of the wheel 222 are fitted onto the end of each respective end of the axle 164 and removably secured to the axle 164 by said fastener 236 engaging said threads 122 . One each of said chair assemblies 309 is removably attached to each of said wheels 222 on the seat 230 side of said wheels 222 by means of a clip 226 . Preferably a multiplicity of clips 226 are used to secure the chair assembly 309 to the wheel 222 while use in transport mode.
Referring to FIGS. 27 through 31 where a more detailed view of the chair assembly 309 and it's several adjustments are demonstrated and shown to include, inter alia, a wheel 222 , a back 224 , a frame 228 , a seat 230 , peg 332 , notch 334 , bore 336 , a cap 424 and a channel 426 .
FIG. 27 illustrates the chair assembly 309 in stationary mode, ready to be used as a chair. The wheel 222 is placed onto a surface such as the ground, a bleacher, sand or other appropriate surface with the seat 230 side up. The frame 228 is erected from its position against the seat 230 as it is used in transport mode (see FIG. 25 ). Pegs 332 formed integral to the frame are set into any of the predetermined notches 334 to secure the angle of the frame 228 relative to the seat 230 . A back 224 spans between edges of the frame 228 to provide a stable support for a person using the chair assembly 309 a comfortable surface to recline upon.
FIGS. 28 through 31 demonstrate in more detail the varying degrees of reclination that frame 228 may be adjusted to relative to the seat 230 . FIG. 28 includes the cross section reference line 29 that corresponds to the cross section view in FIG. 29 . FIGS. 30 and 31 are cross sectioned at the same plane on the wheel 222 as FIG. 29 .
Generally, the frame 228 is held in place gravity. The pegs 332 on each side of the frame 228 engage into one of the several notches 334 on each side of the seat 230 . Caps 424 on each end of the frame 228 seat on each side into the channel 426 . When the pegs 332 are set into the pair of notches 334 nearer the center of the seat 230 the frame 228 and therefore back 224 are oriented more towards the vertical relative to the plane of the seat 230 . As pegs 332 are engaged into notches 334 further from the center of the seat 230 the back 224 reclines further. It can be appreciated that a user of the chair may find it more comfortable to sit in the chair assembly 309 with the back 224 at varying degrees of recline.
It would be understood that any of the wheels 102 (or other variations of wheels) may be rotatably attached to an axle 104 (or other variations of an axle) by means of ball bearings, roller bearings or other type of means commonly available in the art to permit the wheels 102 to readily rotate and remain durable. Any of the wheels 102 (or other variations of wheels) may have a durable cover around the circumference of the wheel 102 such as rubber or other gripping and durable material to grip onto a surface while the device is used in transport mode.
An embodiment of the present invention includes, inter alia, a mobile multi-function convertible transport device comprising a yoke assembly having a yoke on a first end and a and a handle on a second end, two wheel assemblies each having a wheel with a first side and a second side, each of said wheels having a disk coaxially and removably attached to said first side of each of said wheels, said wheels each having an erectable seat back on each of said second side of said wheels, a case assembly having a case openable to provide access to a hollow interior volume, an axle removably connectable to said yoke, where said multi-function convertible transport device is convertible into a transport mode by attaching said case assembly onto the middle of said axle, attaching said axle to said yoke and attaching each of said wheel assemblies to opposite ends of said axle where both wheel assemblies are rotatable, and where said multifunction convertible transport device may be converted to a stationary mode by placing said first side of each of said wheels onto the ground and erecting said seat back on each of said wheels, erecting a table with one of said disks acting as a table base, the other of said disks acting as a table top and said axle acting as a pedestal disposed between said disks.
The mobile multi-function convertible transport device may be further characterized in that said case is insulated. The mobile multi-function convertible transport device may be further characterized in that said yoke includes a means to fasten an umbrella in said transport mode and a means to erect said umbrella in stationary mode.
Alternatively, the mobile transport device may have an axle disposed between a pair of wheels, each of said wheels having a disk coaxially and removably affixed, said axle supporting a case that is openable to access an interior volume, a yoke having a first end with a handle and a second end comprising a fork attached to each end of said axle, said wheels both being removable from said axle and each convertible to transform into a chair with a back, and said disks and said axle being combinable to form an erected table with said axle disposed between the centers of said disks and acting as a vertical pedestal and where one of said disks is a base and the other said disk is a tabletop.
The mobile multi-function convertible transport device may be further characterized in that said case is insulated. The mobile multi-function convertible transport device may be further characterized in that said yoke includes a means to fasten an umbrella in said transport mode and a means to erect said umbrella in stationary mode.
Alternatively, the mobile convertible beach gear device may comprise an axle, a yoke, a pair of wheels, a pair of disks, a pair of chair assemblies and a case that when in a transport mode: each of said wheels has one of said disks coaxially and removably attached on a first side and a chair assembly hingedly attached to a second side, one of said wheels is removably attached to each end of said axle, each of said wheels being rotatable about said axle, said yoke having a first end with a handle and also having a second end comprising a fork, said fork removably attached to each end of said axle, said case supported by said axle and having an accessible interior volume, and that when in a stationary mode: said first side of each of said wheels in contact with a horizontal surface, each of said chair assemblies being hingedly erected to form the back of a chair and said second side of said wheel forming a seat, and said disks and said axle being combinable to form an erected table with said axle disposed between the centers of said disks and acting as a vertical pedestal and where one of said disks is a base and the other said disk is a tabletop.
The mobile multi-function convertible transport device may be further characterized in that said case is insulated. The mobile multi-function convertible transport device as described in claim 7 further characterized in that said yoke includes a means to fasten an umbrella in said transport mode and a means to erect said umbrella in stationary mode.
Alternatively, the mobile multi-function convertible transport may device comprise a yoke assembly having a yoke on a first end and a and a handle on a second end, two wheel assemblies each having a wheel with a first side and a second side, each of said wheels having a disk coaxially and removably attached to said first side of each of said wheels, said wheels each having an erectable seat back on each of said second side of said wheels, a case assembly having a case openable to provide access to a hollow interior volume, and an axle removably connectable to said yoke.
The foregoing description conveys the best understanding of the objectives and advantages of the present invention. Different embodiments may be made of the inventive concept of this invention. It is to be understood that all matter disclosed herein is to be interpreted merely as illustrative, and not in a limiting sense. | The present invention is a multi-purpose outdoor piece of equipment that combines various features in one design and takes advantage of gravity. In an embodiment it comprises a combination of a cooler or storage bag, two chairs, a table and a rack for an umbrella. The cooler or storage bag stays in a stable orientation due to gravity. The device is quickly assembled into a transport mode and then reassembled into its stationary mode for recreational use. The pull handle can be unscrewed and receive a beach spade to play in the sand. Once assembled into transport mode the device fits comfortably in the trunk of a car and can easily be assembled with the cooler bag slung into position over the axle. The cooler may be used for wet goods like drinks, food, wet wipes and spray bottle and an the upper bag for dry storage like outdoor gear and accessories like keys, sunglasses or other protected items. The cooler bag can also be strapped on as a backpack or a sling bag over your shoulder. The gravity roller van can be attached to the back of your bicycle for more long distance transport. | 0 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application 61/774,388 filed on Mar. 7, 2013, the contents herein incorporated by reference.
BACKGROUND
Large aquatic electrical barriers are installed for various purposes related to aquatic species management, especially in the field of non-native species management. The goal is to protect the habitats or microhabitats from the effects of non-native species.
Aquatic electrical barriers are deployed in two general scenarios: the first is for the prevention of fish passage from one location to another, and the second is for inducing fish to move from one locality to another. In the first scenario, an electrical field is used to prevent fish from moving between two locations: from a river or stream to a lake, from a river or stream to an irrigation canal, from a river to a hydroelectric facility intake, or from migrating upstream that would avoid entry into a fish hatchery. In the second scenario, an electrical field is used to guide fish: to induce fish movement out of a navigation lock to insure that it is devoid of fish before the entry of a boat into that lock. In both scenarios, the electrical field is used as a mechanism the movement of invasive and/or native species.
Aquatic electrical barriers pass an electrical current through a body of water which, in turn, causes a physiological reaction by the aquatic species. A terrestrial analog to aquatic barriers is the “electric fence”. Both aquatic barriers and electric fences use electric current to cause a deterrent effect. But since aquatic species are immersed in a conductive liquid, (e.g. water), the gradient electric field is continuous as opposed to the contact imposed field of the electric fence. This gradient field is caused by placing a conductive anode and cathode in the water and by passing a current between the conductors.
The physiological reactions of an aquatic species that is affected by an aquatic barrier are typically categorized as repulsion, narcosis (“stunning”), and euthanasia (“death”).
The aforementioned physiological responses generally correlate to the is amount of electrical power that is transferred from the water to the aquatic species. The electrical power transfer occurs as a result of the body of the fish acting as a “voltage divider” in the water. The total amount of energy that is transferred from the water to the aquatic species is calculated by measuring the potential difference across the fish, multiplied by the duty cycle of the pulse, and which is then multiplied by the electrical current that passes through the fish.
Large waterways typically have a barrier system that consists of several electrical barriers that are separated by distances ranging from approximately 200 to 1500 feet. The DC pulse generators that are installed at these barriers are powered by high voltage supplies (“pulsators”) that are connected to the commercial electrical grids. A representative example of such a barrier system is located in the Chicago Sanitary and Ship Canal, where the width of the canal is 160 ft, the depth of the canal is approximately 25 ft, and the conductivity of the water general does not usually exceed 3500 micro Siemens. In this barrier system, a single pulsator has high power output which can reach 1,500 kW.
In large electric fish barrier systems, the use of multiple pulsators are configured to create a series of physically separate electric fields that improve's the deterrence of fish. The barrier system's use of multiple pulsators is also necessary in the event of the failure of one pulsator. Therefore, operating multiple pulsators, that are located physically in series on a waterway, can more effectively prevent is the upstream and/or downstream migration of fish by reducing or screening the number of fish as the water flows through each successive barrier.
Pulsators in a fish barrier system can operate individually (un-synchronized) but are almost always connected to a common electrical grid. While each pulsator in the barrier may be outputting pulses at a fixed frequency, the individual pulses from one pulsator occur are unsynchronized with respect to the pulses from other pulsators in the installation. It is also not uncommon for the individual pulses to slowly drift in time with respect to each other. This results in repetitive periods of time where the pulses occur at unique points in time and later can be seen to be partially or fully temporally overlapped with each other. Overlapping pulses of individual pulsators in an electrical barrier system is undesirable.
There are at least three situations where the unsynchronized operation of multiple pulsators is undesirable:
1) Where there is a navigation lock in the waterway, there is a need to synchronize the energized pairs of bottom mounted electrodes. The objective is to simultaneously expose the fish to physically undesirable (electrified) zones and more desirable (non-electrified) zones that provide the fish with an avenue of escape. In this configuration, it is essential that the individual pulsators connected to the electrodes are synchronized. 2) When high-power pulsators are utilized, there is the possibility that the pulsators cause electrical disturbances that are fed back into the AC power line. AC “line notching” is an example of such a disturbance and is characterized by a sudden, short duration, drop in voltage during a portion of the AC line sine wave. The magnitude of the line notching increases when the output from two (or more) pulsators occur at the same point in time. If the output of the pulsators can be synchronized so that their output pulses occur at unique time “slots” or “windows” then the peak amplitude of line notching can be minimized. 3) The electrodes of electric fish barrier typically do not rest on a perfectly electrically insulating substrate. A small percentage of pulsator current will flow through the substrate and into the rock/earth locally surrounding the in-water electrodes. When the pulses of geographically separate pulsators temporally overlap, a stray electrical current may be induced between the substrates that increases the probability of an interference with adjacent electronic signaling systems.
As noted, during operation, these large pulsators can create localized potential disturbances consisting of, but not limited to: ground loops, line notching, harmonic distortion, and an excessive power factor (collectively “local electrical disturbances”). These local electrical disturbances can also introduce signal noise into local conductors. These local conductors include, but are not limited to local railroad signaling lines which are used for controlling railroad devices, such as cross arms. Signal noise, on these railroad signal lines, can cause local transmission errors which results in operational malfunctions. Although these operational malfunctions (typically cross arms being deployed when a train is not in the proximity) are an inconvenience and are costly for those individuals affected by the malfunction and for the companies must service these types of malfunctions.
The conventional solution to pulsator de-synchronization is to use interconnecting synchronization wires. Wires are susceptible to damage and are expensive to install. It is not uncommon for buried cables to be disturbed and/or broken by earth moving activities such as road building, trenching, general construction, etc.
Although there is prior art that describes the use of GPS to synchronize electrical equipment, for example, U.S. Pat. No. 8,044,855 to Hanabusa on Oct. 25, 2011. But the '855 patent does not describe apparatus and methods for wireless electrical barrier system pulsator desychronization. U.S. Pat. No. 7,333,725 issued to Frazier on Feb. 19, 2008 describes a system for the synchronization of sensors, but this printed publication fails to describe or illustrate how synchronize multiple barriers would operate within an electric barrier system.
Although electrical currents affect all aquatic species, the term “fish” is used in this application to be synonymous with aquatic species and is not to limit the scope of this term.
Therefore, what is needed is a solution that provides for an improved aquatic barrier system that provides for electrical pulse desynchronization between individual pulsators.
BRIEF SUMMARY OF THE INVENTION
The inventive subject matter is directed towards an apparatus for the desynchronization of electrified barrier pulsators so that one or more electrified barrier is capable of receiving a synchronization signal and creating an electrical field that will deter and/or guide aquatic species.
Also described is a system that uses a timing reference point generator by Global Positioning System that is accessed by pulsator synchronizers that are capable of generating a synchronized electrical field to control aquatic species.
Further described is the process for the exclusion of invasive aquatic species involving desynchronized aquatic barriers where a series of geographically separated electrical aquatic barriers create periodic pulses and these periodic pulses activate aquatic barriers by a commonly referenced signal so that there is minimum or no overlap in the electrification of the aquatic barriers.
BRIEF DESCRIPTION OF THE DRAWINGS
These and/or other aspects and advantages of the disclosure will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 depicts the prior art architecture of the aquatic species system barrier.
FIG. 2 shows an unsynchronized pulse diagram for the signals generated by three barriers with overlap
FIG. 3 depicts the architecture of the improved aquatic species system barrier.
FIG. 4 shows the modified pulse diagram for signals synchronized aquatic species system barrier.
FIG. 5 depicts a flowchart of the process of synchronizing the output multiple pulsators.
FIG. 6 depicts a timing diagram showing one embodiment of the multiple pulsators.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Embodiments are described below to explain the disclosure by referring to the figures.
Now referring to FIG. 1 which depicts the prior art of an electrical fish barrier system 100 . The electrical fish barrier system has at least two pulsators 110 A, 110 B, 110 C that are physically separated. Connected to the pulsators 110 A, 110 B, 110 C are the electrodes (anode/cathode pairs) 130 A, 130 B, 130 C on one side and the pulsator controllers 120 A, 120 B, 120 C on the other. Energy from common electrical grid 140 passes through the pulsators 110 A, 110 B, 110 C to which is converted and energizes the electrodes (anode/cathode pairs) 130 A, 130 B, 130 C, that are immersed in a body of water 10 . The magnitude and duration of each electrical pulse is determined by the pulsator controllers 120 A, 120 B, 120 C. Typically this pulse has a frequency of 10 times per second (10 Hz) with a pulse width of 0.005 seconds (5 mS).
Now referring to FIG. 2 which illustrates a timing diagram of the unsynchronized pulsators on an electrical barrier system. In certain circumstances, signal drift occurs when the pulse 210 A from the first pulsator 110 A overlaps 220 with the pulse 210 B from second pulsator 110 B. When these pulses overlap, a local electrical imbalance may be created that will induce line notching or noise in conductors that are in the vicinity.
Now referring to FIG. 3 which illustrates the electrical fish barrier system diagram with the synchronized barriers. Each pulsator 110 A, 110 B, 110 C is connected to a dedicated antenna 320 A, 320 B, 320 C with a receiver controller that references the Global Positioning System (GPS).
Those skilled in the arts will understand that various options exist for the reception and generation of the timing signals. One option is to utilize signals from GPS (Global Positioning System) satellites. GPS is a constellation of earth-orbiting satellites whose purpose is to provide navigation and timing reference signals, and is managed by the US government. Another option is to use signals from GLONASS (Globalnaya Navigatsionnaya Sputnikovaya Sistema) satellites that are managed by Russia. Another option is to use signals from the EGNOS (European Geostationary Navigation Overlay Service) or Galileo satellite navigation system managed by the European Union. Yet another option is to utilize signals from the Chinese BeiDou satellite navigation system.
Further, suitable commercially available Global Navigation Satellite System (GNSS) receivers exist that simultaneously receive signals from two or more GNSS systems. An example is the Trimble BD910 which is capable of simultaneously receiving signals from GPS, Galileo, Glonass, and BeiDou satellites.
Another option, depending on the geographic location of the pulsators, is to use the timing signal from a QZSS (Quasi-Zenith Satellite System). Those skilled in the arts will additionally know that the desired timing signals can also be derived from the timing signal from the output of a suitable receiver designed for reception of 60 KHz transmissions from terrestrial radio station WWVB, operated by the National Institutes of Standards and Technology (NIST) which is an agency of the U.S. Department of Commerce. An example of this type of receiver is the Model 8160A with option 15, manufactured by Spectracom Corporation. Another option is to derive the timing signal from a receiver designed to receive the radio transmission from other precision time and frequency stations such as 3.330 MHz and 7.85 MHz broadcasts from station CHU in Canada, 2.5 MHz, 5.0 MHz, 10 MHz, 15 MHz, and 20 MHz transmissions from WWV and WWVH in Fort Collins, Colo., 3.810 MHz transmissions from station HD2 IOA in Ecuador, 9.9996 MHz transmissions from RWM in Russia, and others. Another possibility is to use is a Low Frequency receiver, such as the UrsaNav UN-151B, that can provide precise time and frequency from LORAN-C (Long Range Aid to Navigation), Enhanced LORAN (eLORAN), Chayka (Russian terrestrial radio navigation system similar to American LORAN), or other suitable low/medium frequency sources.
In addition to the GNSS receiver, a second essential component of the receiver/controller is a Disciplined Oscillator (DO). A typical DO is a high quality quartz or rubidium oscillator whose frequency is disciplined or steered by locking to the output to a GPS signal via a tracking loop. Integrated GNSS receiver/DO modules are available from various manufacturers. If a GPS receiver and DO module is used it is referred to as a “GPSDO”. One example of a suitable GPSDO module is the Trimble Thunderbolt “E GPS” Disciplined Clock.
One advantage of utilizing a GPSDO is its fault tolerance. If the GPS signal is lost, then a “GPS Lock” signal is no longer asserted and the system can issue an alarm. When the “GPS Lock” signal is no longer asserted, the timing signal is derived from an internal high-accuracy oscillator that is typically either a temperature compensated crystal oscillator (TCXO), single or double oven controlled crystal oscillator (OCXO), Rubidium oscillator, Cesium oscillator, or Chip Scale Atomic Oscillator (CSAO). Although the internal oscillator is subject to a change in frequency with respect to time, this change or “frequency drift” is very slow, such that weeks will elapse before there is an occurrence of undesired is pulse overlap.
Now referring to FIG. 4 which depicts a timing diagram of the synchronized barriers. The first pulse 410 A from the first pulsator 120 A is synchronized to a trigger signal 430 A. The second pulse 420 A is synchronized to the trigger signal but with a delay such that there is no overlap with the first pulse 420 A of second pulsator 120 B. The third pulse 410 C of third pulsator 120 C is also synchronized to the trigger signal. The prevention of signal overlap is caused by a trigger signal 430 A, 430 B, 430 C for each pulse which is synchronized by an external and common source. Those skilled in the arts can implement a delay circuit for each pulsator 120 of any length either by digital, analog, or in software. The pulsator trigger is calculated for each pulsator based on the trigger signal and the delay value.
If the GPS signal is lost, then a “GPS Lock” signal is no longer asserted and the system can issue an alarm. When the “GPS Lock” signal is no longer asserted, then a synchronized 1PPS signal is used. This synchronized 1PPS signal may be generated by an internal high-accuracy crystal oscillator, rubidium oscillator, or cesium oscillator. Typically, a high quality crystal oscillator is subject to frequency drift, which is very slow, where weeks will elapse before an occurrence of pulse overlap. In either case, the GPSDO or the alternate signal sources will be known as a reference signal. This reference signal will typically operate at 1PPS.
Now referring to FIG. 5 that illustrates a flowchart 500 that calculates the pulsator trigger 570 . First the system attempts to retrieve the GPS signal 520 . If the GPS signal cannot be retrieved then the alternate oscillator value is stored in Trigger Register 530 , otherwise the GPS signal is stored in the Trigger Register 540 as the reference signal. Next the Trigger delay and Trigger register are added to create a trigger value for the activation of a pulsator 560 . When this time is reached the pulsator is activated. In this design each pulsator can provide a different delay value of the output pulse.
Now referring FIG. 6 , which shows a particular implementation with 3 pulsators. Each pulse duration is approximately 5 mS in width and the time duration in between pulses is 33.3 mS. In this particular example of the three pulsators: the first pulsator initiates a 5 mS pulse 410 A, then there is a delay of 28.3 mS, the second pulsator initiates a 5 mS pulse 410 B, then there is a delay of 28.3 mS, lastly the third pulsator initiates a 5 mS pulse 410 C, there is a delay of 28.3 mS and the sequence repeats. Although FIG. 6 illustrates a particular embodiment, those skilled in the arts will understand that the pulse width of 5 mS may be adjusted depending on the configuration of the electrodes, the waterway, and the aquatic species. Likewise the delay between pulses may be adjusted. Further, the number of pulses per second is also adjustable based on the implementation.
Those skilled in the arts will understand that although the preferred embodiment is a GPS solution, the method of synchronization should not be so limited and one can use other methods of implementation with precise time reference points as alternate embodiments. | The apparatus and methods are described for an electrical fish barrier system that has more than one geographically separate pulsator that are connected to a common electrical grid and are synchronized to prevent the overlapping of electrical pulses to prevent line notching or local line electrical line noise that may interfere with railroad transmission lines. | 0 |
FIELD
This invention relates to implantation of ions in silicon substrates and, more particularly, to a system and method for creating photoresist masks for solar cells.
BACKGROUND
Ion implantation is a standard technique for introducing conductivity-altering impurities into substrates. A desired impurity material is ionized in an ion source, the ions are accelerated to form an ion beam of prescribed energy, and the ion beam is directed at the surface of the substrate. The energetic ions in the beam penetrate into the bulk of the substrate material and are embedded into the crystalline lattice of the substrate material to form a region of desired conductivity.
Solar cells provide pollution-free, equal-access energy using a free natural resource. Due to environmental concerns and rising energy costs, solar cells, which may be composed of silicon substrates, are becoming more globally important. Any reduced cost to the manufacture or production of high-performance solar cells or any efficiency improvement to high-performance solar cells would have a positive impact on the implementation of solar cells worldwide. This will enable the wider availability of this clean energy technology.
Doping may improve efficiency of solar cells. FIG. 1 is a cross-sectional view of a selective emitter solar cell 210 . It may increase efficiency (e.g. the percentage of power converted and collected when a solar cell is connected to an electrical circuit) of a solar cell 210 to dope the emitter 200 and provide additional dopant to the regions 201 under the contacts 202 . More heavily doping the regions 201 improves conductivity and having less doping between the contacts 202 improves charge collection. The contacts 202 may only be spaced approximately 2-3 mm apart. The regions 201 may only be approximately 100-300 μm across. FIG. 2 is a cross-sectional view of an interdigitated back contact (IBC) solar cell 220 . In the IBC solar cell, the junction is on the back of the solar cell 220 . The doping pattern is alternating p-type and n-type dopant regions in this particular embodiment. The p+ emitter 203 and the n+ back surface field 204 may be doped. This doping may enable the junction in the IBC solar cell to function or have increased efficiency.
As shown in FIG. 3 , the doping pattern includes alternating p-type and n-type dopant regions in this particular embodiment. The p+ emitter 203 and the n+ back surface field 204 are appropriately doped. This doping may enable the junction in the IBC solar cell to function or have increased efficiency.
Some solar cells, such as IBC solar cells, require that different regions of the solar cell be p-type and others n-type. It may be difficult to align these various regions without overlap or error. For example, the p+ emitter 203 and n+ back surface field 204 in FIG. 3 must be doped. If overlap between the p-type regions 203 and the n-type regions 204 exists, counterdoping may occur. Any overlap or misalignment also may affect the function of the solar cell. For solar cells that require multiple implants, particularly those with small structure or implant region dimensions, the alignment requirements can limit the use of a shadow mask or proximity mask. In particular, as shown in FIG. 3 , an IBC solar cell requires alternating lines doped with, for example, B and P. Therefore, any shadow mask or proximity mask for the B implant has narrow, long apertures that are carefully aligned to the small features that were implanted with P using a different proximity mask or shadow mask.
In the past, solar cells have been doped using a dopant-containing glass or a paste that is heated to diffuse dopants into the solar cell. This does not allow precise doping of the various regions of the solar cell and, if voids, air bubbles, or contaminants are present, non-uniform doping may occur. Solar cells could benefit from ion implantation because ion implantation allows precise doping of the solar cell. Ion implantation of solar cells, however, may require a certain pattern of dopants or that only certain regions of the solar cell substrate are implanted with ions. Previously, implantation of only certain regions of a substrate has been accomplished using photoresist and ion implantation. Currently, the use of photoresist, however, would add an extra cost to solar cell production because extra process steps are involved. For example, a shadow or proximity mask must be created and used to illuminate a portion of the photoresist, such that a hardened mask is created on the surface of the solar cell.
Accordingly, there is a need in the art for an improved method of implanting a solar cell and, more particularly, a system and method of exposing the photoresist on the surface of the solar cell to light so as to create the appropriate mask.
SUMMARY
A system and method of exposing photoresist on the surface of the solar cell to light so as to create an appropriate mask is disclosed. A microcavity array is used to expose the photoresist to UV light in a pattern that matches the desired pattern on the solar cell. Microcavity arrays consist of an array of cavities, which may include tens of thousands of cavities. When an appropriate potential is applied to an electrode, a plasma is formed in the activated cavity. If the cavity contains a suitable gaseous environment, these activated cavities will emit light in the near ultraviolet spectrum. By properly configuring the locations of the activated cavities, a UV source may be created that exposes the photoresist in a desired pattern. The desired pattern can be created by selectively activating cavities, disabling certain cavities, or filling certain cavities so that they cannot create a plasma.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present disclosure, reference is made to the accompanying drawings, which are incorporated herein by reference and in which:
FIG. 1 is a cross-sectional view of a selective emitter solar cell;
FIG. 2 is a cross-sectional view of an interdigitated back contact solar cell;
FIG. 3 is a view of an interdigitated back contact solar cell;
FIG. 3 is a cross-sectional view of implantation through a mask;
FIG. 4 a cross-sectional view of one embodiment of a microcavity;
FIG. 5 shows a top view of a microcavity array;
FIG. 6 shows a top view of an addressable microcavity array;
FIG. 7 illustrates the use of a microcavity to expose photoresist to ultraviolet light; and
FIG. 8 illustrates the use of a glass surface as a lens to focus the ultraviolet light.
DETAILED DESCRIPTION
Embodiments of this system are described herein in connection with solar cells. However, the embodiments of this system can be used with, for example, semiconductor substrates or flat panels. Thus, the invention is not limited to the specific embodiments described below.
FIG. 4 is a cross-sectional view of one embodiment of a microcavity. In this embodiment, cavities 400 are created in a substrate 401 . A first electrode 410 and a second electrode 420 , having different potentials are formed around the cavity. These electrodes 410 , 420 are separated, such as by dielectric layer 430 . A protective layer 440 , such as a second dielectric layer, is located above the second electrode 420 . In operation, a gas is injected into the cavity 400 . When the electrodes 410 , 420 are activated, a potential difference appears across the height of the cavity 400 . This potential difference causes the injected gas to become plasma 403 . If a suitable gas is selected, this plasma will emit light in the ultraviolet spectrum. Such gasses include, for example, argon, xenon, xenon-neon, argon-deuterium and nitrogen.
FIG. 5 shows a top view of a microcavity array 407 . In this embodiment, the cavities 400 are arranged in rows and columns to form an array. In some embodiments, the microcavities 400 are formed through the use of photolithography. For example, photoresist is not deposited in those areas that will form the cavities 400 . An etching process is then performed which removes material in the exposed regions of the substrate, thereby creating the cavities 400 . Linear cavities have been built as small as 5 um in width, and point cavities with spacings of 100 um have been made. Therefore, a resolution of 100 um is readily achievable with current technology.
The first electrode 410 and second electrode 420 may be configured in a number of ways. In one embodiment, the first electrodes 410 for all cavities are connected together. Similarly, the second electrodes 420 for all cavities 400 are connected together. In this embodiment, either all of the microcavities 400 are activated or none of the microcavities 400 are activated. In another embodiment, shown in FIG. 6 , all first electrodes 410 in each column 411 are connected together. Similarly, all second electrodes 420 in each row 421 are connected together. In this way, the selection of a particular row 421 and column 411 activates exactly one microcavity. Of course, other configurations can be created whereby groups of microcavities may be addressable. For example, multiple rows 421 or columns 411 may be electrically connected such that clusters of cavities are activated simultaneously.
The use of microcavity arrays allows new methods of exposing photoresist to ultraviolet light, for purposes of creating a mask on the substrate.
In one embodiment, a microcavity array having individually addressable microcavities (or addressable groups of microcavities) is used. A photoresist is applied to the surface of the substrate. The microcavity array is then brought in close proximity to the surface of the substrate. In some embodiments, this distance is approximately 1 mm.
In some embodiments, the environment in which the microcavity array is placed is filled with a suitable gas, such as nitrogen. In other embodiments, shown in FIG. 7 , a surface 460 , such as a glass surface, is placed over the microcavity array 407 , so as to form a tight seal. The individual cavities 400 are filled with the desired gas, which is contained in the volume defined by the cavities 400 and by the surface 460 . Such a configuration may be advantageous if the gas used is rare or expensive. In this embodiment, the microcavity array may be constructed such that the surface 460 is sealed to the array 407 and gas is injected prior to the sealing of the surface 460 .
The desired microcavities 400 are then activated, which causes a plasma 403 to form in these desired cavities. This plasma emits ultraviolet light, which exposes the photoresist 480 located directly beneath the plasma. If a positive photoresist is used, the photoresist located beneath the activated cavities 471 becomes hardened. If a negative photoresist is used, the photoresist located beneath the unactivated cavities 472 becomes hardened.
In another embodiment, the pattern of light is predetermined. In this embodiment, the microcavity array is created having cavities only in those regions where light is desirable. Microcavity arrays are produced using semiconductor processes, such as photolithography. In one case, a grid of thin photoresist lines is deposited on a silicon wafer, and an anisotropic etch is applied. The etch then creates inverted pyramids between each line in the photoresist. These pyramids become the microcavities. By proper application of photoresist, arrays having microcavities only in particular locations can be fabricated. The inactive parts of the array may be covered with photoresist, such that no inverted pyramids are created in the appropriate regions. This creates a specific pattern of cavities and can be particularly effective for patterns that are commonly used. For example, FIG. 3 shows the patterns used for IBC solar cells. One or more specially designed microcavity arrays can be designed to create the masks needed to implant regions 203 , 204 .
In another embodiment, the microcavity array is manufactured so as to create a complete array, as shown in FIG. 5 . Certain cavities are then disabled, such as by filling them with a suitable material to prevent a plasma from forming in specific cavities. In one embodiment, inkjet or screen print technologies are used to dispense a material, such as an organic material, to effectively “clog” the inactive cavities. Alternately, photolithography could be used to set the resist in the appropriate regions of the array. This may be more flexible than the first inkjet approach because the coating could be removed and re-printed to change the pattern. The resulting pattern, much like that described in the previous embodiment, is useful for commonly needed patterns, such as the back surface of an IBC solar cell.
In another embodiment, the electrical connections to the cavities that need to be deactivated can be broken mechanically to render a set of cavities inactive. This technique may work best when the active cavities are contiguous, but by choosing positive or negative photoresist, there is some flexibility in this choice. In one embodiment, a laser can be used to ablate the dielectric layer 430 and the electrode 420 on select parts of the array. This would be between cavities 400 where the laser can be easily focused and the electrode 420 readily accessed. Etching through a mask may accomplish the same result. In this case, a mask would be, for instance, inkjet printed over the array and the dielectric and electrode removed.
In summary, several methods are disclosed to modify the operation of a traditional microcavity array for the purpose of creating ultraviolet light for exposure to photoresist. First, the power to one or more cavities can be controlled. This can be done using addressable cavities, or by separating one or more electrodes from the power source. Secondly, gas can be prevented from entering one or more cavities, such as by applying a material to fill certain cavities. Thirdly, the cavities can be eliminated, such as by manufacturing the microcavity array without one or more of the cavities.
In order to achieve smaller features than the cavity size, the glass surface of FIG. 7 can be used as a lens. FIG. 8 shows an embodiment, where the glass surface is used as a lens. The diverging light 490 emitted by the cavity 400 becomes focused as it passes through the lens 475 . Such a technique is possible, as the scale (size) of the microcavity array is roughly the same as the size of a CMOS sensor. This lens structure allows better collection of the emitted light to improve the fidelity of the transfer of the pattern of microcavities to the substrate.
While this form of lithography may find many applications for structures in the scale of tens of microns, a primary application would be for the manufacture of silicon solar cells. In solar cell manufacture, this lithography method can be used for various processes and solar cell architectures.
In the case of implanting ions into the substrate, the photoresist can be used as a soft mask for ion implantation to allow patterned doping of the substrate.
In the case of etching, the photoresist can be used as an etch resist to allow etching. Patterned etching can be used to make holes in passivating dielectrics (for example the front side anti-reflective coating on a standard solar cell design) or to etch back the silicon substrate (for example to remove the heavily doped surface between the metal lines on the emitter of a standard solar cell design).
In the case of metallization, the photoresist can be used to liftoff a metallization that covers the entire face of the solar cell, such as evaporation or sputtering.
In one application, when doping an interdigitated back cell, the same pattern on the microcavity array can be used with negative and positive photoresists to create complementary regions of p-type and n-type dopants. The fact that the same array of UV sources is used to create each pattern removes most of the problems of relative alignment.
Relative to conventional proximity masking the microplasma exposure offers several advantages. First, the UV source is very close to the wafer, and the UV light is created with some level of parallelism. By contrast, when using a proximity mask the UV source must either be very far from the substrate to ensure that the light is parallel, or expensive optics must be used to make the light parallel. Secondly, because almost all the emitted UV light will be absorbed in the photoresist the power required for the microcavity array is much smaller than that required for a proximity mask where most of the UV light will be absorbed in the mask, and the light source may need to be far away from the wafer. The lower power reduces costs, but also reduces heating and thermal expansion. Finally, depending on the technology used, the proximity mask can be expensive. The microcavity array can be manufactured very inexpensively and is very reliably.
The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Furthermore, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein. | A system and method of exposing photoresist on the surface of the solar cell to light so as to create an appropriate mask is disclosed. A microcavity array is used to expose the photoresist to UV light in a pattern that matches the desired pattern on the solar cell. Microcavity arrays consist of an array of cavities, which may include tens of thousands of cavities. When an appropriate potential is applied to an electrode, a plasma is formed in the activated cavity. If the cavity contains a suitable gaseous environment, these activated cavities will emit light in the near ultraviolet spectrum. By properly configuring the locations of the activated cavities, a UV source may be created that exposes the photoresist in a desired pattern. The desired pattern can be created by selectively activating cavities, disabling certain cavities, or filling certain cavities so that they cannot create a plasma. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the adrenal hormone dehydroepiandrosterone (DHEA, Chemical Abstracts registry number 53-43-0, systematic name 3-beta-hydroxyandrosten-17-one) and to improved compositions and methods for topical administration thereof.
DHEA is the major secretory product of the human adrenal gland and is the most abundant hormone in the body. It is weakly active as a sex hormone but is a precursor within the body for the androgen testosterone in the male and for estrogenic hormones such as estrone and estradiol in the female. Once DHEA is released into the body from the adrenal gland it is converted into the sulfate ester DHEA-S by the liver.
The liver and the kidney are the principal organs involved in clearing steroid hormones from the circulation.
Hepatic metabolism accomplishes two functions for DHEA: a decrease in the biologic activity of the hormone, and an increase in its water solubility, because of conversion to the hydrophilic sulfate form that can be excreted in urine.
Amounts of DHEA in the circulation change with age (Table 1) and it has therefore been postulated that they may be involved in the maturing and aging process in humans.
TABLE 1______________________________________REFERENCE RANGES OF DEHYDROEPIANDROSTERONESULFATEAge (years) Males, micrograms/ml Females, micrograms/ml______________________________________Newborn 1.7-3.6 1.7-3.6Prepubertal 0.1-0.6 0.1-0.6Postpubertal-29 1.4-7.9 0.7-4.530-39 1.0-7.0 0.5-4.140-49 0.9-5.7 0.4-3.550-59 0.6-4.1 0.3-2.760-69 0.4-3.2 0.2-1.870-79 0.3-2.6 0.1-0.9______________________________________ Source: Smith Kline Beecham Clinical Laboratories Co.
Blood levels of DHEA-S peak at approximately 20 years of age and then decline past that age in many individuals. Clinical studies have shown a correlation between a decrease in DHEA-S and an increase in age related conditions.
The plasma half-life of free DHEA is under twenty minutes. In its bound form as DHEA-S it dissociates more rapidly from the binding proteins, making them more susceptible to degradation. The episodic secretion of DHEA, combined with this short plasma half-life results in wide fluctuations in plasma free DHEA levels. By contrast, the steroid sulfates (with significantly less biological activity), such as DHEA-S, which bind with high affinity to albumin, are cleared slowly from the circulation and have high stable plasma concentration.
2. Prior Art
El-Rashidy U.S. Pat. No. 4,978,532 discloses a transdermal dosage form for administering dehydroepiandrosterone (DHEA), utilizing a pressure-sensitive medical grade silicone adhesive material which contains DHEA and a permeation enhancer therefor. A "permeation enhancer" is defined as a compound compatible with DHEA that facilitates the uptake of DHEA through the skin and thus enables a therapeutically effective dosage of DHEA to be administered to the patient. The permeation enhancers contemplated are aromatic or aliphatic carbocyclic compounds that have pendant hydroxyl groups, such as butylated hydroxytoluene (BHT), butylated hydroxyanisole (BHA), a hydroxypropyl-beta-cyclodextrin (HPBCD), and the like, as well as mixtures thereof.
El-Rashidy states that "DHEA in the presently contemplated dosage forms can be administered to lower elevated blood cholesterol levels, for prophylactic or palliative treatment of patients suffering from AIDS, heart disease, obesity, diabetes, and the like afflictions." However, no results of such administration to patients are disclosed.
Loria U.S. Pat. No. 5,206,008 cites such clinical uses of DHEA as topical treatment of patients suffering from psoriasis, gout, and hyperlipemia, and administration to postcoronary patients. Loria further discloses the conversion of DHEA, both in the body and by chemical synthesis, to 5-androstene-3-beta-17-beta-diol and 5-androstene-3-beta-7-beta-17-beta-triol, and teaches the clinical use of these two metabolites in preference to DHEA.
Fawzi et al U.S. Pat. No. 4,783,450 discloses that lecithin enhances the penetration of a drug through the skin as well as a pharmaceutical composition adapted for transdermal administration comprising an active ingredient and an effective amount of lecithin. An active ingredient is defined as "an effective amount of any therapeutically active drug". The "preferred drugs" recited by categories and specific compounds do not include DHEA or any steroid or any kind of hormone.
Hsia et al U.S. Pat. No. 5,231,090 discloses a method of lowering serum cholesterol levels in mammals comprising topically administering a phospholipid containing composition such as lecithin with a pharmaceutically acceptable carrier, which can be "any carrier that does not affect the affinity of the phospholipid for cholesterol". The phospholipid containing composition can be present, for example, in a patch which can be adhered to the skin of the individual such that topical administration is effected. There is no mention of any clinically active material to be used together with lecithin. Hence there is no teaching that a phospholipid is of any benefit in increasing serum levels of any substance.
DuBois U.S. Pat. No. 5,075,113 discloses dietetic, laxative, or cosmetic products which are emulsions of an aqueous phase in an oily phase, in which the aqueous phase contains an extract of hydrodispersible lecithin enriched in phosphatidylcholine, and the oily phase is composed principally of oily paraffin hydrocarbons and a purified lipo-soluble lecithin extract. The products can contain an inert mineral powder such as kaolin, talc or calcium carbonate, and monoglycerides melting above 50° C., as well as a variety of flavors. There is no mention or suggestion of transdermal administration of any therapeutic by using the disclosed composition.
Against this background there remains a need for improved methods and compositions for topically administering DHEA and achieving novel therapeutic utilities thereof.
SUMMARY OF THE INVENTION
In accordance with this invention, a non-staining topical composition for enhancing the serum concentration of dehydroepiandrosterone in a mammal being topically administered said composition, comprises an effective amount of at least one dehydroepiandrosterone compound and an amount effective to increase the transdermal transmission thereof of at least one phospholipid.
The term "non-staining" is used to express the substantial absence of color formation on the skin or clothing of one to whom the composition is topically administered, alone or in the presence of one or more agents such as heat, sunlight, artificial light sources, mild to moderate acid solutions having a pH greater than 2 and less than 7, or mild to moderate alkaline solutions having a pH greater than 7 to 12.
In a human subject, an increase in the serum concentration of dehydroepiandrosterone, including free DHEA as well as the sulfate conjugate DHEA-S, over the baseline level can be noted within a day of topical administration of the composition. On continued administration, the serum concentration of dehydroepiandrosterone continues to rise until a peak level at least double the base line concentration and approaching the peak concentration observed in young adults is reached in fourteen days or less, and is maintained at or close to the peak level as long as topical administration of the composition is continued. Consequently, prolonged or even indefinite topical administration of the composition of the invention is safe.
Topical administration of the composition of this invention can provide a number of therapeutic benefits to the recipient thereof in improving all conditions that benefit from treatment with dehydroepiandrosterone. Such benefits include without limitation weight loss, reduction of cellulite, reduction of wrinkles, reduction of malignancy, increased skin elasticity, increased libido in men and women, diminished male erectile dysfunction, improvements in such conditions as systemic lupus erythematosus and seripositive rheumatoid arthritis, hair growth, enhanced memory capability, reduced levels of low density lipoprotein cholesterol, and improvements in general perception of well-being and energy.
The quantities of the composition of this invention that need to be administered in order to achieve the increased serum concentrations of dehydroepiandrosterone and provide the therapeutic benefits are modest, particularly when compared to oral doses given in attempting to achieve the same results.
DESCRIPTION OF PREFERRED EMBODIMENTS
Dehydroepiandrosterone compounds that can be used in the composition of this invention include dehydroepiandrosterone itself, dehydroepiandrosterone sulfate, and fluorinated derivatives of dehydroepiandrosterone such as 16-fluorodehydroepiandrosterone (CAS registry no. 1649-27-0, systematic name 3-beta-hydroxy-16-fluoroandrost-5-en-17-one). Dehydroepiandrosterone of sufficient purity for use in the composition of this invention is commercially available. Mixtures of more than one dehydroepiandrosterone compound can be used.
Phospholipids that can be used in the composition of this invention include phosphatidylcholine, phosphatidylethanolamine, and phosphatidylserine and mixtures thereof. The fatty acid groups in the phosphatidyl moieties of these phospholipids can be saturated, monounsaturated or polyunsaturated groups such as lauroyl, linoleyl, myristoyl, oleoyl, palmitoyl, and stearoyl groups. Soy lecithin, a mixture of phospholipids rich in monounsaturated and polyunsaturated phosphatidylcholines is particularly preferred.
In the composition of the invention, the concentration of dehydroepiandrosterone compound is in the range of 0.1 to 25 grams per 100 grams of composition; preferably 0.2 to 15 grams per 100 grams, and the concentration of phospholipid is in the range of 1 to 90 grams per 100 grams of composition, preferably 2 to 75 grams per 100 milliliters. The relative proportions of phospholipid to dehydroepiandrosterone compound preferably range from 1:1 to 300:1, most preferably from 2:1 to 250:1.
Dehydroepiandrosterone and phospholipid can be combined with little or no other material present into a concentrate suitable for facilitating the subsequent compounding of a variety of formulations presenting the composition of this invention. Surprisingly, even greater concentrations of dehydroepiandrosterone can be achieved in a mixed solvent system combining phospholipid with ethyl alcohol, cetyl alcohol, and a medium chain length triglyceride. Such concentrates can conveniently include 10 to 15 parts by weight of dehydroepiandrosterone and 85 to 90 parts of phospholipid.
Presentations for use of the composition of this invention can, for example, take the form of pastes, gels, and liquids such as solutions, emulsions, creams, and lotions.
In addition to dehydroepiandrosterone compound and phospholipid, the composition of the invention can include a topically acceptable carrier and such adjuvants as are helpful for convenient dispensing and application of the composition by such presentations as pastes, gels, liquid forms such as solutions, emulsions, creams, and lotions, as well as transdermal delivery systems.
Pastes are liquids whose viscosity is enhanced to the point that flow is largely inhibited by the presence of undissolved as well as dissolved solids which can be waxes or finely divided inorganic solids.
Gels are semisolid systems of either containing suspended small inorganic particles (two phase gels) or organic macromolecules interpenetrated by a liquid (single phase gels).
Solutions are single phase liquids substantially free of solid but small amounts of haze or cloudiness can be tolerated.
Emulsions, lotions, and creams are multiphase liquids containing special components known as surfactants that inhibit or delay the separation of the phases. In the composition of this invention, the phospholipid component can function as surfactant. Added surfactants are therefore not necessary but can be included if desired.
Suitable carriers and adjuvants are selected with a view to being safe in prolonged or even indefinite application of the composition, and include:
Solvents such as ethanol, ethyl acetate, glycerine, polyethylene glycols with average molecular weight ranging from 200 to about 1100, and propylene glycol (water miscible); heptane, purified isoparaffinic hydrocarbons boiling in the range from 60° to 300° C. and fractions thereof, canola oil, olive oil, and mineral oil (not miscible with water);
Emollients such as petrolatum, paraffin wax, beeswax, cetyl palmitate, and lanolin;
Emulsifiers and surfactants such as sodium, potassium, and triethanolamine salts of oleic and stearic acids (which can be prepared in situ by including in the formulation suitable sodium, potassium and amine bases along with the desired acids), dioctyl sodium sulfosuccinate, sodium dodecyl sulfate, glycerol monooleate, glycerol monostearate, and ethoxylated sorbitan esters such as Polysorbate 20, Polysorbate 65 and Polysorbate 80;
Finely divided solids such as aluminum hydroxide, bentonite, kaolin, magnesium silicate, silica, titanium dioxide, and zinc oxide;
Thickeners such as agar, carrageenan, food starch, modified starch, gelatin, gum arabic, guar gum, hydroxyethylcellulose, hydroxypropyl methylcellulose, pectin, sodium carboxymethylcellulose and polyacrylic acid adjusted in pH to provide the desired extent of thickening;
Antioxidants and preservatives such as benzalkonium chloride, di-coco-dimethylammonium chloride, dilauryl thiodipropionate, methyl parahydroxybenzoate, propyl parahydroxybenzoate, and tocopherol.
Particularly preferred carriers and adjuvants include medium chain length triglycerides having six to ten carbon atoms in each fatty acid chain, straight chain aliphatic alcohols having twelve to twenty carbon atoms, ethanol, and water. Examples of suitable medium chain length triglycerides include tricaprylin, tricaprin, and a high purity mixed C8-C10 triglyceride available from Unilever GmbH of Hamburg, Germany, under the trade name HB-307. Examples of suitable straight chain aliphatic alcohols include behenyl alcohol, cetyl alcohol, lauryl alcohol, myristyl alcohol, oleyl alcohol, stearyl alcohol and mixtures thereof.
When formulated for presentation as a solution, the composition of the invention can include volatile carriers such as ethanol and water as well as non-volatile carriers such as medium chain length triglyceride and straight chain aliphatic alcohols having twelve to twenty carbona toms to supplement or substitute for volatile carriers. Thus a typical solution composition of the invention includes a concentration of dehydroepiandrosterone compound in the range of 0.5 to 15 grams per 100 grams of composition, preferably 2 to 15 grams per 100 grams, a concentration of phospholipid in the range of 5 to 75 grams per 100 grams of composition, preferably 10 to 65 grams per 100 grams, a concentration of volatile carrier in the range of 0 to 90 grams per 100 grams, and a concentration of non-volatile carrier in the range of 0 to 30 grams per 100 grams.
When formulated for presentation as a lotion, the composition of the invention can, if desired, include a finely divided solid and a thickener. Thus a typical lotion composition of the invention includes a concentration of dehydroepiandrosterone compound in the range of 0.2 to 10 grams per 100 grams of composition, preferably 1 to 5 grams per 100 grams, a concentration of phospholipid in the range of 2 to 30 grams per 100 grams of composition, preferably 4 to 25 grams per 100 grams, a concentration of finely divided solid in the range of 0 to 5 grams per 100 grams of composition and a concentration of thickener in the range of 0 to 5 grams per 100 grams of composition.
When formulated for presentation as a cream, the composition of the invention can, if desired, include an emollient and an emulsifier, as well as an antioxidant and/or preservative. Thus a typical cream composition of the invention includes a concentration of dehydroepiandrosterone compound in the range of 0.1 to 10 grams per 100 grams of composition, preferably 0.25 to 5 grams per 100 grams; a concentration of phospholipid in the range of 2 to 75 grams per 100 grams of composition, preferably 3 to 65 grams per 100 grams; a concentration of emollient in the range of 0 to 50 per 100 grams of composition and a concentration of emulsifier in the range of 0 to 25 grams per 100 milliliters of composition.
When formulated for presentation as a paste, the composition of the invention can, if desired, include a thickener and/or finely divided solid in greater concentrations than in a lotion. Thus a typical paste composition of the invention includes a concentration of dehydroepiandrosterone compound in the range of 1 to 10 grams per 100 grams of composition, preferably 2 to 5 grams per 100 grams; a concentration of phospholipid in the range of 2 to 50 grams per 100 grams of composition, preferably 5 to 40 grams per 100 grams; a concentration of finely divided solid in the range of 0 to 15 grams per 100 grams of composition, and a concentration of thickener in the range of 0 to 15 grams per 100 grams of composition, the combined concentration of finely divided solid-and thickener being at least 5 grams per 100 grams of composition.
When formulated for presentation as a gel, the composition of the invention can include a gelling agent such as a finely divided solid and/or a thickener in concentrations that produce a loose molecular network inhibiting the free movement of liquid ingredients. Thus a typical gel composition of the invention includes a concentration of dehydroepiandrosterone compound in the range of 0.1 to 10 grams per 100 grams of composition, preferably 0.25 to 5 grams per 100 grams; a concentration of phospholipid in the range of 2 to 50 grams per 100 grams of composition, preferably 3 to 25 grams per 100 milliliters; a concentration of finely divided solid in the range of 0 to 15 grams per 100 grams of composition, and a concentration of thickener in the range of 0 to 15 grams per 100 grams of composition, the combined concentration of finely divided solid and thickener being at least 1 gram per 100 grams of composition.
In a particularly preferred embodiment, the composition of this invention is administered to the recipient by means of a transdermal delivery system or patch. Transdermal delivery is accomplished by exposing a source of the substance to be administered to the recipient's skin for an extended period of time. Typically, the substance is incorporated in a matrix or container from which it is released onto the recipient's skin. The rate of release can be controlled by a membrane placed between the container and the skin, by diffusion directly from the container, or by the skin itself serving as a rate-controlling barrier. Many suitable transdermal delivery systems and containers therefor are known, ranging in complexity from a simple gauze pad impregnated with the substance to be administered and secured to the skin with an adhesive bandage to multilayer and multicomponent structures. All such systems are characterized by the use with the substance to be administered of a shaped article sufficiently flexible to snugly fit to the skin of the recipient and thus serve both as container from which the substance is delivered to the recipient's skin and as barrier to prevent loss or leakage of the substance away from the area of the skin to which the substance is to be delivered. For brevity, such a flexible article is referred to in the instant specification and claims as a reservoir.
Typically, a transdermal delivery system or patch also contains an added substance that assists the penetration of the active ingredient through the skin, usually termed a skin enhancer or penetration enhancer. Many penetration enhancers are known in the art, both water soluble and water insoluble. It has been discovered in accordance with this invention that the phospholipid component of the composition of this invention is outstandingly effective in assisting the penetration of a dehydroepiandrosterone compound through the skin and the establishment of increased serum concentrations of dehydroepiandrosterone sulfate in the recipient.
Accordingly, a transdermal delivery system according to this invention comprises a reservoir, a dehydroepiandrosterone compound as the active ingredient, and a phospholipid compound as penetration enhancer in sufficient concentration to effect increased serum concentration of dehydroepiandrosterone in the recipient. Conventional penetration enhancers are not necessary but can be included if desired.
Compositions according to this invention can be prepared by conventional procedures. To minimize contamination from the growth of microorganisms, sterilized equipment is preferably used. Once blended, the composition can be packaged and stored in any suitable container inert to the contents including aluminum, glass, stainless steel, and solvent resistant plastics including polyamide, polyester, polypropylene, and ABS polymer. Storage is preferably in a cool place away from strong light. Continued sterility can be assured by conventional techniques including aseptic packaging and post-sterilization in the final package by electron beam exposure.
In use, compositions according to this invention are applied to areas of the skin of the recipient in any suitable manner. Thus, a solution or emulsion of the composition can be brushed or painted on desired areas of the recipient's body. A paste, gel, cream, or lotion can be taken on the palm of the hand and rubbed into the recipient's shoulder area, chest, abdominal area, buttocks, or thighs. Transdermal patches can be applied to the upper arm or any suitable less visible area.
Delivery of dehydroepiandrosterone to the recipient's blood stream can be confirmed by analysis of a blood sample taken from the recipient. Increased serum levels of dehydroepiandrosterone sulfate are noted within twenty-four hours and continue to increase to a plateau of at least twice baseline levels and beneficial effects thereof are noted within two weeks.
EXAMPLE 1
Preparation of a Stable Concentrated Composition of Dehydroepiandrosterone and Phospholipid
A borosilicate glass flask fitted with stirrer and thermometer was mounted in a water bath heated on an electric hot plate, and charged with 45 grams of phosphatidylcholine and 19 grams of pharmaceutical grade ethyl alcohol. Heat was applied to the water bath, and stirring started as the phosphatidylcholine began to melt. When the material had melted at about 95° F., 18 grams of dehydroepiandrosterone was added in small portions over a thirty minute period, and heating at 95° F. was continued until a homogeneous melt was obtained. Heating was discontinued; 5 grams of mixed C8-C10 triglyceride, 3 grams of cetyl alcohol, and an additional 30 grams of phosphatidylcholine was added with continued stirring until the mixture had cooled to ambient temperature and could be transferred to a brown glass storage bottle.
The result of this preparation was a pale yellow liquid composition according to this invention containing 15% by weight of dehydroepiandrosterone and approximately 62.5% of phosphatidylcholine, 16% of ethanol, 4% of mixed C8-C10 triglyceride, and 2.5% of cetyl alcohol.
The composition remained liquid upon storage at ambient as well as refrigerated temperatures.
Addition of water to this product in a high speed mixture produced a cream in accordance with this invention.
EXAMPLE 2
Preparation of a Stable Concentrated Composition of Dehydroepiandrosterone and Phospholipid
A borosilicate glass flask fitted with stirrer and thermometer was mounted in a water bath heated on an electric hot plate, and charged with 45 grams of phosphatidiylcholine. Heat was applied to the water bath, and stirring started as the phosphatidiylcholine began to melt. When the material had melted at about 135° F., 10 grams of dehydroepiandrosterone was added in small portions over a thirty minute period, and heating at 135° F. was continued until a homogeneous melt was obtained. Heating was discontinued, and an additional 45 grams of phosphatidylcholine was added with continued stirring until the mixture was uniform and could be discharged, cooled to ambient, and broken up for storage.
The result of this preparation was a pale yellow brittle solid composition according to this invention containing 10% by weight of dehydroepiandrosterone and approximately 90% of phosphatidylcholine.
EXAMPLE 3
Preparation of an Emulsion Containing Dehydroepiandrosterone and Phosphatidylcholine
A mixture of 23 grams cetyl alcohol and 24 grams petrolatum is warmed to 75° C. to give a clear melt, to which are added 1 gram of dehydroepiandrosterone and 2 grams phosphatidylcholine. Separately, 1 gram sodium lauryl sulfate, 12 grams propylene glycol, 25 milligrams of methyl p-hydroxybenzoate and 15 milligrams of propyl p-hydroxybenzoate are dissolved in 37 grams of warm water, heated to 75° C., and stirred into the melted first mixture. Stirring is continued with cooling until the resulting oil-in-water emulsion sets into a washable ointment containing approximately 1000 milligrams of dehydroepiandrosterone per 100 ml and 2000 milligrams of phosphatidylcholine per 100 ml in accordance with this invention.
EXAMPLES 4-8
Preparation of Creams Containing Dehydroepiandrosterone and Phosphatidylcholine
Creams are prepared by stirring together at 70° C. separately prepared premixes of the water-soluble ingredients and the water-insoluble ingredients tabulated below (all quantities in grams except as noted), and continuing agitation while cooling to ambient.
______________________________________Example 4 5 6 7 8______________________________________water-insoluble:cetyl palmitate 23 -- -- -- --beeswax 23 -- 10 -- --mineral oil 105 -- 30 -- --petrolatum -- -- 5 -- --DHEA 3 1 5 2 1phosphatidylcholine 7 250 20 6 4cetyl alcohol -- 10 3 -- --C8-C10 triglyceride -- 10 -- -- --isopropyl myristate -- -- 7 -- --lanolin -- -- 20 3 --stearic acid -- -- -- 4 18glyceryl monostearate -- -- -- 9 --olive oil -- -- -- 8 --alpha-tocopherol milligrams 10 20 5 5 5water-soluble:borax 1 -- -- -- --water 38 60 -- 62 75ethanol -- 60 -- -- --sorbitol -- -- -- 5 --triethanolamine -- -- -- 1 --glycerine -- -- -- -- 6.5potassium carbonate -- -- -- -- 0.25methyl paraben preservative 100 200 50 50 50milligramsTOTAL grams 200 391 100 100 109.75______________________________________
The results of these preparations are stable, non-separating creams in accordance with this invention.
EXAMPLES 9-13
Preparation of Lotions Containing Dehydroepiandrosterone and Phosphatidylcholine
The following lotions are prepared by triturating the water-insoluble ingredients with a portion of the pre-mixed water-soluble ingredients to a smooth paste, and adding the remainder of the water-soluble ingredients with high speed stirring.
______________________________________Example 9 10 11 12 13______________________________________water-insoluble:Example 2 product -- -- 10 -- --mineral oil 45 -- -- -- --DHEA 1 1.5 -- 1.5 3phosphatidylcholine 4 5 -- 3.5 7cetyl alcohol 1 -- -- -- 4.2oleyl alcohol -- -- -- 5 --C8-C10 triglyceride -- -- -- 5lanolin 1stearic acid -- -- -- 5 --polyethylene glycol 200 -- 15 -- 9 2.8monostearatePolysorbate 80 -- 1 -- -- --Magnesium aluminum silicate -- 2.5 -- -- --water-soluble:sodium lauryl sulfate 2 -- -- -- --water 48 75* 70* 75.5*triethanolamine -- -- -- 1 --glycerine -- -- 32 5 2carboxymethylcellulose sodium -- -- 2 -- --ammonium chloride -- -- -- -- 0.5TOTAL 100 100* 44 100* 100*______________________________________ *Includes 0.1-0.2 g methyl phydroxybenzoate preservative
The results of these preparations are lotions in accordance with this invention that are readily redispersed by shaking if they should separate on standing.
EXAMPLES 14-15
Preparation of Gels Containing Dehydroepiandrosterone and Phosphatidylcholine
The following gels are prepared by warming together the ingredients shown with stirring, and cooling to ambient with continued mild agitation.
______________________________________Example 14 15______________________________________water-insoluble:Example 2 product -- 10DHEA 2 --phosphatidylcholine 4 --polyacrylic acid 1.2 --glyceryl monostearate 5 --water-soluble:ethyl alcohol 40 34water 46.3 51.2triethanolamine 1.5 --gelatin -- 1.2pectin -- 2.1agar -- 1.5TOTAL 100 100______________________________________
The results of these preparations are thixotropic gels in accordance with this invention.
EXAMPLE 16
Transdermal Administration of a Composition Containing Dehydroepiandrosterone and Phosphatidylcholine
BJR, a 46 year old postmenopausal woman had a long history of fatigue, anxiety, decreased libido, cellulite, and was mildly overweight and otherwise in apparent good health. She volunteered to test the effects of topical lecithin-DHEA. A fasting blood sample was drawn on day 1 through day 21 for complete blood count, chemistry panel and dehydroepiandrosterone sulfate serum levels.
She was given the following instructions.
1) Apply 30 ml (one tablespoon) of the cream to each thigh and rub it in well every morning for three weeks.
2) Wait for at least two hours before washing off the unabsorbed material on the skin.
The cream provided to her had the following composition:
______________________________________Phosphatidylcholine 250 mlEthanol 75 mlCetyl alcohol 10 mlDistilled water 60 mlMedium chain triglycerides 10 mlDHEA 1000 mg______________________________________
BJR returned every third day for analysis.
Over three weeks she related a progressive sense of well being, increased energy and libido, and diminished anxiety. Objectively there was a three pound weight loss and somewhat less cellulite.
Baseline level of DHEA sulfate was 1.8 micrograms/ml. After 10 days and thereafter the serum DHEA sulfate level was over 4 micrograms/ml. There was no change in her complete blood count or liver function tests. There was also no staining or discoloration of her skin or clothing at any time during or after administering the composition.
The results of this example provide positive evidence of successful transdermal administration of DHEA to a person in accordance with this invention.
EXAMPLE 17
Transdermal Administration of a Composition Containing Dehydroepiandrosterone and Phosphatidylcholine and Attempted Transdermal Administration of Dehydroepiandrosterone Without Phosphatidylcholine
RRR, a 69 year old postmenopausal woman in apparent good health volunteered to try four different topical creams for two weeks at a time. Serum levels of DHEA were taken after seven and fourteen days.
1) Topical DHEA in cold cream (30 ml on two sites daily for two weeks) produced no change in serum DHEA levels.
2) Topical DHEA in aromatic carbocyclic permeation enhancer 10% concentration of DHEA in 30 ml on two sites daily for two weeks produced no change in serum DHEA levels.
3) Topical DHEA in aliphatic carbocyclic permeation enhancer with 10% concentration of DHEA in 30 ml on two sites daily for two weeks produced no change in serum DHEA levels.
4) Topical DHEA-phospholipid 10% concentration of DHEA in 30 ml on two sites daily produced a doubling of the baseline serum concentration by the 14th day.
The results of this example provide evidence of the unexpected advantage of phospholipid used together with DHEA to effect dramatically increased serum levels of DHEA.
EXAMPLE 18
Transdermal Administration of Dehydroepiandrosterone and Phospholipid on the Scalp
GM, a 41 year old man volunteered to try DHEA-phospholipid in a lotion comprising 10% DHEA in phospholipid (without cetyl alcohol), 20 ml of glycerin, and two grams of carboxymethylcellulose. He was instructed to 1) shake the bottle of lotion well before each use, 2) for external use only, 3) apply 45 ml to the scalp nightly with a gauze pad and 4) wash out every morning.
After three months, GM experienced significant observable new hair growth as well as thickening of his existing hair.
The results of this example provide evidence of hair growth following transdermal administration of the composition of this invention.
EXAMPLE 19
Transdermal Administration of Dehydroepiandrosterone and Phospholipid on the Face
DC, a 52 year old woman, volunteered to apply DHEA gel to one side of her face nightly for three months. 10% DHEA-phospholipid complex with gelatin, pectin, and agar was applied around the eye, mouth and forehead of the left side of the face.
After three months, there was a significant reduction of the number, width, and depth of the wrinkles on the left side of her face as compared to the right side.
The results of this example provide evidence of reduction of wrinkles following transdermal administration of the composition of this invention.
EXAMPLE 20
Transdermal Administration of Dehydroepiandrosterone and Phospholipid on the Hands
AH, a 62 year old woman volunteered to apply DHEA-phospholipid hand cream daily for three months. Lonaolin and glyceryl monostearate were mixed with 5% DHEA-phospholipid complex.
AH was noted to have progressive younger looking hands, with less wrinkles, smoother skin, and less roughness.
The results of this example provide further evidence of reduction of wrinkles following transdermal administration of the composition of this invention.
EXAMPLE 21
Transdermal Administration of Dehydroepiandrosterone and Phospholipid by a Patch
AM, a 62 year old man volunteered to try a dermal patch for three weeks. The patch had a central drug delivery reservoir surrounded by a peripheral adhesive area and a microporous membrane. A fresh patch was applied daily to any covered area of the body for three weeks. Serum levels of DHEA sulfate tripled by the end of the third week.
The results of this example provide further evidence of successful transdermal administration of DHEA to a person in accordance with this invention.
EXAMPLE 22
Measurement of Free DHEA in a Human Subject After Administration of DHEA
BLW, a 49 year old woman volunteered to have her plasma levels of free DHEA checked every 10 minutes after oral ingestion of 200 milligrams if DHEA. There was no appreciable rise in free DHEA levels as measured over 4 hours. However, there was a mild increase of DHEA-S level at 4 hours.
The following week BLW volunteered to have her plasma levels of free DHEA checked every 10 minutes after transdermal patch application of DHEA-phospholipid composition. At twenty minutes and thereafter, there was a two to four fold sustained increase of free DHEA plasma levels that was maintained for four hours. There was a mild increase of DHEA-S level at 4 hours only.
These results demonstrate the unexpected ability of the composition of this invention to sustainably enhance the plasma level of free DHEA as well as DHEA sulfate.
EXAMPLE 23
Treatment of Systemic Lupus Erythematosus with Dehydroepiandrosterone and Phospholipid
ZB, a 42 year old woman with systemic lupus erythematosus (SLE) according to the AMERICAN COLLEGE OF RHEUMATOLOGY criteria consented to a clinical trial of topical DHEA. Topical cream containing DHEA and phosphatidylcholine was used on a daily basis to achieve double serum DHEA levels for 3 months.
Patient's and physician's overall assessment of disease activity improved. SLE Disease Activity Index score improved.
The results of this trial show the effectiveness of a composition of this invention in the treatment of systemic lupus erythematosus.
EXAMPLE 24
Treatment of Seropositive Rheumatoid Arthritis with Dehydroepiandrosterone and Phospholipid
NP, a 52 year old woman with seropositive rheumatoid arthritis according to the American Colelge of Rheumatology criteria consented to a clinical trial of topical DHEA. Topical cream containing DHEA and phosphatidylcholine was used on a daily basis to achieve double or triple serum DHEA levels for 3 months.
Patient's and physician's overall assessment of disease activity improved.
The results of this trial show the effectiveness of a composition of this invention in the treatment of seropositive rheumatoid arthritis.
EXAMPLE 25
Treatment of Erectile Dysfunction with Dehydroepiandrosterone and Phospholipid
GS, a 43 year old man with erectile dysfunction consented to a clinical trial of topical DHEA. Topical cream containing DHEA and phosphatidylcholine was used on a daily basis to achieve double or triple serum DHEA levels for one month.
Patient's and physician's assessment of the patient's erectile dysfunction revealed modest improvement.
The results of this trial show the effectiveness of a composition of this invention in the treatment of erectile dysfunction.
The foregoing description is intended as illustrative and is not to be taken as limiting. Still other variations within the spirit and scope of this invention as defined by the claims are possible and will readily present themselvers to those skilled in the art. | Disclosed is a novel transdermal delivery system for dehydroepiandrosterone (DHEA). Using phospholipids as vehicles, DHEA can be administered into and through the skin when topically applied. Numerous advantages apply to this modality of therapy. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of and claims the benefit under 35 U.S.C. §120 of U.S. application Ser. No. 11/869,334, filed Oct. 9, 2007, now U.S. Pat. No. ______, which claims priority under 35 U.S.C. §119 to U.S. Provisional Application No. 60/897,616, filed Jan. 26, 2007. The foregoing applications are both specifically incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of air mattresses. More specifically, it relates to a pump system that can be used with mattresses having a varying number of individually-inflatable zones. The pump system has a common platform and a manifold that can accommodate a range of pump sizes, differing numbers of air control valves, and varied configurations of faceplates for easy and cost-effective manufacturing and use with mattresses that have different numbers of inflatable zones.
BACKGROUND
[0003] Pumps for mattresses are well known for providing controlled air flow to inflatable mattresses. One such system is disclosed in U.S. Pat. No. 5,044,029 to Vrzalik. Vrzalik teaches an air control system wherein the bed and frame itself incorporates the system, and therefore greatly increases the cost of manufacturing by requiring integration of the controls into the mattress. Another air control mechanism, which is external to the bed itself, is disclosed in U.S. Pat. No. 6,037,723 to Schafer. A major limitation of this and other similar air control systems is that the systems can inflate only the specific number of chambers for which they are designed, and can therefore be used only with mattresses containing the matching number of inflatable chambers. Separate pumps therefore need to be manufactured for each type of mattress model.
[0004] The requirement for existing pumps to be customized to accommodate the number of inflatable chambers in the mattress with which they will be used greatly increases manufacturing costs and time, and decreases overall market efficiency by requiring a unique pump for each style of bed. None of the existing airbed control systems currently in use provide an interchangeable, efficient pump system, but rather are manufactured and sold with substantial differences in appearance, internal design, and component configuration for use with mattresses with varying numbers of zones. The mechanical and software designs presently used are typically single-pump based and require a manufacturer to create new tool sets for internal components, new circuit board designs, and new external enclosures to create the different pump systems with respect to the number of air zones to be controlled. Existing pump systems do not lend themselves to the development or sale of a comprehensive product line that can be easily and cost-effectively configured to produce multiple finished products that have significantly differentiated functionality but a consistent overall appearance.
[0005] Accordingly, a need exists for a multiple configuration pump system in which a variety of pump sizes and face plates as well as varying number of air control valves can be incorporated into a standard platform and manifold for use with mattresses having different numbers of inflatable zones. This system provides the components that are the most expensive to tool as the common universal components, and the least expensive and simply-tooled components to be the variable ones. Inventory can be built to a nearly-finished state, and quickly and inexpensively configured with the variable components at the last moment based on actual market demand.
[0006] Furthermore, such a system solves the current problems of an increased expense of manufacturing multiple types of pump systems for use with mattresses having different numbers of zones, and also provides a universal pump for convenience of retailers and consumers. A multiple configuration system also allows for streamlined testing procedures and lower testing costs, such as standard durability drop tests, form, fit and function tests, and compliance tests across the configurations. The standardized pump systems also allow for use of the same packaging for each pump system, including both the inner packaging and outer shipping box, fewer inventory SKUs, standardized packaging lines, processes and employee training, and standardized pallet size and storage requirements.
[0007] A need also exists for a sealed manifold for such an air pump system. Pumps for mattresses are well known for providing controlled air flow to inflatable mattresses, however, current pumps are not capable of accurately controlling pressure in the chamber of the manifold. Repeatable accuracy is important in devices aimed at long-term care facilities and other medical applications where accurate control of sleep surface firmness plays a direct role in avoiding pressure sores. Currently, medical grade products which posses this required level of control are orders of magnitude more expensive than consumer level products. Additionally, air leaks through the pump have historically been a perceived weakness of the air chamber type systems. For example, a single hair or dust bunny in the sealing port could cause a chamber leak in such models. A manifold that employs air control valves that use a reinforced or redundant sealing system provides greatly enhanced pressure control and precludes air leaks in the system.
SUMMARY
[0008] The present invention provides a multiple configuration mattress pump. The pump system includes a manifold which is adapted to connect a varying number of air control valves to control air flow to the related number of inflatable mattress zones. The platform can accommodate a variety of pump sizes. Additionally, the platform is adapted to easily hold changeable faceplates containing a number of tube holes corresponding to the number of mattress zones. The number of plugs used to fill the holes in the manifold for unused air control valves for use with beds having fewer than the maximum number of zones can vary. The pump system includes a circuit board which fits onto the platform, the software of which can be programmed to match the number of air control valves corresponding to each inflatable zone. The invention may include a wired or wireless pendant connected to the circuit board of the platform, allowing the user to control the airflow in each inflatable zone. The invention may also include a pony board with a number of connection ports equal to the maximum number of air control openings in the manifold, with the output wires contained in a single arm and allowing for a single connection from the valves to the circuit board where multiple valves are used.
[0009] The present invention has several advantages and benefits over the prior art. Other objects, features and advantages of the present invention will become apparent after reviewing the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a side perspective view of an air mattress pump system in accordance with one embodiment of the present invention shown without an enclosure top and with certain details removed;
[0011] FIG. 2 is a top view of a pump system in accordance with one embodiment of the present invention shown without an enclosure top;
[0012] FIG. 3 is a detail side perspective view of a pump system in accordance with one embodiment of the present invention shown without an enclosure top;
[0013] FIG. 4 is a front perspective view of a manifold, air control valves, a pony board and an air pump in accordance with one embodiment of the present invention;
[0014] FIG. 5 is a front perspective view of three configurations of pump systems with enclosure tops;
[0015] FIG. 6 is a top view of the three configurations of pump systems of FIG. 5 , shown without enclosure tops;
[0016] FIG. 7 is a rear perspective view of a manifold and a faceplate in a two-zone configuration of a pump system;
[0017] FIG. 8 is a rear perspective view of a manifold and faceplate in a six-zone configuration of a pump system;
[0018] FIG. 9 is a front perspective view of a manifold, zone tubing and faceplates of two configurations of pump systems shown without enclosure tops;
[0019] FIG. 10 is a rear view of a manifold with an air control valve and air control plugs in accordance with one embodiment of the present invention;
[0020] FIG. 11 is a top perspective view of an air control valve in accordance with one embodiment of the present invention;
[0021] FIG. 12 is a top view of a platform of a pump system in accordance with one embodiment of the present invention;
[0022] FIG. 13 is an underside view of a top enclosure of a pump system in accordance with one embodiment of the present invention;
[0023] FIG. 14 is a top view of a manifold, a pony board, air valves, and air valve connective wires in accordance with one embodiment of the present invention;
[0024] FIG. 15 is a side perspective view of a manifold and tubing of a pump system in accordance with one embodiment of the present invention;
[0025] FIG. 16 is a side perspective view of a pendant circuit board in accordance with one embodiment of the present invention, shown with the cover removed;
[0026] FIG. 17 is a side perspective view of a pendant attached to a pump system with an enclosure top in accordance with one embodiment of the present invention;
[0027] FIG. 18 is an exploded isometric view of the back of a manifold and solenoid assembly in accordance with one embodiment of the present invention;
[0028] FIG. 19 is a cross-section of a side view of the assembled manifold of FIG. 18 showing a solenoid assembly engaged in an air control hole; and
[0029] FIG. 20 is an enlarged view of the cross-section of the solenoid assembly shown in FIG. 19 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Referring now to the drawings, FIGS. 1-6 are views of a multiple configuration airbed pump system 10 in accordance with a preferred embodiment of the present invention. The pump system 10 may include a pump casing consisting of a platform 20 and an enclosure top 80 . The system may further include a manifold 30 for controlling airflow and including air valves 35 and a pressure measurement valve 37 , air control valves 34 , air control plugs 36 , zone tubing 38 , a pump mounting area 40 for receiving a pump 42 , an interchangeable faceplate 50 , a primary circuit board 60 , internal tubing 62 , a pressure measurement tube 66 , a pendant 70 , and a pony board 100 . The air valves 35 and pressure measurement valve 37 include air inlets, outlets, or ports. The platform 20 , manifold 30 , mounting base 40 , circuit board 60 , internal tubing 62 , pressure measurement tube 66 , pendant 70 , pump 42 , pony board 100 , and enclosure top 80 , are the shared components of the system, and can be used with mattresses varying from one to six individual inflatable zones. Of course, the system 10 could be used with mattresses having other numbers of zones if desired by modifying the manifold 30 to include additional air valves 35 . The faceplate 50 , number of air control valves 34 , zone tubing 38 , and number of air control plugs 36 are the only components that vary in the use of the system 10 with different mattresses. The software of the circuit board 60 can be programmed to correspond to the number of zones to be inflated.
[0031] As seen in FIGS. 1-3 , the manifold 30 and circuit board 60 can be mounted to the platform 20 , and the platform 20 may have a pump area 40 for holding a pump 42 . The use of a manifold 30 is well-known in the art as a component for regulating air flow pumped from a pump 42 to air chambers. A diaphragm pump is shown, but other types of pumps could be used. The platform 20 can also include a slot 52 for holding an changeable faceplate 50 . The platform 20 may also include screw holes 22 for attaching the manifold 30 and circuit board 60 . The platform 20 may also include screw holes 44 for attaching the pump 42 , as well as screw holes 23 for attaching the enclosure top 80 ( FIG. 11 ). Of course, other means of attaching the enclosure top 80 to the platform 20 , such as adhesives, sonic welding, or snap-fitting, may also be used.
[0032] As seen in FIG. 2 , the assembled pump system 10 with the enclosure top 80 secured to the platform 20 is identical for pump systems 10 used with, for example, six-, four-, and two-zone mattresses, with the exception of the faceplate 50 and number of zone tubes 38 exiting the faceplate 50 . This allows continuity in the overall product line, in addition to the cost savings, in using such an interchangeable pump system 10 . As the casing platform 20 , enclosure top 80 , and manifold 30 ( FIGS. 12-13 ) are three of the more intricate and therefore expensive components to tool in manufacturing, the standardization provides cost savings by allowing these expensive components to be used across the entire product line, with any mattress model. The standardized platform 20 and enclosure top 80 casing also allow for standardized packing, shipping, and storage of the pump systems 10 to be used with the varying mattress models. The standardized casing also provides brand equity by keeping the same overall look across multiple price points and SKUs, and also provides packaging and advertising cost savings.
[0033] Referring now to FIGS. 3-4 , 7 - 8 and 10 , one side of a manifold 30 includes air control holes 32 . In the embodiment shown, seven air control holes 32 are shown. This allows up to seven air control valves 34 to be inserted into the holes 32 of the manifold 30 for a six-zone mattress, with six air control valves 34 used for air flow to the zones, and one air control valve 34 for exhaust. In FIG. 11 , solenoid valves are shown but other types of air control valves 34 could be used. See, e.g., FIGS. 18-20 and related discussion. Of course, manifolds 30 with more or fewer air control holes 32 could be manufactured to accommodate mattresses with more or fewer than six inflatable zones. The manifold 30 includes a cover 31 which can be connected with screws using manifold screw holes 33 . There may also be a manifold gasket 28 between the manifold cover 31 and the manifold 30 . A manifold gasket 28 may help with sealing the manifold and preventing air leaks. In one embodiment, shown in FIGS. 18-20 , the manifold cover 31 also has a groove 29 to help secure and compress the manifold gasket 28 between the manifold 30 and manifold cover 31 . The inclusion of a groove 29 in the manifold cover 31 creates a substantially more airtight seal between the manifold cover 31 and the manifold 30 because it tolerates molding irregularities better than other types of gasketing options and allows for a lower cost manufacturing and assembly option while still preserving the option for disassembly and repair. Other methods of sealing the manifold cover 31 to the manifold 30 include solvent bonding, heat or sonic welding, and sealing adhesives.
[0034] Having a standardized manifold 30 , the most expensive component due to its complexity and detailed tooling, provides a large cost savings. When fewer than the maximum number of zones are being inflated, the corresponding number of air control valves 34 can be used, and air control plugs 36 can be used to block the empty holes 32 not being used. For example, in the embodiment shown, in a mattress with only two zones, three air control valves 34 would be used (two for air flow to the zones, one for exhaust), and four air control plugs 36 would be inserted into the four unused holes 32 . FIG. 7 shows a system 10 configured for a two-zone mattress, with the manifold 30 having three air control valves 34 and four air control plugs 36 blocking the unused holes 32 . FIG. 8 shows a system 10 configured for a six-zone mattress, with the manifold 30 having seven air control valves 34 and therefore no air control plugs 36 . The air control plugs 36 ( FIG. 10 ) fit any hole 32 in the manifold 30 and are very inexpensive to manufacture; having these air control plugs 36 as one of the variable components therefore allows for only a small cost to change the configuration for use with different mattress models. It also allows for volume discounts, in that the same parts can be used across different SKUs.
[0035] As seen in the embodiment shown in FIGS. 1-3 , two air valves 35 are connected by internal tubing 62 to the pump 42 , whereby air is pumped from the pump 42 to the manifold 30 . On the opposite side of the manifold 30 , air valves 35 are coupled to each of the seven holes 32 . For each zone of the mattress that is to be inflated, a zone tube 38 is attached to the air valve 35 opposite an air control valve 34 and runs to an inflatable zone of the mattress. The manifold 30 is one of the more difficult and expensive components to tool for manufacturing, but, by simply plugging any unused holes 32 with plugs 36 , the manifold 30 can be used with beds ranging from, in the embodiment shown in the FIGS., one to six inflatable zones without any additional manufacturing or machining costs.
[0036] Referring now to FIGS. 1 , 6 , and 9 , the faceplate 50 includes openings 54 through which the zone tubes 38 can pass. In a preferred embodiment, the faceplate 50 fits into a slot 52 in the casing platform 20 and top enclosure 80 . Faceplates 50 can therefore be changed to accommodate the number of zone tubes 38 (and air control valves 34 ) corresponding to the number of inflatable zones in each particular mattress. Where a mattress has four inflatable zones, for example, a faceplate 50 with four openings 54 would be placed in the slot 52 , and four tubes 38 would run from the air valves 35 opposite the air control valves 34 , through the openings 54 and to each zone of the mattress. The faceplates 50 are a small and inexpensive component of the pump 10 , and requiring only this component to be manufactured differently for use of the pump 10 with different mattresses saves time and money. Additionally, the faceplate 50 protects the tube 38 connections to the air valves 35 . Some pump systems currently on the market have the tube connections exposed, which subjects the existing pump systems to a greater risk of breakage. This “hiding” of the internal components in the pump system 10 of the present invention also adds aesthetic value to the system 10 giving it an overall clean, finished look.
[0037] The platform 20 in a preferred embodiment also includes a pump mounting area 40 for supporting a pump 42 . A diaphragm pump is shown, but other types of air pumps could also be used. The mounting area 40 in the embodiment shown in FIG. 12 includes four pump screw holes 44 by which the pump 42 can be secured. Of course, the mounting area 40 could be configured differently and include a different number and configuration of pump screw holes 44 depending on the pump 42 used. Alternative methods of securing the pump 42 to the mounting area 40 of the platform 20 could also be used. The mounting area 40 is sized such that a variety of types and sizes of pumps 42 can be used with the pump system 10 . Internal tubing 62 connects the pump 42 to the manifold 30 to pump air from the manifold 30 to the mattress zones.
[0038] As seen in FIGS. 1-3 , a circuit board 60 may also be affixed to the platform 20 . The circuit board 60 contains software programmable for the varying number of zones to be inflated. It also contains all connection assemblies for system power and for the pendant 70 used by the mattress user to control the inflation of the zones. The air control valves 34 can be connected to the circuit board 60 by connective wires 64 , and air flow is controlled by the user selecting desired firmness on the pendant 70 which is connected to the circuit board 60 . This allows the corresponding amount of air to be pumped to each zone based on the firmness level selected by the user on the pendant 70 . A pressure measurement tube 66 connects a pressure measurement valve 37 on the manifold 30 to the circuit board 60 to allow the software to determine the pressure in the manifold 30 to control the proper release of air for the firmness selected by the user. The circuit board 60 can be used for any configuration of air control valves 34 and pump sizes 42 by loading it with the appropriate software program. A power cord 68 may be attached to the circuit board 60 to provide power to the pump system 10 . The power cord 68 may alternatively be attached through a transformer (not shown) depending on circuitry design. In a preferred embodiment, the power cord 68 passes through the top enclosure 80 and/or the platform 20 of the casing.
[0039] As shown in FIGS. 1 and 16 - 17 , a pendant 70 can be connected to the circuit board 60 via a pendant cord 72 . An aperture 74 in the enclosure top 80 allows the pendant cord 72 to pass through the enclosure top 80 for connection to the circuit board 60 . Alternatively, the pendant 70 may be configured with the circuit board 60 for wireless control of the pump system 10 (not shown). The pendant 70 includes a pendant circuit board 76 onto which pendant software is uploaded. The pendant 70 and pendant software are standard and can be can be used in connection with any pump system 10 configuration; the pendant 70 and pendant software are designed such that a pendant 70 can be plugged into the circuit board 60 of any pump system 10 configuration and allow the user to control the number of zones in her or her particular air mattress. The pendant 70 includes an LCD display 78 and control buttons 79 to allow the user to control the amount of air pumped from the pump 10 to each inflatable zone. The size of the LCD display 78 and number of control buttons 79 can of course vary. Alternatively, the LCD display 78 could be a touch screen on which firmless level is selected, or a track wheel or ball could be used for selection by a user. Multiple pendants 70 could also be used depending on the need for individual controllers in the system.
[0040] As seen in FIGS. 4 and 14 - 15 , the air control valves 34 may be connected to the circuit board 60 through a pony board 100 instead of directly to the circuit board 60 itself. In this embodiment, connective wires 64 connect the air control valves 34 to the pony board 100 , which is then connected to the circuit board 60 . The pony board 100 may be attached to the cover 31 of the manifold 30 by screws. This pony board 100 includes connection ports 102 equal to the maximum number of air control holes 32 in the manifold 30 and an output arm 104 . In the embodiment shown in the FIGS., the pony board has seven connection ports 102 , equal to the number of air control holes 32 in the manifold 30 shown. Of course, the pony board 100 could include a different number of ports 102 to accommodate the number of holes 32 in the manifold 30 . The pony board 100 allows each air control valve connective wire 64 to be plugged into the pony board 100 instead of directly into the circuit board 60 , with a single output arm 104 running from the pony board 100 to the circuit board 60 . The output arm 104 provides for a single connection from the valves 34 to the circuit board 60 where multiple valves 34 are used, making connection of the pump 10 components faster and easier. It also provides for faster and simpler external testing of the valves 34 and manifold 30 by allowing connection of the single output arm 104 of the pony board 100 to a separate testing unit.
[0041] Air control holes 32 into which air control valves 34 are inserted can be a source of air leaks, and the system can be optimized using air control valves 34 that form a strong seal with the manifold 30 . FIGS. 18-20 show an embodiment of a manifold 30 in which the air control valves 34 form a strong seal with the manifold overmolding 99 to avoid such air leaks. The air control valve 34 in FIGS. 18-20 is a solenoid assembly 82 . The solenoid assembly 82 shown includes a solenoid coil 83 , a solenoid frame 84 , a retaining clip 85 , a first solenoid o-ring 86 , a plunger stop 87 , a carrier sleeve 88 , carrier overmolding 89 , a plunger 90 , a return spring 91 , and a second solenoid o-ring 92 . The solenoid coil 83 is typically an electrical wire coil attached to an electrical source. The solenoid frame 84 can be made from any material permeable to magnetic flux and is preferably made from steel. The carrier sleeve 88 may be made from any non-magnetic metal but is preferably made from copper or brass. The carrier overmolding 89 may be made from any non-magnetic material, and preferably is made from a high temperature resistant thermoplastic. The plunger stop 87 and plunger 90 is preferrably made from a high quality, high magnetically permeable iron with limited residual magnetic retention properties. The first solenoid o-ring 86 and the second solenoid o-ring 92 can be made from a variety of types of temperature resistant rubber or plastic, including nitrile. The retaining clip 85 and return spring 91 could be made from any suitable material including, but not limited to, a variety of metals, plastic, or rubber. The return spring 91 should be made from high temperature, non-magnetic material, such as 302 Stainless Spring Wire.
[0042] Further detail of the solenoid assembly 82 is shown in FIG. 19 . In the solenoid assembly 82 shown, the plunger stop 87 is positioned partially within the carrier sleeve 88 . There are two grooves around the mid-section of the plunger stop 87 that form two moats, namely the first moat 94 and second moat 95 , between the plunger stop 87 and the carrier sleeve 88 . These moats are filled with a sealant to provide a strong seal between the plunger stop 87 and the carrier sleeve 88 . Whatever sealant is used should be able to withstand high temperatures since temperatures in the solenoid assembly 82 may be significant, for example, around 85-90° C., depending on the frequency and duration of the operation of the system. Many suitable sealants could be used, but a particularly effective sealant is Loctite® branded 620, a selant from Henkel Corporation, which is specifically designed for high temperature environments. During assembly, the carrier sleeve 88 is dipped in the sealant and swaged onto the plunger stop 87 ; this causes the sealant to fill the moats, sealing the assembly.
[0043] The plunger 90 also fits partially inside the carrier sleeve. The plunger 90 has a plunger head 93 that is screwed or otherwise attached into the end of the plunger that is opposite the plunger stop. The plunger head 93 is shaped such that it blocks the valve seat 96 into which it is inserted when the plunger 90 is in a closed position. The return spring 91 surrounds the plunger 90 and is compressed when the plunger 90 is in a closed position so that no air can pass when the solenoid assembly 82 is not energized.
[0044] A carrier overmolding piece 89 surrounds the outside of the carrier sleeve 88 on the end of the carrier sleeve that surrounds the plunger 90 . The carrier overmolding 89 is threaded such that it can be screwed into or connected to the air control hole 32 , which is threaded or otherwise shaped to receive the carrier overmolding and solenoid assembly 82 . The first solenoid o-ring 86 and second solenoid o-ring 92 are positioned on each side of the carrier overmolding 89 and compressed to form seals that prevent air leaking from the air control hole pathway. The first solenoid o-ring 86 is compressed between the carrier overmolding 89 , carrier sleeve 88 , and the solenoid frame 84 . The second solenoid o-ring 92 is compressed between the air control hole 32 and the carrier overmolding 89 . This system of employing moats, sealant between the carrier tube and plunger stop, and compressed o-rings 86 , 92 on either side of the carrier overmolding 89 creates a reinforced seal between the carrier sleeve and the plunger stop 87 . The default position for the solenoid assembly and in particular the plunger head 93 is that the return spring 91 will be compressed and the plunger head 93 will be blocking the air control hole 32 due to pressurized contact between the plunger head 93 and the valve seat 96 . When the solenoid coil 83 is energized, the plunger 90 will be retratcted until stopped by the plunger stop 87 , therefore opening the valve seat 96 and allowing air to pass through the manifold chamber 27 , through the interior space of the air valve 39 , and through the zone tubing 38 . Other sealing methods and air control valves and devices could be used to seal air pathway around the air control valves 34 and control the flow of air into the manifold as well.
[0045] The combination of compressed first and second soleinoid o-rings 86 , 92 , compressed manifold gasket 28 , and sealant-filled first and second moats 94 , 95 creates a reinforced sealed manifold. This reinforced sealing isolates the manifold chamber 27 from outside of the manifold, which acts as a redundant seal for zone tubing 38 , even in the event of a leak at the seal created by plunger head 93 and valve seat 96 .
[0046] Although the invention has been herein described in what is perceived to be to most practical and preferred embodiments, it is to be understood that the invention is not intended to be limited to the specific embodiments set forth above. Rather, it is recognized that modifications may be made by one of skill in the art of the invention without departing from the spirit or intent of the invention and, therefore, the invention is to be taken as including all reasonable equivalents to the subject matter of the appended claims and the description herein. | A multiple configuration air mattress pump system is disclosed. The pump system includes a number of standard components with a few inexpensive varied components to allow for easy and less expensive use of the pump with mattresses having varying numbers of inflatable zones. An improved sealed manifold is also disclosed. | 5 |
FIELD OF THE INVENTION
This invention relates to a device for moving a cloth clamp under which tailoring cloths are pressed to be sewn on a sewing work table. Particularly, this invention relates to a mechanism for moving a cloth clamp or a presser foot to accommodate variations in density of the sewing operation including, for instance, condensed stitch at an end in a pocket formation on a fabric suit.
BACKGROUND OF THE INVENTION
A cloth clamp set in an automatic sewing machine is normally required to vary the speed at which the cloth clamp travels so that a stitch needle is able to make a halt stitch (or stop stitch) and a condensed stitch at the start and end of a travel, as well as stitch with an acceptable sewing speed in a normal manner. Further, movement of the cloth clamp with a high speed is desired while the stitch needle is idle or out of stitch service.
Conventional devices proposed in connection with the above art have been designed including extremely complex electro-mechanical elements having especially designed solenoid-operated valves which are necessary to control oil flow through a number of by-pass lines. Therefore, individual parts of such devices had to be of high grade. The finished mechanism then became, as a whole, so intricate that such conventional devices are only employed in the manufacture of highly priced gentleman's suits. But, because of the high grade parts, employment of such conventional devices has been difficult in tailoring lower priced fabric products, for instance, working uniforms. This difficulty has prevented the popularizing of such an automatic sewing machine in the tailoring business.
SUMMARY OF THE INVENTION
The principal object of this invention is to provide a simple electro-mechanical circuit useful for moving a cloth clamp in accordance with the necessary variations in stitch speed to be met in a sewing cycle. The circuit comprises a drive cylinder and associated piston where one side space of the piston is filled with hydraulic oil and the other by a gas such as air. In particular, one directional stroke (a backward stroke) of the piston, irrespective of stitch operation, introduces the hydraulic oil or non-compressible medium into circuit pipes and a reciprocal stroke thereof (a forward stroke) for performing the stitch work is actuated by a compressible medium which is counterbalanced by the working hydraulic oil. Then, simple control elements are utilized to define a plurality of branches to readily achieve different desired speeds of the cloth clamp.
Other features and advantages available from this invention will be apparent from the following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a main mechanical layout including a cloth clamp and a sectional view in part.
FIG. 2 is a diagram for a control circuit to operate the clamp.
FIG. 3 is a speed-time chart of the clamp during an exemplary travel.
These drawings are presented by way of illustrating specific embodiments of the invention. Therefore, these should not be construed as limiting the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereinbelow, the invention will be detailed with reference to a preferred embodiment illustrated in the drawings.
In FIG. 1 a slide carriage 1 is shown for holding a cloth clamp 2 which is disposed to press tailoring cloths (not shown) on a work table (T). Cloth clamp 2 is slidably guided with the aid of a guide rail 3. A drive cylinder 4 is secured horizontally at almost the same level as carriage 1. A piston 4a is reciprocably set or engaged in cylinder 4, and piston 4a is connected at one end with carriage 1. Carriage 1 is also provided with an extension 1' having a length comparable with two control points in a travel, which will be referred to hereinlater, in the direction parallel to guide rail 3 or the sliding movement of carriage 1. Two projections or blocks 12, 12' are mounted, respectively, at the front and back end of the extension 1' with a space therebetween. As will be described later, blocks 12, 12' are adapted to engage and to turn angularly a contact switch 11' of a check valve 11. Arrow Ar in FIG. 1 indicates the forward direction in the same way as in FIG. 2.
In FIG. 2, a five port three position solenoid operated valve 6 is used to supply and to exhaust pressurized air from an air source 6' to two different service points, namely, an oil accumulator 5 and a pneumatic side 4b of cylinder 4 via lines Pf, Pb respectively. Accumulator 5 is arranged to actuate hydraulic pipe lines or a hydraulic circuit 7 entering into an oil side 4c of cylinder 4 via branched or shunted routes.
A first branch route (which will be noted as a backward route) is the line formed of line portions P2, P3 and Pl. A check valve 8 is disposed in line portion P3 to permit a flow as indicated by an arrow Al to cause a backward movement of piston 4a. A second branch route (which will be noted as a low and intermediate route) is the line formed of lines P2, P4, and Pl, which permits a flow as indicated by an arrow A2. A two part two position solenoid operated valve 9 is disposed on line portion Pl and disposed on line portion P4 is a flow control valve 11. Flow control valve 11 is equipped with a throttle valve lla and a check valve llb in parallel, and also with angularly turnable contract switch 11' discussed above and also shown in FIG. 1. A third branch route (which will be noted as a high speed route) is formed of line portions P2, P5 and Pl to permit a flow as indicated by an arrow A5. Solenoid valve 9, noted above, and another one solenoid valve 10 of the same type are disposed on line portion Pl.
As will be understood from the following description, a backward movement of piston 4a is merely a stroke or a movement for a reset action of cloth clamp 2. This movement serves to supply hydraulic oil back into circuit 7 as well as cylinder oil side 4c as a whole. On the other hand, a forward movement thereof (the direction of the arrow Ar) is for moving cloth clamp 2 utilizing electro-mechanical functions of the invention.
Referring now to FIG. 3 which shows a typical speed variation in time for cloth clamp 2, a time portion of (I) to (II) is a preliminary time of movement up to a stitch job which stitch job is indicated by the next time portion of (II) to (III), and the last time portion of (III) to (IV) is a movement after finishing of the stitching and wherein:
H1 is a high speed travel without stitch,
L1 is a low speed approach to a stitch start without stitch,
S1 is a halt stitch at the stitch start (II),
L2 is a condensed stitch with a low speed,
M is a normal stitch with an intermediate speed,
L3 is a low speed condensed stitch near the end,
S2 is a halt stitch at the end (III),
H2 is a high speed travel without stitch work.
The operation of the present invention is hereafter explained with reference to the operations and behaviors of cloth clamp 2 and related elements in connection with the movement thereof as shown in FIG. 3. At the start of the movement (I), piston 4a has been brought to the backward position in cylinder 4 by a reset action in the previous cycle and valve 6 is set to supply air to cylinder side 4b. Then, piston 4a is allowed to start moving with a high speed (H1) by the action of opening the two serial valves 9, 10. At the end of high speed travel (H1), contact element 11' engages with projection 12. This effects closure of valve 10 to stop the flow of oil through the third route and the opening of throttle valve lla which provides a reduced flow path for the oil to use the second route and thus for cloth clamp 2 to move at the low speed (L1).
At the stitch start (II), valve 9 is controlled by a timer device (not shown) to close for time (S1). When valve 9 is closed, cloth clamp 2 is stopped and the.halt stitch is allowed. It should be appreciated that FIG. 1 shows slide carriage 1 positioned at the halt stitch stage. Next, cloth clamp 2 is moved forward at low speed (L2) when time S1 expires. The moment that switch 11' is disengaged, the throttle effect of check valve 11 is lost so that cloth clamp 2 then moves at the speed of the intermediate level (M). The next action is re-engagement of switch 11 and the projection 12', which again causes increased throttling of throttle valve 11a and which reduces the speed of cloth clamp 2 down to the low level (L3). Finally, cloth clamp is stopped for the halt stitch (S2) by the timer device (not shown).
At the stitch end (III), valve 10 is opened and cloth clamp 2 is sent to the travel end (IV) with a high speed (H2). Thus, one forward cycle is completed by the above sequence. Then, piston 4a is moved backward or reset by action of valve 6 in preparation of the next cycle.
It is believed that the descriptions hereinabove have disclosed the invention in detail such that various advantages are apparent. One such advantage is that during the forward travel, the actuating or supplying medium is pneumatic air and the exhausting medium is hydraulic oil. Thus, the setting of a stop point and speed control for the cloth clamp are accomplished with high accuracy with relatively simple electro-mechanical elements in the present invention. Another advantage is that the electro-mechanical elements included in the invention are those readily available in the market. In addition, the inventive control device may be manufactured in such a compact apparatus that sewing machines intended for popular tailoring products are able to employ the inventive device.
It is further understood by those skilled in the art that the foregoing descriptions are directed to a preferred embodiment of the disclosed device and that various changes and modifications may be added to the invention without departing from the spirit and scope thereof. | A device for moving a cloth clamp in an automatic sewing machine with desired speed variations which are necessary to change stitch densities during a sewing travel, wherein the speed variation is attained by arranging a hydraulic-pneumatic circuit including solenoid operated valves and other control elements in branched routes. | 3 |
DESCRIPTION
The present invention relates to a cardiac valve prosthesis and more particularly refers to a mechanical cardiovascular valve of the type comprising a plurality of leaflets as means for closing and opening the valve.
It is well known in the cardiovascular medical technology to provide heart valve prothesis designed to replace defective and/or diseased natural cardiac valves. A cardiac valve must allow the blood flow to freely circulate there through when in an open position and must prevent blood back flow through the valve when the same is closed. These are basically the functions of a natural cardiac valve and the same objectives must be accomplished by any prosthetic heart valve. Many shortcomings and drawbacks of the several attempts made to obtain a heart valve prosthesis have caused to fail in providing a mechanical valve capable of resembling a natural heart valve and complying with the functions thereof. This is mainly due to the fact that the fluid under processing, the blood, is not a fluid like any other one, instead, the blood is a very delicate tissue that is able to be spoiled by even minor undue treatment caused, for instance, by turbulence and high shear stresses in the flow that can either produce thrombosis or emboli at local regions of stagnation, for example.
Several prosthetic heart valve mechanisms have been developed in an attempt to comply with the above remarked requirements without the mentioned drawbacks and failures. These valves typically are comprised of a valve body that accommodate valve members such as a single occluder or a plurality of occulders consisting of articulated or pivoting leaflets, for example. In other types of valves the occluder consists of a ball located in a cage, also known as ball-in-cage valves, wherein the ball is capable of seating against a seat of the valve body to close the pass through the valve, and moving away from the seat to open the valve. In some valves, members are provided that are capable of pivoting around fixed shafts or movable shafts, and some valves have been developed to have some freedom by altering the leaflet position relative to the central axis of the valve, always to improve the desired washing effect of such areas where the blood flow is zero and the blood remains stationary, also known as “dead areas”.
U.S. Pat. No. 4,274,437 to Lens S. Watts discloses a heart valve prosthesis comprising leaflets that both pivot and gradually orbit about an axis of the valve thus eliminating localized wear which otherwise occur at the locations in the valve body against which the rotating pivot would bear. It is not clearly disclosed, however, how the necessary forces are generated and applied to the leaflets for producing the orbiting about the axis of the valve. Moreover, leaflets do not open fully and there is no solution provided for eliminating turbulence and drag forces when the valve is open.
U.S. Pat. No. 5,197,980 to Jury V. Gorshkov discloses a cardiac valve prosthesis having valve members that open and close freely and rotate simultaneously around the body axis. The object of this invention is to produce additional back swirling of the blood flows forcing the valve members to rotate about the body axis and to intensively flush the prosthesis components by means of forward and reverse blood flows, thereby effectively improving the resistance to a thrombus formation. Again, this valve does not open in a fully mode to provide complete pass to the blood and does not provide a solution to the prevention of turbulence and drag forces when the valve is open.
U.S. Pat. No. 5,861,029 to Sergey Evdokimov discloses a heart valve prosthesis having leaflets with an additional degree of freedom, wherein the leaflets have the possibility of rotating around a central axis of an annular body. The problem underlying the invention is to create a heart valve prosthesis comprising a hinge mechanism that holds the leaflets within the valve body. This patent attempts to prevent thrombus formation by eliminating localized stagnation zones inaccessible to blood washing, and improve the hemodynamic characteristics of the valve prosthesis and extend its lifetime. This valve does not provide a full opening thereof and does not provide a solution to the turbulence and drag forces when the valve is open.
It is well known that the key of a hemodynamic flow in a natural valve is the ability to produce non turbulent flow. Natural valves open fully to provide a complete section pass and offer little or no resistance to the flowing fluid. There are no dead areas wherein blood flow stagnates and may coagulate. Further, there are no areas of turbulent flow that can damage the red blood cells and the platelets.
Unfortunately, the prior art valves still suffer from dead areas and turbulent flow. In the fully open position leaflets form an angle with the flow to assure proper closing of the valve upon dropping of the blood pressure and reversing of the blood flow during the diastolic movement of the cardiac cycle. Alternatively, the leaflets may hang parallel to the blood flow in the open position but with their downstream edges curved slightly to favour closing during diastolic cycle.
The dilemma is that a rapid valve closure has been obtained till now at the price of more turbulence and drag forces.
It is therefore an object of the present invention to provide a mechanical valve with minimal or no turbulence and minimal or no drag forces generated in the open position of the valve during the systolic pulse of the heart cycle.
It is still another object of the present invention to provide a mechanical heart valve having at least two leaflets rotating around a central axis of an annular body of the valve when the valve is not in a closed position.
Accordingly, the present invention provides a prosthetic heart valve comprising an annular body having an inner surface and an outer surface and defining a central axis of the annular body, at least two leaflets pivotally mounted to said annular body, the leaflets including pivoting means connecting the leaflets together and to the inner surface of the annular body, the pivoting means defining a pivoting axis dividing each leaflet in two sectors, one sector larger than the other, whereby the blood flow impinging onto the larger sector of each leaflet causes the leaflet to pivot around the pivoting axis and rotate around the central axis so as to define a uniform and axial flow in the blood passing through the valve.
It has been found that leaflets rotating around the central axis of the annular body are effective to eliminate the turbulent flow and drag forces when the valve is not in the closed position.
Preferably, the pivoting axis extends normally to the central axis.
The pivoting means may also comprise a central axis shaft connected to the annular body, a rotary sleeve freely mounted around the central shaft, the sleeve having radially extending pins, and each leaflet being rotatably mounted to each pin whereby each pin defines the pivoting axis for the associated leaflet.
The above and other objects, features and advantages of the present invention will be better understood when taken in connection with the accompanying drawings and description.
The present invention will now be illustrated by way of example only to the accompanying drawings in which:
FIG. 1 is a top plan view of a heart bi-leaflet valve in accordance with the present invention, shown in the closed position;
FIG. 2 is a perspective top view of the bi-leaflet valve of FIG. 1, shown in the closed position;
FIG. 3 is a top perspective, partially cross-sectioned, view of the valve in accordance with the present invention, shown in an open position;
FIG. 4 is a side diametrical cross-section view taken along a plane, perpendicular to a common pivoting axis of the leaflets, of the valve in accordance with the present invention, shown in the open position;
FIG. 5 is a side partial cross-section view of the valve of the present invention, shown in the open position;
FIG. 6 is a side diametric cross-section view of a valve in accordance with an alternative embodiment of the present invention, shown in the closed position; and
FIG. 7 and FIG. 8 are respective top plan views of alternative embodiments of the present invention with three and four leaflets, shown in the open position.
Now referring in detail to the drawings it may be seen from FIGS. 1, 2 a heart valve according to the invention comprising an outer annular body 1 , preferably an axis-symmetrical body and more preferably a cylindrical body defining an outer surface 2 and an inner surface 3 , housing two leaflets 4 , 5 pivotally mounted in body 1 , preferably on inner surface 3 . Each leaflet 4 , 5 has a semi-circular shape with a circular periphery 6 , 8 and an inner edge 7 , 9 with the inner edges of the leaflets abutting each other to perfectly close the pass through the valve when the valve is, as illustrated in FIGS. 1 and 2, in the closed position. Leaflets 4 , 5 are pivotally connected to each other and to body 1 by means of pivoting mens comprising a pivoting axis shown in phantom lines and indicated by reference number 10 . Annular body 1 defines a central axis 11 passing by the centre of the cylindrical body and the intersection of edges 7 , 9 and pivoting axis 10 .
Axis 10 may comprise a pivoting shaft 12 extending through the leaflets, passing along respective orifices 13 (see FIG. 5) formed in the leaflets. Shaft 12 may comprise any kind of rod or wire made of a proper medical material, such as a metal. Shaft 12 may comprise a continuous elongated piece extending along the entire diameter of the valve or may comprise separate pieces each one extending in the corresponding leaflet. In any event it is convenient that shaft 12 has opposite ends 14 , 15 protruding from the peripheral edges 6 , 8 of the leaflets, the ends 14 , 15 defining a pivoting mounting in the inner surface 3 of the body 1 , preferably ends 14 , 15 will be freely housed in a continuous groove 16 formed in inner surface 3 , whereby shaft 12 may move along the entire circumference of the groove.
Pivoting axis 10 crosses edges 7 , 9 of the leaflets forming an acute angle a whereby each leaflet is divided into two sectors, one sector A being larger than the other sector B. Therefore, when the valve is fixed to a blood vessel the blood flow, indicated by arrow F in FIG. 5, impinging onto the leaflets will generate on larger sectors A respective forces larger than the forces resulting from the blood flow onto sectors B. This will result in that the hydraulic torque about axis 10 due to sectors A being larger than the hydraulic torque about axis 10 due to sectors B. This causes the leaflets to pivot around the pivoting axis in a pattern as it is illustrated in FIGS. 3 to 5 , with the larger sectors A moving in the sense of the blood flow and sectors B rotating against the blood flow. Under these circumstances, the leaflets behave like a fan under the wind action, or a propeller, thus rotating around central axis 11 , as indicated by arrow R in FIG. 5, whereby the leaflets define a rotation in a pattern to define an axial and uniform flow in the blood passing through the valve, as indicated by arrows F. The rotation and opening movement velocity of the leaflets will be inversely proportional to the value of angle α. FIG. 4 shows a diametrical section taken along a plane perpendicularly passing through the shaft 12 to illustrate the opening pattern of the leaflets.
FIG. 6 shows another embodiment of the present invention wherein the valve comprises an annular body 20 defining an inner surface 21 including a continuous shoulder 22 forming a closing seat for leaflets 23 , 24 which are similar to the leaflets shown in FIGS. 1 to 5 but differing therefrom in the mounting of the leaflets on the body. According to this embodiment, a support 25 is fixed to body 20 and a central axis shaft 26 is provided at a central portion of support 25 . A sleeve 27 is freely mounted on shaft 26 and is free to rotate around shaft 26 and axially move along shaft 26 up to a stop 28 . Sleeve 27 has two or more pins 29 radially extending from the sleeve. Pins 29 may be connected to a sleeve 27 in a way that can rotate relative to the sleeve or may be fixed to the sleeve. In the latter case where the pins are firmly fixed to the sleeve, each pin will be inserted into a respective leaflet 23 , 24 in such a way that the associated leaflet is capable of rotation around pin 29 , thus each pin defining the pivoting axis for the associated leaflet.
FIG. 7 shows another alternative of the valve of the invention, showing a valve body 30 comprising three leaflets 31 , 32 , 33 pivotally mounted in associated pivoting axis 34 , 35 , 36 by means of any of the above described and mentioned pivoting and mounting means.
FIG. 8 shows another alternative of the valve of the invention, showing a valve body 40 comprising four leaflets 41 , 42 , 43 , 44 pivotally mounted in associated pivoting axis 45 , 46 , by means of any of the above described and mentioned pivoting and mounting means.
According to the invention, it has been found that when the valve is in the open position blood flow pressure onto the leaflets produces a torque around central axis 11 that causes the leaflets to rotate as shown in FIG. 5, when the blood flow circulates in an axial and uniform pattern, as it is also shown in the drawings (FIG. 5 ).
The angular velocity of the leaflets around the central axis 11 is inversely proportional to the opening angle of the leaflets.
The continuous fluid flow behaviour through a valve with leaflets rotating around the central axis of the valve body is mathematically defined by the Euler equation. According to Euler, the torque on leaflets 4 and 5 due to the hydraulic forces is proportional to the variation of the tangential component of the fluid velocity. The Euler equation is: ( R · C u ) 1 - ( R · C u ) = η g · H ω
where,
Ω=angular speed of the leaflets;
R=radius of a flow surface;
C u =tangential component of absolute velocity;
H=pressure drop;
g=acceleration due to gravity;
η=efficiency;
index 1 is used for the valve inlet;
index 2 is used for the valve outlet;
The torque M on the leaflets is: M = η g · H ρ Q ω
where
ρ=blood specification mass
Q=flow discharge
If the Euler equation is multiplied by ρQ, then: ρ Q [ ( R · C u ) 1 - ( R · C u ) 2 ] = η g · H ρ Q ω
Or
ρ Q [( R,C u ) 1 −( R,C u ) 2 ]=M
Since the tangential component of the blood flow at the valve inlet is 0 (zero), and the torque on the leaflets is 0 (zero), when the leaflets are rotating freely around the central axis, then:
( R,C u ) 1 =0
M =0
Therefore, the tangential component at the outlet must be 0 (zero).
( R,C u ) 2 =0
This is to demonstrate that, thanks to the leaflets rotation the blood exits the valve without a tangential flow component, that is, the blood flow exiting the valve is not helical, but is uniform and axial.
Therefore, the fluid uniformly flows through the valve and the drag forces due to static prior art leaflets disappear. There is a decrease of pressure drop and a dramatic reduction of blood damage and blood clotting. Given that the leaflets rotate around the central axis of the valve, there are no dead areas where, like in the prior art, the blood would remain stationary, and the desired washing effect is continuous during the open mode of the valve.
The present invention provides a mechanical heart valve with rotating leaflets when the valve is not in the closed position.
While preferred embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined in the appended claims. | A multi-leaflet cardiovascular valve having a generally annular valve body ( 1 ) and at least two leaflets ( 4, 5 ) mounted within the valve body such that the leaflets rotate around a central axis ( 11 ) and a transverse pivoting axis ( 12 ) between an open configuration wherein blood is permitted to flow through the annular valve body and a closed configuration wherein blood is prevented from flowing in at least one direction through the annular valve body. During the open configuration, the leaflets rotate around the flow axis. | 0 |
REFERENCE TO PRIOR APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 13/180,227, filed Jul. 11, 2011, now pending, which is a continuation of U.S. application Ser. No. 12/488,427, filed Jun. 19, 2009, which is issued as U.S. Pat. No. 7,990,125 on Aug. 2, 2011, which is a continuation of U.S. application Ser. No. 12/052,609, filed Mar. 20, 2008, which is issued as U.S. Pat. No. 7,567,070 on Jul. 28, 2009, which is a continuation of U.S. application Ser. No. 11/732,209, filed Apr. 2, 2007, which issued as U.S. Pat. No. 7,359,225 on Apr. 15, 2008, which is a continuation of U.S. application Ser. No. 11/179,144, filed Jul. 11, 2005, which issued as U.S. Pat. No. 7,215,107 on May 8, 2007. U.S. patent application Ser. No. 13/180,227 and U.S. Pat. Nos. 7,990,125, 7,567,070, 7,359,225, 7,215,107 are hereby incorporated by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] The present invention relates generally to electronic circuits, and more specifically, the invention relates to switched mode power supplies.
[0004] 2. Background Information
[0005] A typical requirement for power supplies of electronic equipment is that they limit their output power. One reason to limit output power is to meet the requirements of safety agencies for prevention of personal injury. Another reason to limit output power is to avoid damage to electronic components from an overload.
[0006] Power supplies typically have self-protection circuits that respond when an output becomes unregulated for a specified time. However, if output power is not limited, a fault at a load can consume enough power to cause damage or to exceed regulatory requirements while the outputs remain regulated. Thus, the self-protection feature can be ineffective if the power supply can deliver too much power.
[0007] A common way to limit output power of a switching power supply is to limit the current in a power switch at the input of the power supply. The maximum output power is related to the peak current in the switch. Inherent delays in the responses of electrical circuits create an error between the desired limit for peak current in the switch and the actual maximum peak current in the switch. The error is greater at higher input voltages, causing the maximum output power to be greater at higher input voltages than it is at lower input voltages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention detailed illustrated by way of example and not limitation in the accompanying Figures.
[0009] FIG. 1 is a functional block diagram of one embodiment of a switching power supply that may limit output power in accordance with the teaching of the present invention.
[0010] FIG. 2 is a graph of power capability for one embodiment of a switching power supply with respect to the peak current of the switch.
[0011] FIG. 3 shows waveforms of the current in the switch for one embodiment of a switching power supply in accordance with the teaching of the present invention.
[0012] FIG. 4 shows parameters of timing signals with parameters of the current in a switch of a power supply that may limit output power in accordance with the teaching of the present invention.
[0013] FIG. 5 is a flow diagram that illustrates a method to limit output power of a switching power supply in accordance with the teaching of the present invention.
[0014] FIG. 6 shows timing signals with waveforms of the current in a switch of a switching power supply to illustrate operation of one embodiment of the present invention.
[0015] FIG. 7 is a functional block diagram of one embodiment of the present invention that includes the power switch in an integrated circuit.
DETAILED DESCRIPTION
[0016] Embodiments of a power supply regulator that may be utilized in a power supply are disclosed. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one having ordinary skill in the art that the specific detail need not be employed to practice the present invention. Well-known methods related to the implementation have not been described in detail in order to avoid obscuring the present invention.
[0017] Reference throughout this specification to “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 present invention. Thus, the appearances of the phrases “for one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0018] As will be discussed, the power from a switching power supply may be limited according to embodiments of the present invention by limiting the current in a switch of the power supply. For one embodiment, a switch is coupled to an energy transfer element of a power supply with a controller generating a drive signal to control switching of the switch to regulate the output of the power supply. The controller includes a current limiter, which will adjust the drive signal to limit a current though the switch to a variable current limit value. For one embodiment, the current limiter based on the input line voltage of the power supply sets the variable current limit value. For example, the variable current limit may be to a nominal current limit value for nominal or a low input line voltage. If, however, the input line voltage is relatively high, then the variable current limit is set to a reduced current limit value in accordance with the teachings of the present invention. For one embodiment, the controller deduces the magnitude of the input voltage by measuring how long the current takes to go between two values and the variable current limit is then adjusted accordingly.
[0019] The variable current limit value for the switch is adjusted according to the input voltage of the power supply to compensate for a delay between the time when the current reaches the current limit and the time when the switch turns off. A lower value of current limit for higher input voltages prevents excess output power at high input voltage. For one embodiment, input voltage may be determined indirectly from a measurement of time to reach current limit from an initial value of zero current when the power supply operates in discontinuous conduction mode. In general, a design can deliver a required output power and also limit the maximum output power over the operating range of input voltage by compensating for the error between desired maximum peak current in the switch and the actual maximum peak current in the switch.
[0020] As will be discussed, a measurement of time is used to determine an appropriate adjustment of the desired maximum peak current in the switch to meet the requirements of the design. A current limit threshold for a switch is adjusted in response to a measurement of time during the conduction of the switch to compensate for the undesirable influence of input line voltage on the actual peak current in the switch. For instance, a relatively high input line voltage is indicated for an embodiment of the present invention if an over current condition is identified during a first switching cycle after a skipped switching cycle of the switch.
[0021] As will be discussed, it is likely that the power supply will operate in a discontinuous conduction mode of operation in the first switching cycle after a skipped switching cycle. In this situation, the energy in the energy transfer element typically goes to zero before the switch turns on in the next switching cycle. Therefore, if an over current condition occurs during this first switching cycle with the energy in the energy transfer element initially at zero at the beginning of the switching cycle, a high input line condition is indicated, and the variable current limit is set accordingly to the reduced value in accordance with the teachings of the present invention. If, on the other hand, an over current condition is not identified in the first switching cycle after a skipped switching cycle of the switch, then it is assumed that the input line voltage of the power supply is nominal or relatively low, and the variable current limit is set accordingly to the nominal value in accordance with the teachings of the present invention.
[0022] To illustrate, FIG. 1 shows a functional block diagram of a power supply that may include an embodiment of a method that limits peak switch current in accordance with the teachings of the present invention. The topology of the power supply illustrated in FIG. 1 is known as a flyback regulator. It is appreciated that there are many topologies and configurations of switching regulators, and that the flyback topology shown in FIG. 1 is provided to illustrate the principles of an embodiment of the present invention that may apply also to other types of topologies in accordance with the teachings of the present invention.
[0023] As illustrated in the power supply example of FIG. 1 , an energy transfer element T 1 125 is coupled between an unregulated input voltage V IN 105 and a load 165 at an output of the power supply. A switch S 1 120 is coupled to the primary winding 175 at an input of energy transfer element 125 to regulate the transfer of energy from the unregulated input voltage V IN 105 to the load 165 at the output of the power supply. A controller 145 is coupled to generate a drive signal 157 that is coupled to be received by the switch S 1 120 to control switching of switch S 1 120 . In the example of FIG. 1 , the energy transfer element T 1 125 is illustrated as a transformer with two windings. A primary winding 175 has N P turns with an inductance L P . A secondary winding has N S turns. In general, the transformer can have more than two windings, with additional windings to provide power to additional loads, to provide bias voltages, or to sense the voltage at a load.
[0024] A clamp circuit 110 is coupled to the primary winding 175 of the energy transfer element T 1 125 to control the maximum voltage on the switch S 1 120 . In one embodiment, switch S 1 120 is a transistor such as for example a power metal oxide semiconductor field effect transistor (MOSFET). In one embodiment, controller 145 includes integrated circuits and discrete electrical components. The operation of switch S 1 120 produces pulsating current in the rectifier D 1 130 that is filtered by capacitor C 1 135 to produce a substantially constant output voltage V O or a substantially constant output current I O at the load 165 .
[0025] The output quantity to be regulated is U O 150 , that in general could be an output voltage V O , an output current I O , or a combination of the two. A feedback circuit 160 is coupled to the output quantity U O 150 to produce a feedback signal U FB 155 that is an input to the controller 145 . Controller 145 also includes a current sensor coupled to receive current sense 140 that senses a current I D 115 in switch S 1 120 . Any of the many known ways to measure a switched current, such as for example a current transformer, or for example the voltage across a discrete resistor, or for example the voltage across a transistor when the transistor is conducting, may be used to measure current I D 115 . The controller may use current sense signal 140 to regulate the output U O 150 or to prevent damage to the switch S 1 120 .
[0026] FIG. 1 also shows an example waveform for current I D 115 . During any switching period T S 190 , switch S 1 120 may conduct in response to drive signal 157 from controller 145 to regulate the output U O 150 . When current I D 115 reaches a current limit value I PEAK 195 after a time t ON 180 from the beginning of the switching period T S 190 , switch S 1 120 turns off and stays off for a time t OFF 185 , which is the remainder of the switching period T S 190 . The current waveform shows two fundamental modes of operation. The trapezoidal shape 170 is characteristic of continuous conduction mode (CCM) whereas the triangular shape 175 is characteristic of discontinuous conduction mode (DCM).
[0027] FIG. 2 shows how the peak current I PEAK 190 is related to the maximum output power of the power supply in FIG. 1 . In DCM, the output power increases as the square of I PEAK . In CCM, the output power increases linearly with I PEAK . The current limit value I PEAK is used to help limit the output power of the power supply. A difficulty in limiting the current limit value I PEAK is that there is always a delay between the time when the current reaches the limit and the time the switch turns off.
[0028] To illustrate, FIG. 3 shows how a delay influences peak current in the switch. In the example illustrated in FIG. 3 , I PMAX is the maximum desired value for I D . A controller having a current limit threshold I LIMIT1 that is the same value of I PMAX takes action to turn off the switch when I D exceeds I LIMIT1 . The unavoidable time delay t d allows I D to exceed I LIMIT1 by an amount ΔI DELAY that depends on the delay t d and on how fast I D is changing after it passes I LIMIT1 . A current limit I LIMIT1 produces a peak current I PEAK1 that is greater than the desired I PMAX . If the delay t d and the rate of change of I D are known, the current limit can be compensated to a lower value I LIMIT2 such that addition of ΔI DELAY will give a peak current I PEAK2 that is less than I PMAX .
[0029] A complication in the use of a lower current limit value to compensate for the delay is that in general ΔI DELAY will be larger at higher input voltages than at lower input voltages because I D increases at a greater rate when the input voltage is high. Therefore, a power supply that uses a single compensated current limit I LIMIT2 to limit maximum output power to the desired value at a high input voltage would have less than the desired maximum output power at low input voltage. Indeed, if the circuit to limit the power has only one desired limit for peak current such as I PEAK2 , a design that meets the requirement for maximum power at high input voltage may be unable to deliver the required power at low input voltage.
[0030] For one embodiment, a power supply may use a first compensated current limit I LIMIT1 at a low input voltage and a second compensated current limit I LIMIT2 at high input voltage to limit the maximum output power to a desired value over a wide range of input voltages in accordance with the teachings of the present invention.
[0031] To illustrate, FIG. 4 shows example timing signals that are used with the current I D for one embodiment of the invention to determine whether the current limit will be I LIMIT1 or I LIMIT2 . In particular, FIG. 4 shows two full switching periods, T 1 and T 2 of switch current I D with timing signals I LIM , I LIMMAX , and D MAX . In FIG. 4 , current limit signal I LIM is high whenever I D is greater than the current limit. Signal I LIMMAX is a timing reference that is compared to current signal I LIM to determine whether the current limit will be I LIMIT1 or I LIMIT2 . Signal D MAX sets the maximum on time of the switch. The switch is forced off when D MAX is high.
[0032] FIG. 5 is a flow diagram for one embodiment of a power supply controller that uses the timing signals of FIG. 4 in accordance with the teachings of the present invention. The flow starts at Block 505 when the switch is off. Block 510 sets a nominal current limit, which for one embodiment corresponds to I LIMIT1 in FIG. 4 , and is more suitable for a nominal or low input voltage. Block 515 interprets feedback signal U FB to determine whether the switch should turn on or remain off in the next switching period. If the switch is enabled, then Block 520 directs the switch to turn on in Block 525 . If the switch is not enabled, then Block 520 directs the switch to be off in Block 545 .
[0033] Once the switch is turned on, the state of the current limit signal I LIM is evaluated in Block 535 . The on time of the switch is compared to the maximum permissible on time in Block 540 . Block 545 turns off the switch immediately if I LIM is high or if the on time exceeds the maximum on time t D MAX . After the switch turns off, Block 550 directs the flow depending on whether the mode of operation was CCM or DCM when the switch turned on. The mode is DCM if the energy in the energy transfer element goes to zero before the switch turns on. In one embodiment, a single switching period with the switch disabled is sufficient to reduce the energy to zero. Therefore, in one embodiment, Block 550 has a memory of whether or not the switch was enabled during a previous switching period to determine the mode of operation at the start of the present switching period.
[0034] If the mode of operation was not DCM, the controller continues with the interpretation of the feedback signal in Block 515 . If the mode of operation was DCM, the flow is diverted to Block 555 . Block 555 compares the time to reach current limit against the reference time t LIMMAX . Although delays in practical circuits prevent exact measurement of the time t LIM to reach the current limit, it is sufficient to measure a signal that includes the delays for an approximate measurement of t LIM . For one embodiment, the sum of t LIM and delay t d , which is the on time t ON in FIG. 3 , is measured in Block 555 as an approximation to t LIM for comparison against the reference time t LIMMAX . When the operation is in DCM, the current can reach current limit in less time than t LIMMAX only if the input voltage is high in accordance with the teachings of the present invention.
[0035] If the time to reach current limit is less than t LIMMAX , the controller sets a reduced current limit in Block 530 . The reduced current limit for a high input voltage corresponds to I LIMIT2 in FIG. 4 . If the time to reach current limit is not less than the reference time t LIMMAX , then the controller sets the nominal current limit in Block 510 . The latter condition is also true when the switch turns off before the current reaches current limit, causing the controller to set the nominal current limit in Block 510 .
[0036] FIG. 6 shows several switching periods that illustrate operation according to the flow diagram of FIG. 5 . In Period 1 , the switch operates at a high input voltage when the current limit has been set at the nominal value I LIMIT1 that is appropriate for a nominal or low input voltage. The surplus energy from the high peak current at the high input voltage causes the controller to disable the switch in Period 2 . The controller detects a high input voltage condition from the short time to reach current limit in Period 3 , and sets the reduced current limit I LIMIT2 in Period 4 . The operation continues with the reduced current limit until the controller detects a period of DCM operation where the time to reach current limit is not less than the reference time t LIMMAX . In Period n, the switch is disabled and the input voltage is low. The controller has determined that the time to reach current limit in a period of DCM was not less than the reference time t LIMMAX . Consequently, the controller sets the current limit to the nominal value I LIMMAX in Period (n+1). The current does not reach current limit in Period (n+1) so the switch is turned off by maximum on time and the current limit remains at I LIMIT1 . The power supply operates in CCM at low input voltage and current limit I LIMIT1 in Period (n+2) and Period (n+3).
[0037] FIG. 7 shows one embodiment that includes a power switch 736 in an integrated circuit 700 . Power switch 736 is a MOSFET that conducts current between a drain terminal 702 and a source terminal 758 . Circuits internal to the integrated circuit are powered from an internal voltage V CC 705 that is referenced to source terminal 758 . For one embodiment, drain terminal 702 provides internal voltage V CC 705 . Internal voltage V CC may be provided from drain terminal 702 or from a different terminal of the integrated circuit by several techniques that are known to one skilled in the art.
[0038] A feedback terminal 754 receives a feedback signal U FB . A modulator 752 interprets the feedback signal U FB to set an enable signal 744 high or low. An oscillator 756 provides a clock signal 748 and a D MAX signal 746 to determine respectively the length of a switching period and the maximum on time of the switch 736 . Switch 736 may be on while D MAX 746 is low. Switch 736 is off while D MAX 746 is high. AND gate 740 sets latch 738 to turn on switch 736 with drive signal 757 at the beginning of a switching period if the enable signal 744 is high. OR gate 742 resets latch 738 to turn off switch 736 with drive signal 757 if switch current I D 706 exceeds the current limit or if signal D MAX 746 goes high.
[0039] Switch current I D 706 is sensed as a voltage V D that is compared to a current limit voltage V LIMIT by a comparator 704 . Resistor 732 with current sources 728 and 730 generates current limit voltage V LIMIT . Current source 730 is switched on and off by p-channel transistor 724 . In one embodiment, current source 730 is one-tenth the value of current source 728 . Thus, the current limit voltage V LIMIT increases by 10 per cent to make a nominal current limit 10 per cent higher than a reduced current limit when current source 730 is switched on.
[0040] The drive signal 757 that is output by latch 738 is delayed by leading edge blanking time t LEB delay 734 before being received by AND gate 708 . AND gate 708 receives the output of current limit comparator 704 and the output of leading edge blanking time delay 734 to provide an over current signal 760 . Leading edge blanking time t LEB delay 734 is long enough to allow switch 736 to discharge stray capacitance on drain terminal 702 . Discharge of stray capacitance at drain terminal 702 can produce a high drain current I D 706 that temporarily exceeds the current limit, but is unrelated to the output of the power supply. The leading edge blanking time t LEB delay 734 prevents the over current signal 760 from going high during a time t LEB after switch 736 turns on. Over current signal 760 in FIG. 7 corresponds to signal I LIM in FIG. 4 or FIG. 6 .
[0041] Flip-flop 750 remembers the state of enable signal 744 at the beginning of the switching period. Flip-flop 750 is clocked at the start of every switching period by the complement of D MAX signal 746 from inverter 720 . A change in the state of the clocked enable signal 745 from one switching period to the next switching period is detected by XOR gate 716 .
[0042] XOR gate 716 with delay 718 at one input receives the clocked enable signal 745 to set latch 714 whenever there is a change in the clocked enable signal 745 . Delay 718 is long enough to produce an output that sets latch 714 . In one embodiment, delay 718 is ten nanoseconds. Latch 714 is set at the beginning of a switching period whenever there has been a change in the state of the clocked enable signal 745 from the previous switching period.
[0043] Latch 726 is allowed to set if enable signal 744 is high at the beginning of the current switching period. Inverter 722 resets latch 726 if enable signal 744 is low at the beginning of the current switching period.
[0044] Latch 714 is set to indicate DCM operation in the present switching period. DCM is indicated when the output of latch 714 is high. Latch 726 is set to reduce the current limit.
[0045] In the embodiment of FIG. 7 , the maximum on time signal D MAX 746 is also the timing reference that is compared to over current signal L LIM 760 to determine whether the current limit will be I LIMIT1 or I LIMIT2 . In the embodiment of FIG. 7 , t LIMMAX =t DMAX , representing an embodiment where the signals I LIMMAX and D MAX of FIG. 4 are identical. For another embodiment, however, it is appreciated that t LIMMAX does not necessarily have to equal t DMAX in accordance with the teachings of the present invention, such as the example illustrated in FIG. 4 . Latch 726 will not be set if there is no over current condition detected or the current limit is not reached during the time when D MAX 746 is low. Thus, current source 730 remains switched on by transistor 724 if the over current condition is not detected in accordance with the teachings of the present invention.
[0046] It is appreciated that although FIG. 7 illustrates an integrated circuit 700 for an example of the present invention that employs a switching regulator that may skip switching cycles of power switch 736 in response to enable signal 744 , other examples of integrated circuits may also be covered in accordance with the teachings of the present invention. For example, a pulse width modulated (PWM) regulator circuit may also be covered in accordance with the teachings of the present invention. For instance, an example PWM controller deduces the magnitude of the input voltage by measuring how long the current takes to go between two values and then adjusts the variable current limit in accordance with the teachings of the present invention.
[0047] In the foregoing detailed description, the methods and apparatuses of the present invention have been described with reference to a specific exemplary embodiment thereof. It will, however, be evident that various modifications and changes may be made thereto without departing from the broader spirit and scope of the present invention. The present specification and figures are accordingly to be regarded as illustrative rather than restrictive. | An example power supply includes an energy transfer element, a switch, and a controller. The controller includes a modulator, a drive signal generator, a comparator, and a variable current limit generator. The modulator generates an enable signal having logic states responsive to a feedback signal. The drive signal generator either enables or skips enabling a switch of the power supply during a switching period in response to the logic state of the enable signal. The comparator asserts an over current signal to disable the switch if the switch current exceeds a variable current limit. The variable current limit generator sets the variable current limit to a first current limit in response to one logic state of the enable signal and sets the variable current limit to a second current limit if the enable signal transitions logic states and the over current signal is asserted during the switching period. | 7 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application relates to and claims priority from Japanese Patent Application No. 2002-234301, filed on Aug. 12, 2002, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a defect inspection method for manufactured products, and more particularly to a method for detecting defects in semiconductor products such as LSIs, TFTs, PDPs and thin-film display elements that require highly accurate defect detection, and relates to a method for evaluating these detected defects.
2. Description of the Related Art
As semiconductor design rules have become more detailed, the size of the manufacturing defects of semiconductor products has also become extremely small. The practice of detecting and reviewing defects by means of images detected using a conventional visible light source has grown difficult, and hence inspections and reviews of defects have come to be performed by using images detected by means of inspection devices employing DUV light as the light source, as well as images detected using SEM.
However, the increase in sensitivity afforded by using a DUV light source and SEM has frequently produced problems such as the detection of minute inconsistencies in the pattern not originally requiring detection, the detection of parts exhibiting thin film interference which is generated through the use of DUV light, the detection of locations which are targeted for charging by electrons that are emitted when an SEM image is picked up and so forth, or the detection of locations that were not originally defects.
As an example of a corresponding conventional technology, a method for determining, on the basis of localized correlations between a defect image and a reference image from inconsistencies in localized gray scale values generated between the defect image and the reference image, whether or not the resulting image constitutes a defect, is described in Japanese Patent Application Laid-Open No. 2001-77165, for example.
Furthermore, Japanese Patent Application Laid-Open No. 2000-105203 discloses a technology that involves calculating
scattering on the basis of the locations in which identical patterns were originally formed or of signals that are obtained through detection of regions in the vicinity of these locations, and then detecting defects from a signal detected on the basis of a determination reference which is established on the basis of the scattering thus calculated.
However, the above conventional technology has failed to adapt to the increased detail of the defects detected or to the increase in pattern detail.
For example, according to the technology disclosed by Japanese Patent Application Laid-Open No. 2001-77165, a correlation between the defect image and the reference image is found for each region in which the gray scale unevenness is different and then defects are detected on the basis of the correlations thus found. However, feature amounts such as texture and gray scale values, and so forth, are used as the means for performing segmentation into regions in which the gray scale unevenness is different. Consequently, reliable segmentation into regions in which the gray scale unevenness is different is problematic, no consideration having been paid to the problem that sections with varying degrees of gray scale unevenness belong within the same region, which is a possibility that results from such segmentation.
On the other hand, according to the method disclosed by Japanese Patent Application Laid-Open No. 2000-105203, although scattering is calculated on the basis of signals that are obtained by means of detection from regions in the vicinity of locations in which identical patterns were originally formed, this method does not take into consideration the elimination of grain effects which are most evident in the wiring step and so forth. Grains are a phenomenon that is clearly visible in the wiring step and constitute a phenomenon according to which there is a variation in the detected brightness of the wiring due to the wiring surface's possessing minute undulations. Grains are generated on the wiring alone, but are not limited by the generation, with the highest possible frequency, of a treatment with dispersion scattering amounts based on detection signals obtained from identical chip locations as described in Japanese Patent Application Laid-Open No. 2000-105203.
Although this problem is alleviated by enlarging the neighboring regions as per the above-described conventional technology, the problem exists that regions with different attributes then lie within neighboring regions. That is, in this grain example, even though there is a requirement to calculate the scattering of the original wiring pattern, the enlargement of the neighboring region results in the calculation of scattering that includes regions other than the wiring parts, which means that the scattering of the wiring pattern cannot be calculated. Hence, with the conventional technology, the higher the sensitivity of the inspection or defect observation method, the more locations that do not constitute defects are detected, and this technology has therefore been confronted by the problem that the detection and observation of the defects originally intended is problematic.
Furthermore, because the detection of defects is performed in one step, due to memory restrictions there is no other recourse but to assume that the calculation of scattering is performed using a Gaussian distribution and the like, and it has therefore not been possible to determine a complex scatter. Furthermore, because scattering using a Gaussian distribution is first found after an inspection of the entire wafer has been performed, it has not been possible to determine this scattering in the course of actually performing an inspection, and hence the threshold value could only be determined from the scattering at a point that lies several chips before the location ultimately inspected.
SUMMARY OF THE INVENTION
The present invention provides a defect detection or observation method that detects fine defects in the course of defect inspection and observation, avoids false detection of defects, and does not classify as a defect candidate a grain phenomenon or another phenomenon that does not affect a product.
In accordance with an aspect of the present invention, a method for inspecting defects of a product having a plurality of product units formed repetitively at different locations comprises obtaining an image of the product units on the product having an appearance to be observed; detecting regions of the image each having an appearance which differs from an expected appearance by greater than a preset threshold; calculating feature amounts for the detected regions; classifying the detected regions into groups of defect candidates, each group including defect candidates having similar or identical appearances, or defect candidates which are disposed at corresponding identical locations or adjacent locations on the different product units and have similar or identical appearances; forming an aggregate of the feature amounts of the detected regions in the different product units, for each of the groups of defect candidates; and determining for each product unit attributes for the detected regions by comparing the feature amounts of the detected regions belonging to each group of defect candidates with a distribution of the aggregate of the feature amounts for the group of defect candidates. The attributes include a broad classification of the detected regions based on whether the detected regions belonging to each group are genuine defects.
In accordance with another aspect of the invention, a method for inspecting defects of a sample having a plurality of sample regions repetitively formed at different locations comprises capturing an image of the sample; extracting defect candidates from the captured image; dividing the extracted defect candidates into groups; and identifying, for each of the divided groups, genuine defects from the defect candidates by using criteria corresponding to the groups.
In accordance with another aspect of this invention, a method for inspecting defects comprises capturing an image of a sample; generating a differential image by comparing the captured image with a pre-stored reference image; extracting a plurality of defect candidates from the generated differential image by using a first threshold value; grouping adjacent defect candidates among the plurality of defect candidates extracted into separate groups; and identifying genuine defects from among the defect candidates of each of the groups.
In accordance with another aspect of this invention, a method for inspecting defects comprises capturing an image of a sample; detecting defect candidates by comparing the captured image with a pre-stored reference image; extracting feature amounts for the detected defect candidates; storing images of the detected defect candidates and the feature amounts of the defect candidates; and identifying genuine defects from the defect candidates by using the stored defect-candidate images and feature amounts of the defect candidates.
In accordance with another aspect of this invention, a method for inspecting defects comprises detecting defect candidates while sequentially inspecting patterns in chips formed repetitively on a sample, with respect to a plurality of chips formed on the sample; grouping defect candidates into groups of defect candidates, each group including defect candidates which are disposed at corresponding identical locations or adjacent locations on the different chips when overlapped with each other; setting a threshold value for defect extraction in accordance with feature amounts for the defect candidates for each of the groups; and extracting genuine defects from among the defect candidates for each of the groups by using the threshold value.
In accordance with another aspect of the present invention, a graphical user interface (GUI) for inspecting defects comprises items on a display representing defect candidates which are classified into defects and false alarm defect candidates of a product using one or more parameters; and a user input device to permit a user to modify the one or more parameters used to classify the defects and false alarm defect candidates from the defect candidates so as to reclassify the defect candidates. The input device may be a mouse, a trackball, or the like.
These and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing the basic constitution of the defect inspection device according to an embodiment of the present invention;
FIG. 2 is a block diagram showing a modified example of the constitution of the defect inspection device according to an embodiment of the present invention;
FIGS. 3( a ) to 3 ( c ) serve to illustrate the generation of false defects, and FIG. 3( d ) serves to illustrate the grouping of false defects according to an embodiment of the present invention;
FIGS. 4( a ) and 4 ( b ) shows an example of a dispersion map and a brightness differential mock distribution;
FIG. 5( a ) shows an example of the golden pattern used in specific embodiments of the present invention; FIG. 5( b ) shows the frequency distribution with respect to reference brightness; and FIG. 5( c ) shows a feature space frequency distribution for a detected defect candidate;
FIG. 6 is a sequence diagram for the defect inspection method according to an embodiment of the present invention;
FIG. 7 serves to illustrate the image comparison method according to an embodiment of the present invention;
FIG. 8 serves to illustrate the image comparison method according to an embodiment of the present invention;
FIG. 9 is an explanatory view of a feature space that is used when performing subclassification of genuine defects detected according to an embodiment of the present invention; and
FIG. 10 is a simplified view of a screen display illustrating a user interface for displaying defect candidates including defects and non-defects according to an embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an overall constitutional view of the semiconductor defect analysis device that constitutes the first embodiment of the present invention. The reference character 101 refers to a semiconductor wafer which is the inspection object. A plurality of chips with the same design are formed on the semiconductor wafer. The reference character 102 represents an illumination device which illuminates the inspection object 101 . Image pickup device 103 is provided for detecting reflected light that is reflected by the inspection object, via an objective lens 100 .
The light signal thus detected is converted by image pickup device 103 into an electrical signal, and is converted into a digital signal by an AD converter (not shown) before being inputted to image processing apparatus 104 . The reference character 105 refers to a positional shifting device. The positional shifting device shifts the phase by means of a FIFO circuit and the like that is provided therein and exercises control such that the output signal of the positional shifting device 105 and the output signal of the image pickup device 103 are signals for different locations formed having the same original appearance.
The reference character 106 refers to a brightness correction device which corrects the brightness of the output signal of the image pickup device 103 and the output signal of the positional shifting device 105 by means of the method described in Japanese Patent Application Laid-Open No. 2001-77165, for example. The reference character 109 refers to a comparing device which calculates the difference between the output signal of the image pickup device 103 and the output signal of the brightness correction device 106 . Locations in which this difference is large can be regarded as defect candidates.
The reference character 110 refers to a defect candidate extractor which performs binary processing with respect to the output signal of the comparing device 109 . Two types of binary threshold values are established, the first binary threshold value being used to extract defect candidates. In other words, assuming that the output signal of the comparing device 109 is S, the absolute value thereof is ABS(S); and assuming that the first threshold value is Th 1 , in cases where the absolute value is equal to or less than this threshold value, the signal is extracted as a defect candidate.
ABS(S)>Th1 (First equation)
The second threshold value Th 2 is set lower than the first so that the extraction region is larger. In addition, locations for which the output signal S of the comparing device 109 is larger than Th 2 are subjected to leveling processing. Of the leveled regions, locations for which the S absolute value ABS(S) exceeds Th 1 are called defect candidates, the other locations being called large differential image regions.
The feature amounts for the regions which are judged to be defect candidates or large differential image regions are extracted by the defect candidate extractor 110 . Here, the feature amounts extracted by the defect candidate extractor 110 are as follows: (1) Inspection signal average value, (2) inspection signal scattering, (3) reference signal average value, (4) reference signal scattering, (5) brightness differential average value, (6) brightness differential scatter, (7) detected coordinate position, and (8) defect elliptical approximation size. Here, the inspection signal corresponds to the output signal of the image pickup device 103 , the reference signal corresponds to the output signal of the positional shift device 105 , and the brightness differential corresponds to the output signal of the comparing device 109 .
The reference character 107 refers to an image accumulation controller which possesses the following functions.
(a) The storage of feature amounts for the defect candidates and for the large differential image regions detected by the defect candidate extractor 110 in an image information storage memory 108 . (b) The storage of an image of the vicinity of a defect candidate detected by the defect candidate extractor 110 in the image information storage memory 108 . (c) The storage of an image of the vicinity of a defect candidate detected by the defect candidate extractor 110 and of images of regions having the same original appearance, in the image information storage memory 108 in a set quantity and position.
The reference character 111 refers to a defect candidate classifier which determines classes for defect candidates on the basis of the images and feature amounts stored in the image information storage memory 108 , that is, whether or not the defect candidates are genuine defects. Further, depending on requirements, more detailed classification is performed for those defect candidates which are judged to be genuine defects. The results of the defect evaluation and classification are provided to an output unit 120 .
The reference character 112 refers to an XY stage, and a semiconductor wafer which is the inspection object is secured on top of XY stage 112 . The image processing apparatus 104 and the XY stage 112 are controlled by sequence control device 113 .
Next, a description will be provided, using FIG. 3 , of the method whereby the defect candidate classifier 111 classifies the defect candidates. The reference character 301 in FIG. 3( a ) refers to an inspection image and 302 in FIG. 3( b ) is a comparison image. The inspection image 301 and the comparison image 302 are images which are picked up in the wiring step and grains can be observed on the wiring. While 303 is a defect, 304 and 305 are grains.
FIG. 3( c ) shows a brightness differential image 306 which is outputted by the comparator 109 . Defects and grains are actualized in the brightness differential image 306 . However, it is difficult to distinguish the defects from grains based on the single image shown in 306 . This is because although there is a grain of low brightness in the brightness differential image as indicated by 305 of FIG. 3( a ), there is also a grain with a higher brightness differential than the defects as denoted by 304 .
FIG. 3( d ) shows a stored differential image 307 in which large differential image regions and defect candidates which are detected for the same chip coordinates are displayed overlapping one another. Because locations in which grains are readily generated are set, in patterns that are formed having the same appearance, grains are readily generated in corresponding locations of the patterns. Hence, in the stored differential image 307 , in the vicinity of grain defect candidates of one chip, grain defect candidates or large differential image regions of another chip can be seen. Therefore, groups are created according to adjacent defect candidates and large differential image regions in the stored differential image 307 .
In FIG. 3( d ), because there are no other defect candidates in the vicinity of the defect candidate 308 , when a group is established to contain the defect candidate 308 , 308 is the only defect candidate contained, as denoted by 310 . On the other hand, in the case of a group containing defect candidate 309 , a defect candidate that lies in the vicinity of the defect candidate 309 is also contained, as denoted by 311 . Defect candidates which are not originally defects that are generated as a result of grains and thin film interference are typically generated in the form of an area or a line.
In order to increase the sensitivity with respect to defects in the vicinity of the wiring, groups are desirably created in the form of lines. Line-shaped groups in which noteworthy defect candidates belong and in which the largest number of defect candidates or large differential image regions belong are generated. The possibility of a defect candidate being generated is determined on the basis of the defect candidates and large differential image regions in the groups. In other words, if defect candidates and large differential image regions exist in large numbers in the groups and are similar in terms of the corresponding feature amounts, such as the brightness differential of the defect candidates evaluated for example, it is considered that the defect candidates evaluated are not defects.
Japanese Patent Application Laid-Open No. 2000-105203 discloses a method involving treatment with dispersion scattering amounts based on detection signals obtained from identical chip locations. However, there are frequent cases where grain defect candidates and large differential image regions, and the like, generally deviate greatly from a Gaussian distribution. In addition, because grains are generated locally, the probability is high that grains will not be generated in the same location on another chip.
Consequently, favorable accuracy cannot be ensured by simply calculating scattering in identical locations as has been the case conventionally. The present invention makes it possible, by means of the above-described grouping, to calculate the distribution of the brightness differential to also include neighboring locations which are not necessarily the same, whereby defects can be determined with greater accuracy.
The present invention can also be combined with the method disclosed by Japanese Patent Application Laid-Open No. 2000-105203, that is, a method for setting a threshold value on the basis of signal scattering which is calculated for each region in the chips formed on the semiconductor wafer.
The brightness differential in regions which are not detected as being defect candidates and large differential image regions can be approximated by means of a Gaussian distribution which is centered on zero. The calculation of scattering by means of a comparison of signals including peripheral regions which is dependent on grouping is effective in order to accurately determine scattering with a low frequency of occurrence. However, the possibility exists that regions that possess a plurality of attributes, such as regions on the wiring or beyond the wiring for example, will be allocated to the same group. Therefore, where signals which are not detected as being defect candidates and large differential image regions are concerned, scattering is therefore desirably calculated from only signals that correspond to the same chip coordinates, without grouping being performed.
This is because in cases where an approximation using the limitations of a Gaussian distribution is feasible, there is not a large amount of data and data scattering that can be found accurately. A conceptual view in which the standard deviation of the distribution is mapped is shown in the dispersion map 401 of FIG. 4( a ). The reference character 402 of FIG. 4( b ) represents the brightness differential frequency distribution corresponding to the defect candidate 309 . The brightness differential of the defect candidate 309 is evaluated on the basis of the frequency distribution of 402 , whereby a determination of whether or not this defect candidate is a genuine defect can be made.
The grouping problem relative to defect candidates arises where defect candidates or large differential image regions of a plurality of attributes are mixed in a single group. This mixing can be effectively prevented by combining feature amounts that exclude positional information. A method that involves using the brightness values of a reference image has been suggested as one such method. The brightness of locations which have different attributes generally differs. Therefore, a method can be employed whereby regions of different brightness are not mixed in the same group even if defect candidates or large differential image regions lie in the vicinity of such regions.
Care must therefore be directed toward inconsistencies in brightness generated so as to differ in different chips. On the basis of the brightness of the reference image upon detection of defect candidates and/or large differential image regions, a large influence is exerted by inconsistencies in the brightness of the reference image and it is difficult to stably separate locations with different attributes. Hence a golden pattern or ideal pattern such as 501 in FIG. 5( a ) is calculated and separation is carried out based on the corresponding brightness. The golden pattern is produced by converting the average values or median values of the brightness for the same chip coordinates into an image. Usage of this golden pattern means that defect candidates or large differential image regions are separated without being affected by brightness inconsistencies from chip to chip.
This is shown schematically by the frequency distribution 502 with respect to reference brightness in FIG. 5( b ). Similarly to the bright differential frequency distribution 402 , the frequency distribution is constituted by a Gaussian distribution 503 , and by a distribution 504 other than a Gaussian distribution for large differential image regions and defect candidates. Because the Gaussian distribution regions 503 match a distribution that corresponds to the pixels of the defect candidates which are evaluated, a distribution for the brightness of these pixels is shown. The reference character 504 represents the distribution of defect candidates and large differential image regions which lie in the vicinity of these pixels. The distribution 504 differs from the distribution 503 and is therefore not judged as being the same group.
The feature space frequency distribution 505 of FIG. 5( c ) represents a method for specifying groups according to a multi-dimensional feature space using other feature amounts. For example, Japanese Patent Application Laid-Open No. 2001-77165 describes the use of image texture and edge information for space segmentation. Although a multidimensional feature space can also be formed using such feature amounts, the problem then occurs that, generally, where texture and edge information are concerned, feature amounts are calculated on the basis of a plurality of pixels, which means that the spatial resolving power is then poor.
Therefore, as an effective measure, a feature amount which is based on pixels that correspond to pixels obtained by picking up, parts on the sample which have the same original appearance, such as the scattering of a differential image, for example, may be used. Originally, a multi-dimensional feature amount space was used for the purpose of preventing locations of large and small scatter from being mixed in the same group. However, because the groups are established by using this feature amount, locations that possess at least different scattering are no longer established as the same group. After the groups have been established, it is determined whether or not defect candidates are actual defects based on scattering which is calculated from information on the defect candidates and large differential image regions belonging to these groups.
Further, the usage of design information has been suggested as another possible feature. For example, supposing that the object pattern is a semiconductor memory, the memory cell parts have a very narrow wiring pitch in comparison with the border pattern, and the respective grain generation condition and behavior of thin film interference, and the like, differ greatly. Results similar to those for the method described above can also be produced by establishing groups on the basis of design data exerting a large influence, after detecting defects such as the fineness of the wiring pitch.
In order to perform grouping as described above, grouping can be performed using the following four criteria: 1) the criterion that large differential image regions and defect candidates detected for the same chip coordinates and which are adjacent as a result of overlap therebetween should be grouped; 2) similarity between feature amounts calculated based on inspection signals or reference signals; 3) scattering of the inspection signals or brightness differential signals for the same chip coordinates; and 4) design information. More simply, grouping may be performed using any one of these criteria or a combination of any of these criteria.
This sequence is shown in FIG. 6 . Grouping is performed after an image of the entire wafer has been detected and all the defect candidates and large differential image regions have been detected, and the defect candidates are evaluated once again by means of the method described above in order to identify whether or not these defect candidates are defects.
The present invention has been described using the constitution shown in FIG. 1 , but similar functions can also be implemented by using the constitution shown in FIG. 2 . Unlike the constitution of FIG. 1 , where the constitution of FIG. 2 is concerned, the images of the defect candidates and the large differential image regions are not stored, only the feature amounts being stored. Instead of the image information accumulation controller 107 and image information storage memory 108 of FIG. 1 , the embodiment in FIG. 2 includes a feature amount storage controller 201 which controls the storage of feature amount information, a feature amount extractor 202 which detects the feature amount information, and a feature amount storage memory 202 which stores the feature amount information. Because, as per the constitution of FIG. 2 , the images of the defect candidates are not stored, the constitution can be achieved by means of a comparatively small memory.
Here, the generation of the golden pattern 501 and the dispersion map 401 is assumed as a precondition. The brightness of the golden pattern pixels of the defect candidate regions and the values of the dispersion map can be found. Here, according to the constitution of FIG. 2 , because data for the differential image values is not obtained, the differential image values of the pixels of the defect candidate regions cannot be binarized again on the basis of scattering. However, by making the assumption that the defect candidate regions possess the same differential image average values and dispersion in any position, it is possible to determine the presence or absence of pixels that exceed the threshold value in the defect candidate regions.
Methods for identifying defects which have been used hitherto have been based on the premise that there are basically no major fluctuations in the inspection signals and in the reference signals used in the extraction of defect candidates. However, in the most recent defect inspection that employs a short-wavelength illumination light source such as DUV light, the inspection signals and reference signals are both affected by thin film interference and there is therefore the possibility of there being a large deviation from the golden pattern. In cases where the inspection signals and reference signals are conversely shifted toward the golden pattern, the brightness differential is very large and hence it becomes difficult to identify the defective parts and satisfactory parts even by using the technique described above.
Therefore, in order to deal with such a case, this problem can be resolved by setting different reference signals and re-calculating the brightness differential. One straightforward setting method involves a comparison relative to the golden pattern. Because the golden pattern is an average of a plurality of locations, the S/N is high, and the phenomenon in which the extremities of the pattern are light or dark is not produced. In addition, in order to diminish the effects of thin film interference, the creation of the reference signals using a larger number of images is employed. This method will now be described using FIG. 7 .
In FIG. 7 , suppose that a comparison is made with 701 as the reference signal and that the inspection object pattern 702 is detected as a defect candidate. Here, image information accumulation controller 107 in FIG. 1 stores patterns with the same chip coordinates as 702 in the image information storage memory 108 . The capture of a fixed number of patterns is completed and a reference image is calculated so as to be as close as possible to 702 . For example, the minimum squaring method and the like may be used as this method. For example, when the images 701 , 703 , and 707 are I 1 , I 2 and I 6 expressed in vector form, the reference pattern 709 thus generated is the linear sum G 1 I 1 +G 2 I 2 + . . . +G 6 I 6 , and, in cases where the pattern 702 is ID, 709 may be generated by calculating G 1 , G 2 , . . . G 6 so as to minimize (ID-(G 1 I 1 +G 2 I 2 + . . . +G 6 I 6 )) 2 .
Further, as a more straightforward method, a method of establishing, as the reference image, the pattern which is the closest to 702 of the patterns 701 , 703 to 707 may be adopted. In cases where the brightness differential between the newly generated reference image and inspection image is calculated and this brightness differential is equal to or less than the threshold value, this differential is removed from the defect candidates or large differential image regions. The constitution is shown in FIG. 8 .
The description has hitherto related to a method for eliminating the contamination of defects by grain and thin film interference phenomena which are thought to be defects. However, the objective behind the inspection of manufactured products is generally that of specifying the cause of product defects, and hence the extraction of genuine defects alone is unsatisfactory and there is the possibility that defect candidates that are not defects will also come to contaminate defect candidates which are judged as being genuine defects. Therefore, the defect candidates which are classified as defects are subject to classification using more complex feature amounts. This is illustrated by FIG. 9 .
The image feature space is broadly divided such that defects are classified on the basis of features which are, namely, a differential image feature 901 , a golden pattern feature 902 , an inspection image feature 903 , and a scatter distribution 904 . These feature amounts are calculated from the defect regions and represented as feature vectors. As far as the class boundaries for defects to be classified are concerned, separation is performed on the basis of instructions issued by the user beforehand or boundaries already registered in the system. The large differential image region distribution 905 represents a non-defect region.
In order to determine defect class boundaries, boundaries will typically be set automatically by the system as a result of the user's issuing instructions for the attributes of defect images that have already been picked up. However, here, the user may issue instructions specifying, from among the locations which are detected by the defect candidate extractor 110 of FIG. 1 as defect candidates, only the defect candidates which are determined by the defect candidate classifier 111 as being defects. Further, rather than issuing instructions within the feature space such that the defect candidates which are determined by the defect candidate classifier 111 as non-defects are automatically sampled as non-defects, performance can be improved more effectively by making it possible to undermine, by means of this classification, the determination of defect candidates which are judged by the defect candidate classifier 111 to be defects.
FIG. 10 shows an example of a screen display 1000 illustrating a user interface for displaying defect candidates including defects and non-defects according to an embodiment of the invention. The box 1001 is labeled defect, and represents a class of defect candidates which are evaluated as defects, for instance, using the method as described above in connection with FIGS. 4 and 5 . The other class of defect candidates are “false alarm” cases which have been evaluated as being normal or non-defects using the method of FIGS. 4 and 5 . The defects under box 1001 are further classified into subclasses of defects such as black particle, white particle, scratch, and grain in defect subclass boxes 1003 . This may be done using the method as shown in FIG. 9 . Pictures of the defect candidates are shown in the display area 1005 which an operator can browse and view in more detail by clicking on the pictures. Box 1004 shows a “modify” function which the operator can click using an input device such as a mouse or the like to change the parameters or criteria that are used to control the evaluation of the defect candidates, such as the threshold value and the feature amounts as discussed above. For example, the evaluation of the inspection signal average value, brightness differential average value, the defect elliptical approximation size, or the like may be adjusted so that the defect candidates will be classified differently as being defects or “false alarm” defect candidates. This may be necessary, for example, if a significant amount of “false alarm” cases are classified as defects or vice versa during the previous defect evaluation. After the operator changes one or more of the parameters, the defect candidates are re-evaluated and the results are displayed to show the shift in the evaluation. In this way, the operator can examine the results of the defect determination, modify the parameters and re-evaluate the defect candidates interactively until the operator is satisfied with the results of the defect evaluation.
As described hereinabove, the present invention detects defect candidates and performs a broad classification according to whether these defect candidates are defects or not and then implements subclassification once again. This is true for the reasons provided below.
First of all, one reason for such processing is to be able to eliminate the labor which user instruction entails. In cases where a multiplicity of images that are not defects are detected, it takes a very long time for the user to judge this fact and to issue instructions to that effect, and this is presented as a reason for the delay of the shipping of products in a multiple product type process. A large number of feature amounts is generally required for subclassification. However, if a large number of feature amounts are present, a great many instruction samples are required in order to perform classification of the feature space accurately. This fact also means that it is difficult to issue instructions for all product types. Also, if instructions are issued in a state in which even a judgment of whether a defect candidate is a defect or not a defect is difficult, the system operating efficiency inevitably drops.
By using this method, defect candidates can be classified into defects and non-defects without instruction even when subclassification is practiced and it is possible to provide the user with a convenient system even in a multiple product type process. Further, because false defects can be removed prior to subclassification, classification can be simplified and the efficiency with which a correct classification is made can be improved.
Furthermore, the present invention was described above in terms of a case which involved the inspection of a semiconductor device. However, the present invention is not limited to such a case, and can also be applied to any objective such as, for example, the inspection and evaluation of defects in a TFT panel manufacturing process, the inspection and evaluation of defects in a PDP panel manufacturing process, the inspection and evaluation of defects in a hard-disk GMR head manufacturing process, and the inspection and evaluation of defects in a print substrate.
Further, to describe this semiconductor inspection in more detail, a number of methods have been proposed for inspecting the semiconductor, such as bright field detection methods, dark field detection methods, laser multi-focus detection methods, SEM-type detection methods, AFM-type detection methods, and SIM-type detection methods, the present invention being applicable to all such methods.
The application of the above-described defect inspection and evaluation method makes it possible, in an inspection and evaluation that is directed toward a detailed semiconductor pattern and other samples, to correctly classify genuine defects and false defects and to then classify genuine defects in more detail.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiment is therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | The present invention relates to a defect detection or observation method that detects fine defects in the course of defect inspection and observation, does not detect locations not constituting defects, or classifies a defect candidate as a grain phenomenon or other phenomenon that does not affect a product. In one embodiment, a method for inspecting defects of a product having a plurality of product units formed repetitively at different locations comprises obtaining an image of the product units on the product having an appearance to be observed; detecting regions of the image each having an appearance which differs from an expected appearance by greater than a preset threshold; calculating feature amounts for the detected regions; classifying the detected regions into groups of defect candidates; forming an aggregate of the feature amounts of the detected regions in the different product units, for each of the groups of defect candidates; and determining for each product unit attributes for the detected regions by comparing the feature amounts of the detected regions belonging to each group of defect candidates with a distribution of the aggregate of the feature amounts for the group of defect candidates. | 6 |
BACKGROUND
[0001] Herein disclosed are imaging members, such as layered photoreceptor structures, and processes for making and using the same. The imaging members can be used in electrophotographic, electrostatographic, xerographic and like devices, including printers, copiers, scanners, facsimiles, and including digital, image-on-image, and like devices. More particularly, the embodiments pertain to a photoreceptor that incorporates specific molecules to facilitate electron transport across the layers of the photoreceptor device.
[0002] Electrophotographic imaging members, e.g., photoreceptors, typically include a photoconductive layer formed on an electrically conductive substrate. The photoconductive layer is an insulator in the substantial absence of light so that electric charges are retained on its surface. Upon exposure to light, charge is generated by the photoactive pigment, and under applied field charge moves through the photoreceptor and the charge is dissipated.
[0003] In electrophotography, also known as xerography, electrophotographic imaging or electrostatographic imaging, the surface of an electrophotographic plate, drum, belt or the like (imaging member or photoreceptor) containing a photoconductive insulating layer on a conductive layer is first uniformly electrostatically charged. The imaging member is then exposed to a pattern of activating electromagnetic radiation, such as light. Charge generated by the photoactive pigment move under the force of the applied field. The movement of the charge through the photoreceptor selectively dissipates the charge on the illuminated areas of the photoconductive insulating layer while leaving behind an electrostatic latent image. This electrostatic latent image may then be developed to form a visible image by depositing oppositely charged particles on the surface of the photoconductive insulating layer. The resulting visible image may then be transferred from the imaging member directly or indirectly (such as by a transfer or other member) to a print substrate, such as transparency or paper. The imaging process may be repeated many times with reusable imaging members.
[0004] An electrophotographic imaging member may be provided in a number of forms. For example, the imaging member may be a homogeneous layer of a single material such as vitreous selenium or it may be a composite layer containing a photoconductor and another material. In addition, the imaging member may be layered. These layers can be in any order, and sometimes can be combined in a single or mixed layer.
[0005] Typical multilayered photoreceptors have at least two layers, and may include a substrate, a conductive layer, an optional charge blocking layer, an optional adhesive layer, a photogenerating layer (sometimes referred to as a “charge generation layer,” “charge generating layer,” or “charge generator layer”), a charge transport layer, an optional overcoating layer and, in some belt embodiments, an anticurl backing layer. In the multilayer configuration, the active layers of the photoreceptor are the charge generation layer (CGL) and the charge transport layer (CTL). Enhancement of charge transport across these layers provides better photoreceptor performance.
[0006] The demand for improved print quality in xerographic reproduction is increasing, especially with the advent of color. Common print quality issues are strongly dependent on the quality of the undercoat layer. Conventional materials used for the undercoat or blocking layer have been problematic. In certain situations, a thicker undercoat is desirable, but the thickness of the material used for the undercoat layer is limited by the inefficient transport of the photo-injected electrons from the generator layer to the substrate. If the undercoat layer is too thin, then incomplete coverage of the substrate results due to wetting problems on localized unclean substrate surface areas. The incomplete coverage produces pin holes which can, in turn, produce print defects such as charge deficient spots (“CDS”) and bias charge roll (“BCR”) leakage breakdown. Other problems include “ghosting,” which is thought to result from the accumulation of charge somewhere in the photoreceptor. Consequently, when a sequential image is printed, the accumulated charge results in image density changes in the current printed image that reveals the previously printed image. Thus, there is a need, which is addressed herein, for a way to minimize or eliminate charge accumulation in photoreceptors, without sacrificing the desired thickness of the undercoat layer.
[0007] The terms “charge blocking layer” and “blocking layer” are generally used interchangeably with the phrase “undercoat layer.”
[0008] Conventional photoreceptors and their materials are disclosed in Katayama et al., U.S. Pat. No. 5,489,496; Yashiki, U.S. Pat. No. 4,579,801; Yashiki, U.S. Pat. No. 4,518,669; Seki et al., U.S. Pat. No. 4,775,605; Kawahara, U.S. Pat. No. 5,656,407; Markovics et al., U.S. Pat. No. 5,641,599; Monbaliu et al., U.S. Pat. No. 5,344,734; Terrell et al., U.S. Pat. No. 5,721,080; and Yoshihara, U.S. Pat. No. 5,017,449, which are herein incorporated by reference in their entirety.
[0009] More recent photoreceptors are disclosed in Fuller et al., U.S. Pat. No. 6,200,716; Maty et al., U.S. Pat. No. 6,180,309; and Dinh et al., U.S. Pat. No. 6,207,334, which are herein incorporate by reference in their entirety.
SUMMARY
[0010] According to embodiments illustrated herein, there is provided a way in which print quality is improved, for example, CDS is minimized or substantially eliminated in images printed in systems.
[0011] In one embodiment, there is provided an electrophotographic imaging member, comprising a substrate, an undercoat layer formed on the substrate, wherein the undercoat layer comprises a metal oxide and a porphine additive, and an imaging layer on the undercoat layer.
[0012] In another embodiment, there is provided an electrophotographic imaging member, comprising a substrate, an undercoat layer formed on the substrate, the undercoat layer having a thickness of from about 0.1 μm to about 30 μm, and wherein the undercoat layer comprises a metal oxide and a porphine additive, the metal oxide further comprising TiO 2 and the porphine additive further comprising meso-tetraphenylporphine-4,4′,4″,4′″-tetracarboxylic acid, and a charge transport layer comprising charge transport materials dispersed therein.
[0013] There is also provided an image forming apparatus for forming images on a recording medium comprising an electrophotographic imaging member having a charge retentive-surface to receive an electrostatic latent image thereon, wherein the electrophotographic imaging member comprises a substrate, an undercoat layer formed on the substrate, wherein the undercoat layer comprises a metal oxide and a porphine additive, and at least one imaging layer formed on the undercoat layer, a development component to apply a developer material to the charge-retentive surface to develop the electrostatic latent image to form a developed image on the charge-retentive surface, a transfer component for transferring the developed image from the charge-retentive surface to another member or a copy substrate, and a fusing member to fuse the developed image to the copy substrate.
DETAILED DESCRIPTION
[0014] It is understood that other embodiments may be utilized and structural and operational changes may be made without departure from the scope of the embodiments disclosed herein.
[0015] The embodiments relate to a photoreceptor having a undercoat layer which incorporates an additive to the formulation that helps reduce, or substantially eliminates, specific printing defects in the print images that are present in specific conditions.
[0016] According to embodiments herein, an electrophotographic imaging member is provided, which generally comprises at least a substrate layer, an undercoat layer, and an imaging layer. The undercoating layer is generally located between the substrate and the imaging layer, although additional layers may be present and located between these layers. The imaging member may also include a charge generation layer and a charge transport layer. The imaging member can be employed in the imaging process of electrophotography, where the surface of an electrophotographic plate, drum, belt or the like (imaging member or photoreceptor) containing a photoconductive insulating layer on a conductive layer is first uniformly electro statically charged. The imaging member is then exposed to a pattern of activating electromagnetic radiation, such as light. The radiation selectively dissipates the charge on the illuminated areas of the photoconductive insulating layer while leaving behind an electrostatic latent image. This electrostatic latent image may then be developed to form a visible image by depositing oppositely charged particles on the surface of the photoconductive insulating layer. The resulting visible image may then be transferred from the imaging member directly or indirectly (such as by a transfer or other member) to a print substrate, such as transparency or paper. The imaging process may be repeated many times with reusable imaging members.
[0017] Thick undercoat layers are desirable for photoreceptors due to their life extension and carbon fiber resistance. Furthermore, thicker undercoat layers make it possible to use less costly substrates in the photoreceptors. Such thick undercoat layers have been developed, such as one developed by Xerox Corporation and disclosed in U.S. patent application Ser. No. 10/942,277, filed Sep. 16, 2004, entitled “Photoconductive Imaging Members,” which is hereby incorporated by reference. However, certain conditions may still cause deficiencies in print quality. For example, “A zone” refers to hot and humid conditions while “C zone” and “J zone” refer to cold and dry conditions, each of which may cause conductivity changes that present problems in xerographic reproduction. High relative humidity hinders image density in the xerographic process, may cause background deposits, leads to developer instability, and may result in an overall degeneration of print quality.
[0018] Common print quality issues are strongly dependent on the quality of the undercoat layer. Conventional materials used for the undercoat or blocking layer have been problematic because print quality issues are strongly dependent on the quality of the undercoat layer. For example, charge deficient spots (“CDS”) and bias charge roll (“BCR”) leakage breakdown are problems the commonly occur. Another problem is “ghosting,” which is thought to result from the accumulation of charge somewhere in the photoreceptor. Consequently, when a sequential image is printed, the accumulated charge results in image density changes in the current printed image that reveals the previously printed image.
[0019] There have been formulations developed for undercoat layers that, while suitable for their intended purpose, do not address the ghosting effect problem. To alleviate the problems associated with charge block layer thickness and high transfer currents, the addition of a charge transfer molecule to a formulation containing a metal oxide, such as TiO 2 , is performed to help reduce or substantially eliminate ghosting failure in xerographic reproductions. One such charge transfer molecule is disclosed in commonly assigned U.S. patent application Ser. No. 11/213,522, filed Aug. 26, 2005, entitled “Photoreceptor Additive,” which is hereby incorporated by reference in its entirety.
[0020] In embodiments, additives, specifically porphine or porphine derivatives, are incorporated into the thick undercoat layer containing the metal oxide. Porphine is also called porphyrin, comprising a fundamental skeleton of four pyrrole nuclei united through the α-positions by four methine groups to form a macrocyclic structure. The combination has demonstrated to substantially reduce CDS levels in xerographic reproduction, even in specific conditions such as A zone conditions.
[0021] Typical porphine additives that can be used with embodiments disclosed herein include, but are not limited to, (1) 21H, 23H-Porphine, (2) meso-Tetraphenylporphine-4,4′,4″,4′″-tetracarboxylic acid, (3) 5,10,15,20-Tetra(4-pyridyl)-21H,23H-porphine, (4) 5,10,15,20-Tetraphenyl-21H,23H-porphine, (5) 5,10,15,20-Tetrakis(o-dichlorophenyl)-21H,23H-porphine, (6) 5,10,15,20-Tetrakis(4-trimethylammoniophenyl)porphine tetrachloride, (7) meso-Tetraphenylporphine-4,4′,4″,4′″-tetracarboxylic acid copper (II), (8) 5,10,15,20-Tetrakis(4-sulfonatophenyl)-21H,23H-porphine copper(II), (9) 5,10,15,20-Tetrakis(pentafluorophenyl)-21H,23H-porphine palladium(II), (10) 2,3,7,8,12,13,17,18-Octaethyl-21H,23H-porphine vanadium (IV) oxide, (11) Phytochlorin, (12) 5,10,15,20-Tetrakis(3-hydroxyphenyl)-21H,23H-porphine, (13) 3,8,13,1 8-Tetramethyl-21H,23H-porphine-2,7,12,17-tetrapropionic acid dihydrochloride, (14) 8,13-Divinyl-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid cobalt(III) chloride, (15) 8,13,-Bis(ethyl)-3,7,12,17-tetramethyl-21H, 23H-porphine-2,18-dipropionic acid chromium(III) chloride, (16) 3,7,12,17-Tetramethyl-21H,23H-porphine-2,18-dipropionic acid dihydrochloride, (17) meso-Tetraphenylporphine-4,4′,4″,4′″-tetracarboxylic acid, iron (III) chloride, (18) 8,13-Bis(1-hydroxyethyl)-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid, (19) 5,10,15,20-Tetrakis(4-sulfonatophenyl)-21H,23H-porphine, manganese (III) chloride, (20) Pyropheophorbide-α-methyl ester, (21) 5,10,15,20-Tetraphenyl-21H,23H-porphine nickel(II), (22) N-Methyl Mesoporphyrin IX, (23) 8,13-Bis(vinyl)-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid, (24) 29H,31H-tetrabenzo porphine, (25) Uroporphyrin I dihydrochloride, (26) 8,13-Bis(vinyl)-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid zinc(II), (27) 5,10,15,20-Tetrakis (1-methyl-4-pyridinio) porphine tetra (p-toluenesulfonate), (28) 8,13-Bis(ethyl)-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid tin(IV) dichloride, and the like and the mixtures thereof. The chemical structures are shown below:
[0022] The additives comprise a porphine moiety in its structure, and the porphine additive can be either metal free or metal-containing, with metals such as Cu, Pd, V, Zn, Fe, Sn, Mn and the like. Porphine derivatives with acid substitutes, such as carboxylic acid, sulfonic acid, and the like, may be readily used because they are bind easily onto the surface of a metal oxide like TiO 2 . Both soluble and dispersible porphine derivatives may be used with embodiments of the invention.
[0023] In embodiments, the metal oxide can be selected from, for example, the group consisting of ZnO, SnO 2 , TiO 2 , Al 2 O 3 , SiO 2 , ZrO 2 , In 2 O 3 , MoO 3 , and a mixture thereof. In various embodiments, the metal oxide can be TiO 2 . In various embodiments, TiO 2 can be either surface treated or untreated. Surface treatments include, but are not limited to aluminum laurate, alumina, zirconia, silica, silane, methicone, dimethicone, sodium metaphosphate, and the like and mixtures thereof. Examples of TiO 2 include MT-150W (surface treatment with sodium metaphosphate, Tayca Corporation), STR-60N (no surface treatment, Sakai Chemical Industry Co., Ltd.), FTL-100 (no surface treatment, Ishihara Sangyo Laisha, Ltd.), STR-60 (surface treatment with A1203, Sakai Chemical Industry Co., Ltd.), TTO-55N (no surface treatment, Ishihara Sangyo Laisha, Ltd.), TTO-55A (surface treatment with Al2O3, Ishihara Sangyo Laisha, Ltd.), MT-150AW (no surface treatment, Tayca Corporation), MT-150A (no surface treatment, Tayca Corporation), MT-100S (surface treatment with aluminum laurate and alumina, Tayca Corporation), MT-100HD (surface treatment with zirconia and alumina, Tayca Corporation), MT-100SA (surface treatment with silica and alumina, Tayca Corporation), and the like. The metal oxide is incorporated into the undercoat layer formulation.
[0024] Undercoat layer binder materials are well known in the art. Typical undercoat layer binder materials include, for example, polyesters, MOR-ESTER 49,000 from Morton International Inc., VITEL PE-100, VITEL PE-200, VITEL PE-200D, and VITEL PE-222 from Goodyear Tire and Rubber Co., polyarylates such as ARDEL from AMOCO Production Products, polysulfone from AMOCO Production Products, polyurethanes, and the like. Other examples of suitable undercoat layer binder materials include, but are not limited to, a polyamide such as Luckamide 5003 from DAINIPPON Ink and Chemicals, Nylon 8 with methylmethoxy pendant groups, CM 4000 and CM 8000 from Toray Industries Ltd and other N-methoxymethylated polyamides, such as those prepared according to the method described in Sorenson and Campbell “Preparative Methods of Polymer Chemistry” second edition, p. 76, John Wiley and Sons Inc. (1968), and the like and mixtures thereof. These polyamides can be alcohol soluble, for example, with polar functional groups, such as methoxy, ethoxy and hydroxy groups, pendant from the polymer backbone. Another examples of undercoat layer binder materials include phenolic-formaldehyde resin such as VARCUM 29159 from OXYCHEM, aminoplast-formaldehyde resin such as CYMEL resins from CYTEC, poly (vinyl butyral) such as BM-1 from Sekisui Chemical, and the like and mixtures thereof.
[0025] The weight/weight ratio of the porphine additive and the metal oxide is from about 0.0001/1 to about 0.5/1, or from about 0.001/1 to about 0.1/1, or from about 0.01/1 to about 0.05/1. The weight/weight ratio of the porphine additive in the undercoat layer formulation is from about 0.0001/1 to about 0.3/1, or from about 0.001/1 to about 0.05/1, or from about 0.01/1 to about 0.03/1.
[0026] The undercoat layer may consist of one, one or more, or a mixture thereof, of the above porphine structures and a polymeric binder. In one embodiment, the binder is hydrophilic melamine-formaldehyde resin. The weight/weight ratio of the porphine additive and the binder is from about 0.001/1 to about 0.1/1, or from about 0.01/1 to about 0.03/1.
[0027] In various embodiments, the undercoat layer further contains an optional light scattering particle. In various embodiments, the light scattering particle has a refractive index different from the binder and has a number average particle size greater than about 0.8 μm. The light scattering particle can be amorphous silica or silicone ball. In various embodiments, the light scattering particle can be present in an amount of from about 0% to about 10% by weight of the total weight of the undercoat layer.
[0028] In various embodiments, the undercoat layer has a thickness of from about 0.1 μm to about 30 μm, or from about 2 μm to about 25 μm, or from about 10 μm to about 20 μm. The metal oxide may be present in an amount of from about 20 percent to about 80 percent by weight of the total weight of the undercoat layer.
[0029] In embodiments, the porphine additive is physically mixed or dispersed into the undercoat formulation comprising TiO 2 , phenolic resin, and melamine resin. Some methods that can be used to incorporate an additive into a formulation to form an undercoat layer include the following: (1) simple mixing of a porphine additive, with an undercoat layer formulation, with the formulation being previously dispersed before adding the porphine or its derivative (2) ball milling a porphine additive with the undercoat layer formulation. In particular embodiments, where the metal oxide is TiO 2 , the TiO 2 may have a powder volume resistivity of from about 1×10 4 to about 1×10 10 Ωcm under a 100 kg/cm 2 loading pressure at 50 percent humidity and at 25° C.
[0030] After forming the coating for the undercoat layer, the coating is applied to the imaging member substrate. The coating having the metal oxide and the porphine additive is applied onto the substrate to form an undercoat layer.
[0031] The undercoat layer may be applied or coated onto a substrate by any suitable technique known in the art, such as spraying, dip coating, draw bar coating, gravure coating, silk screening, air knife coating, reverse roll coating, vacuum deposition, chemical treatment and the like. Additional vacuuming, heating, drying and the like, may be used to remove any solvent remaining after the application or coating to form the undercoat layer.
[0032] While the description above refers to particular embodiments, 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 embodiments herein.
[0033] The presently disclosed embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, the scope of embodiments being indicated by the appended claims rather than the foregoing description. All changes that come within the meaning of and range of equivalency of the claims are intended to be embraced therein.
EXAMPLES
[0034] The examples set forth herein below and are illustrative of different compositions and conditions that can be used in practicing the invention. All proportions are by weight unless otherwise indicated. It will be apparent, however, that the invention can be practiced with many types of compositions and can have many different uses in accordance with the disclosure above and as pointed out hereinafter.
Comparative Example I
[0035] A controlled undercoat layer dispersion was prepared as follows: a titanium oxide/phenolic resin/melamine resin dispersion was prepared by ball milling 15 grams of titanium dioxide (MT-150W, Tayca Company), 8 grams of the phenolic resin (VARCUM 29159, OxyChem Company, M w of about 3,600, viscosity of about 200 cps) and 7.5 grams of the melamine resin (CYMEL 323, CYTEC) in 7.5 grams of 1-butanol, and 7.5 grams of xylene with 120 grams of 1 millimeter diameter sized ZrO 2 beads for 5 days. The resulting titanium dioxide dispersion was filtered with a 20 micrometer pore size nylon cloth, and then the filtrate was measured with HORIBA CAPA 700 Particle Size Analyzer, and there was obtained a median TiO 2 particle size of 50 nanometers in diameter and a TiO 2 particle surface area of 30 m 2 /gram with reference to the above TiO 2 /VARCUM/CYMEL dispersion. 0.5 grams of methyl ethyl ketone were added into the dispersion to obtain the coating dispersion. An aluminum drum, cleaned with detergent and rinsed with deionized water, was then coated with the above generated coating dispersion, and subsequently dried at 160° C. for 40 minutes, which resulted in the TUC8 layer deposited on the aluminum and comprised of TiO 2 /VARCUM/CYMEL with a weight ratio of about 60/16/24 and a thickness of 5.5 microns.
Example I
[0036] An invented undercoat layer dispersion was prepared as follows: a porphine/titanium oxide/phenolic resin/melamine resin dispersion was prepared by ball milling 0.25 grams of meso-Tetraphenylporphine-4,4′,4″,4′″-tetracarboxylic acid (commercially available from Frontier Scientific, Inc., Logan, Utah), 15 grams of titanium dioxide (MT-150W, Tayca Company), 8 grams of the phenolic resin (VARCUM 29159, OxyChem Company, M w of about 3,600, viscosity of about 200 cps) and 7.5 grams of the melamine resin (CYMEL 323, CYTEC) in 7.5 grams of 1-butanol, and 7.5 grams of xylene with 120 grams of 1 millimeter diameter sized ZrO 2 beads for 5 days. The resulting titanium dioxide dispersion was filtered with a 20 micrometer pore size nylon cloth, and then the filtrate was measured with HORIBA CAPA 700 Particle Size Analyzer, and there was obtained a median TiO 2 particle size of 50 nanometers in diameter and a TiO 2 particle surface area of 30 m 2 /gram with reference to the above Porphine/TiO 2 /VARCUM/CYMEL dispersion. 0.5 grams of methyl ethyl ketone were added into the dispersion to obtain the coating dispersion. An aluminum drum, cleaned with detergent and rinsed with deionized water, was then coated with the above generated coating dispersion, and subsequently dried at 160° C. for 40 minutes, which resulted in the TUC8 layer deposited on the aluminum and comprised of TiO 2 /VARCUM/CYMEL with a weight ratio of about 60/16/24 and a thickness of 5.5 microns.
Example II
[0037] An invented undercoat layer dispersion was prepared as follows: a porphine/titanium oxide/phenolic resin/melamine resin dispersion was prepared by ball milling 0.5 grams of 8,13-Bis(vinyl)-3,7,12,17-tetramethyl-21H,23H-porphine-2,18-dipropionic acid zinc(II) (commercially available from Frontier Scientific, Inc., Logan, Utah), 15 grams of titanium dioxide (MT-150W, Tayca Company), 8 grams of the phenolic resin (VARCUM 29159, OxyChem Company, M w of about 3,600, viscosity of about 200 cps) and 7.5 grams of the melamine resin (CYMEL 323, CYTEC) in 7.5 grams of 1-butanol, and 7.5 grams of xylene with 120 grams of 1 millimeter diameter sized ZrO 2 beads for 5 days. The resulting titanium dioxide dispersion was filtered with a 20 micrometer pore size nylon cloth, and then the filtrate was measured with HORIBA CAPA 700 Particle Size Analyzer, and there was obtained a median TiO 2 particle size of 50 nanometers in diameter and a TiO 2 particle surface area of 30 m 2 /gram with reference to the above Porphine/TiO 2 /VARCUM/CYMEL dispersion. 0.5 grams of methyl ethyl ketone were added into the dispersion to obtain the coating dispersion. An aluminum drum, cleaned with detergent and rinsed with deionized water, was then coated with the above generated coating dispersion, and subsequently dried at 160° C. for 40 minutes, which resulted in the TUC8 layer deposited on the aluminum and comprised of TiO 2 /VARCUM/CYMEL with a weight ratio of about 60/16/24 and a thickness of 5.5 microns.
[0038] A chlorogallium phthalocyanine (CIGaPc) photogeneration layer dispersion was prepared as follows: 2.7 grams of CIGaPc Type B pigment was mixed with about 2.3 grams of polymeric binder VMCH (Dow Chemical) and 45 grams of n-butyl acetate. The mixture was milled in an ATTRITOR mill with about 200 grams of 1 mm Hi-Bea borosilicate glass beads for about 3 hours. The dispersion was filtered through a 20-μm nylon cloth filter, and the solid content of the dispersion was diluted to about 5 weight percent with n-butyl acetate. The CIGaPc photogeneration layer dispersion was applied on top of the above undercoat layers, respectively. The thickness of the photogeneration layer was approximately 0.2 μm. Subsequently, a 16 μm charge transport layer was coated on top of the photogeneration layer from a dispersion prepared from N,N′-diphenyl-N,N-bis(3-methylphenyl)-1,1′-biphenyl-4,4′-diamine (5.38 grams), a film forming polymer binder PCZ 400 [poly(4,4′-dihydroxy-diphenyl-1-1-cyclohexane, Mw=40,000)] available from Mitsubishi Gas Chemical Company, Ltd. (7.13 grams), and PTFE POLYFLON L-2 microparticle (1 gram) available from Daikin Industries dissolved/dispersed in a solvent mixture of 20 grams of tetrahydrofuran (THF) and 6.7 grams of toluene via CAVIPRO 300 nanomizer (Five Star technology, Cleveland, Ohio). The charge transport layer was dried at about 120° C. for about 40 minutes.
[0039] The above prepared photoreceptor devices were tested in a scanner set to obtain photo induced discharge curves, sequenced at one charge-erase cycle followed by one charge-expose-erase cycle, wherein the light intensity was incrementally increased with cycling to produce a series of photo induced discharge characteristic curves (PIDC) from which the photosensitivity and surface potentials at various exposure intensities were measured. Additional electrical characteristics were obtained by a series of charge-erase cycles with incrementing surface potential to generate several voltages versus charge density curves. The scanner was equipped with a scorotron set to a constant voltage charging at various surface potentials. The devices were tested at surface potentials of about 500 and about 700 volts with the exposure light intensity incrementally increased by means of regulating a series of neutral density filters. The exposure light source was a 780-nanometer light emitting diode. The aluminum drum was rotated at a speed of about 61 revolutions per minute to produce a surface speed of about 122 millimeters per second. The xerographic simulation was completed in an environmentally controlled light tight chamber at ambient conditions (about 50 percent relative humidity and about 22° C.).
[0040] Very similar photo-induced discharge curves (PIDC) were observed for all the photoreceptor devices, thus the incorporation of the porphine additive does not adversely affect PIDC.
[0041] The above photoreceptor devices were then acclimated for 24 hours before testing in A-zone (85° F./80% Room Humidity). Print tests were performed in Imari Work centre using black and white copy mode to achieve machine speed of 52 mm/s. CDS levels were measured against an empirical scale, where the smaller the CDS grade level, the better the print quality. In general, a CDS grade reduction of 1 to 2 levels was observed when the porphine additive was incorporated in undercoat layer. Therefore, incorporation of the porphine additive in undercoat layer significantly improves print quality such as CDS. | The presently disclosed embodiments relate in general to electrophotographic imaging members, such as layered photoreceptor structures, and processes for making and using the same. More particularly, the embodiments pertain to a photoreceptor additive to eliminate charge deficient spots in specific conditions and improve image quality. | 6 |
BACKGROUND OF THE INVENTION
1. Field of Invention
The instant invention relates generally to chairs and more specifically it relates to an orthopedic chair that is both adjustable and portable.
2. Description of the Prior Art
Numerous chairs have been provided in prior art that are adapted to adjustably conform to people sitting in the chairs. For example U.S. Pat. Nos. 3,288,525; 3,554,599; 3,877,750; 3,990,742; 4,017,118; 4,108,492; 4,367,897 and 4,437,702 all are illustrative of such prior art. While these units may be suitable for the particular purpose to which they address, they would not be suitable for the purposes of the present invention as heretofore described.
SUMMARY OF THE INVENTION
A principle object of the present invention is to provide an orthopedic chair whose seat and backrest are readily adjustable in various attitudes to conform to the unique requirements of a physically impaired person.
Another object is to provide an orthopedic chair that has a tray, armrests and footrests that are also readily adjustable in various attitudes.
An additional object is to provide an orthopedic chair that has casters and an adjustable rear handle so that the chair can be portable to be moved into different environments.
A further object is to provide an orthopedic chair that is economical in cost to manufacture.
A still further object is to provide an orthopedic chair that is simple and easy to use.
Further objects of the invention will appear as the description proceeds.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a side view of the invention showing various attitudes in phantom.
FIG. 2 is a top view of the backrest showing various attitudes in phantom.
FIG. 3 is a perspective view of the upper portion of the backrest.
FIGS. 4 through 6 are side views of part of the packrest in various adjustable positions in phantom.
FIG. 7 is a diagrammatic view of the various adjustable positions as shown in FIGS. 4 through 6.
FIG. 8 is a perspective view of the invention.
FIG. 9 is an enlarged top plan view of one of the side body pads.
FIG. 10 is a side view with parts broken away of the invention showing additional various attitudes in phantom.
FIG. 11 is a diagrammatic view of the various adjustable positions of one of the foot rests.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 11 illustrates an orthopedic chair 10 for a physically impaired person (not shown).
The chair 10 includes a base member 28, a padded seat 70, a backrest 11, and back pads 20. The padded seat 70 is on top of the base member 28. The backrest 11 has a substantially vertical and adjustable stantion 12 supported by the base member with bolts 26. The stantion 12 is positioned transversely to the back of the physically impaired person. The back pads 20 are adjustably affixed via braces 16 having horizontal slots 18 to the stantion 12 having vertical slots 14 by bolts 22 and wing nuts 24. The back pads 20 engage the back of the physically impaired person in various attitudes as shown in phantom.
Casters 30 are mounted to underside of the base member 28 making the chair 10 portable. A handle 72 is pivotally mounted to the rear portion of the base member 28 so that another person (not shown) may manually push the chair 10.
The seat 70 is adjustably affixed to the base member 28 by pivot pin 42 and bolt 48 extending through curved slot 44 in the base member with wing nut 46. The seat 70 can be positioned in various attitudes.
Two foot rests 36, 36 are independently adjustably affixed to front of the base member 28. Each of the foot rests can be properly adjusted to needs of the physically impaired person.
Two arm rests 34, 34 are each adjustably affixed to one side of the base member so that they can be properly adjusted to needs of the physically impaired person.
A tray 32 slidably engages with the armrests 34, 34 so that the physically impaired person can utilize the tray 32 as a table top.
A headrest pad 21 is adjustably affixed in the same manner as the back pads 20, to the upper portion of the stantion 12 to engage head of the physically impaired person in various attitudes.
A pair of side head pads 40, 40 are each adjustably affixed via adjustment member 38 to one side of the headrest pad 21. The side head pads 40, 40 can be properly adjusted to needs of the physically impaired person.
A pair of side body pads 50, 50 are each adjustably affixed to one side of each of the back pads 20. Each of the side body pads can be properly adjusted to needs of the physically impaired person.
As best seen in FIG. 9, a typical side body pad 50 is affixed by a bolt 64 to a pad brace 58 that has a transverse adjustment rod 60. The adjustment rod slides within a sleeve 56 that has a securement bolt 62. The sleeve 56 is attached transversely to one arm of an L-shaped back brace 54 with other arm of the back brace secured to the back pad 20 via bolts 66 and wing nuts 68.
A pair of side leg pads 52, 52 are each adjustably affixed to one of the arm rests 34. Each of the side leg pads can be properly adjusted to needs of the physically impaired person.
The back pad 20 and/or headrest pad 21 can tilt in an upward attitude as shown in position "A" in FIGS. 4 and 7 by off setting the bolts 22 with upper bolt to the right.
The back pad 20 and/or headrest pad 21 can tilt in a downward attitude as shown in position "B" in FIGS. 5 and 7 by off setting the bolts 22 with upper bolt to the left.
The back pad 28 and/or headrest pad 21 can move in a horizontal attitude as shown in postion "C" in FIGS. 6 and 7 by aligning the bolts 22 one above the other.
While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it will be understood that various omissions, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing from the spirit of the invention. | An orthopedic chair for a physically impaired person is provided and consists of a seat, backrest, armrests, footrests and a tray that are readily adjustable in various attitudes to conform to the unique requirements of the physically impaired person. The chair also has casters and an adjustable rear handle so that the chair can be portable. | 0 |
FIELD OF THE INVENTION
This invention relates to signage and to a method of making a sign which produces the visual effect of a pleasant "glow" to an observer whereby the brilliance of a back lighted design image subtly fades from a uniformly illuminated central image to a diffuse edge.
BACKGROUND OF THE PRIOR ART
Graphic and back-lighted illuminated displays are well known, and self-illuminating graphic displays using neon tubes are popular.
My prior U.S. Pat. Nos. 4,711,044 and No. 4,767,477 discuss the disadvantages of back-lighted displays and neon tubes in the prior art and disclose a novel method and sign which produces "neon look" lighting.
Since the invention of my prior Letters Patent, I have developed improved signage which expands the range of uses and sizes appropriate for "neon" type glow displays and images and I have also developed new methods which facilitate the manufacture thereof.
OBJECTS OF THE INVENTION
It is an object of the invention to provide an enhanced signage product which produces, in an extended image, a pleasant and colorful aurora, glow or halo effect around the image. It is a further object to provide an efficient method by which such signage may be manufactured. And it is yet a further object to provide line type signage having a glow effect in line widths appreciably broader than the widths associated with conventional neon tubes.
These and other objects will be evident when considered in view of the following description of the preferred embodiment taken in conjunction with the drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front view of a sign panel in accordance with the invention.
FIG. 2 shows the rear view of the sign panel of FIG. 1.
FIG. 3 is a figurative cross-sectional view of the panel of FIG. 2 at section 3→♭3 showing the various layers of the materials and components which form a light panel of the invention.
FIG. 4 is another cross-sectional representation in a side view showing the sign panel in conjunction with an illuminating source, and the "glow" effect.
FIG. 5 shows a perspective view of an installed sign panel of the invention in a retail environment.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the sign panel shown at FIG. 1 a substrate panel 2 having front 3 and reverse 4 surfaces is shown having a display image 5 of the invention formed of component letter images "G" 6, "L" 7, "O" 8 and "W" 9. In signs, the image to be displayed 5 is typically provided in a color which contrasts with a background color 10, for example, green on black, red on blue, etc. The image to be displayed may be informational, aesthetic, utilitarian and can be of a suitable size and shape appropriate to the message and environment. The signs of the invention are particularly appealling for retail, food service and supermarket displays.
FIG. 2 shows the reverse side of the panel of FIG. 1. FIG. 3 is a vertical cross-section through the panel of FIG. 1 at the approximate location of the letter "G" at 6.
The invention provides a sign which produces the visually pleasant effect of a glow radiating from a display image. The sign includes a transparent base panel to which a background color in the form of a pigment, paint or ink is applied on one side of the base panel in a reverse image of the display image, in areas of the panel which do not correspond to the display image. A light reflective layer covers the reverse image in the areas of the panel covered by the reverse image; and a light absorbent layer covers the light reflective layer in the areas of the panel covered by the reverse image. A cast luminescent material, which contrasts with the background color on the panel in the areas of the panel which correspond to the display image, provides the display image on the sign panel which is preferably illuminated by fluorescent backlighting.
With reference to FIG. 3, the clear substrate panel is shown at 2. On the substrate, the design 6 (here, sections of the letter "G") intended to be the sign display is reverse print stenciled, preferably by a silk screen method, on the reverse side of the panel 4, such that the display design remains as a reverse printed clear (i.e. a "negative" of the display expected from the front) section of the panel, as indicated in the cross-section at 6a and 6b. Thus, an opaque ink or paint layer 11 is provided as the background for the sign display which shows as the contrasting background 10 for the sign display when viewed from the front. The background is of a predetermined color selected for aesthetic or utilitarian impact. Over the reverse print (negative) layer 11, there is stenciled a white, or otherwise light reflective layer 12 in the same area as layer 11. Over the layer 12, a next layer in the same area, being a light absorber such as a black ink or paint 13 is stenciled or otherwise applied.
Preferably the ink or paint layers are based on an epoxy type resin material because the polyester casting material subsequently applied thereover is quite chemically active and/or corrosive and may etch through a layer of lesser durability than epoxy, adversely affecting the appearance of the sign front.
Over the stenciled layers on the substrate, a mat 14 is applied as an overcut cut-out in the area of the design 6. The mat defines the area within which a luminescent casting material 20 is applied and may be cut from an adhesively bondable rubber sheet material.
Thus, there is provided a layered medium for the sign on one side of the base transparent substrate in which a visible background color 11, seen through the panel as the sign front 10 is first applied. A reflecting layer 12, a light absorbing or screening layer 13, and the overcut mat 14 which defines the casting area for a luminescent polymer follow successively.
The luminescent casting material is applied in the cut-out areas of the mat, which correspond to the image of the display design. In brief, the containment mat has a cut-out in correspondence with the display image and is applied to the base after the light absorbent layer is provided, such that the cut-out is aligned with the display image (previously applied as the reverse negative to the panel); and the luminescent material is cast on the panel in the areas of the cut-out of the mat. A suitable luminescent casting material may be one such as described in my above-referenced Letters Patent, essentially as follows:
While many types of fast curing polyester compositions are suitable, a particularly useful polyester is Silmar Polyester Resin S-250 produced by the Silmar Division of Vistron Corporation, 12335 S. Van Ness Avenue, Hawthorne, California 90260 and 3535 Latonia Avenue, Covington, Kentucky 41015. This resin has good color, cures water white, is of medium viscosity and is promoted for room temperature cure. Tables I and II respectively set forth the uncured properties and curing data for the S-250 resin.
TABLE I______________________________________Uncured PropertiesLiquid Resin at 77° F.______________________________________Color Pal Blue-GreenViscosity, centipoise 450Specific Gravity 1.12Lbs. per gallon 9.3Stability, 77°. 3-4 months(covered)Stability, 100° F. 10 days(uncatalyzed)______________________________________
TABLE II______________________________________Curing DataTypical Gel Data 77° f. 50 gram castingCatalyst Gel time, minutes______________________________________0.4% MEK Peroxide 24.00.8% MEK Peroxide 13.51.0% MEK Peroxide 12.0______________________________________
To prepare the casting material, to a measure of 100% by weight of polyester resin there is added 1% MEK Peroxide catalyst and 10% by weight in the same relative proportion of a dry fluorescent, oil-soluble powder, color, dye or pigment which is suitable for fluorescent activation. Such fluorescent pigments capable of being cast in a polymer gel are available from several sources, including Rosco, Iddings Dry Pigments, 36 Busch Avenue, Port Chester, New York 10573, which markets such colorants as a "fluorescent" powder color. These proportions are not critical and may be modified by those experienced in color polymer gel casting. It is noted that the pigment also serves as a filler for the polyester gel. An improvement in stabilizing the longevity of the color fastness of the gel is achieved by the use of a dry fluorescent color with a UV inhibitor in a mixture of UV protected polyester resin. A fluorescent powder color will not dissolve in the gel mixture, but will break up into molecules or other minute particles suspended in the polyester; and each molecule or particle in the mixture will be coated with a layer of UV protected resin.
This resin is so prepared and is then applied as a gel to the cut-out opening in the mat or sheet layer 14 that is applied over the sequentially stenciled areas of the panel. The gel is allowed to cure. Upon curing, the sheet or mat layer 14 need not be removed.
FIG. 4 shows a more realistically proportioned cross-section of the sign in a side view showing panel 2, the display image area 6, the sign background 10 and the luminescent cast polymer 20 in the areas defined by the overcut mat 14. The reverse stenciled ink or paint layers are shown at the interface 25 of the panel 2 and the mat layer 14. The visual appearance of the luminescent area of the glow effect is shown by the lines 6g depicting the visual effect of a bright central image 6 mutely, gradually, or gradiently fading out from the side edges thereof. In FIG. 4, an illuminating lamp, which may be a conventional fluorescent tube lamp is shown at 15 providing back-lighted illumination 16 to the luminescent casting 20. FIG. 4 also shows the configuration of a light box which is suited to the invention. The sign is included in a holding frame with top and bottom sides indicated at 17 and 18 and on the reverse side of the "box" interior the fluorescent lamp 15 is mounted. More than one lamp may be used as the appearance and visibility of the sign is dependent upon ambient light intensity at the sign location. The lamp may be mounted with respect to the top, bottom, center or other location with respect to the sign, and the light box itself may be a permanent fixture in a location, in front of which the sign is appropriately placed.
Signs are made in numerous shapes and sizes for particular displays and applications, thus dimensions of letters, lines and/or designs are determined by the application. In a display application of the invention, a conventional forty-eight (48) inch fluorescent lighting tube provides backlighting in a display for a sign forty-eight (48) inches×ten (10) inches centered in front of the tube at a distance from the surface of the tube of six (6) inches. The panel used as the substrate may be a cast or extruded clear acrylic having a nominal thickness of 0.125 inch and is readily available from numerous manufacturers. A scratch resistant surface is frequently specified for sign panels and is likewise a feature of transparent acrylic panels that is readily available commercially. Although acrylic is a preferred material because of its crystal clarity, other transparent panels such as polycarbonate, glass and co-polymers may be used with suitable adaptations being made so that the luminescent casting gel bonds to the surface.
The containment layer 14 for the casting gel is a cut-out mat of an appropriate thickness. Particularly suitable is an adhesive rubber mat, otherwise intended to be used as a stencil material itself, manufactured as "Continental Stencil," Styles 111, 112 or 123, by Anchor Continental Inc., 2000 S. Beltline Boulevard, Columbia, S.C. 29205. This stencil material has an intrinsic adhesive by which the mat, overcut in size with respect to the reverse stenciled image, may be applied and bonded to the base panel. Other solid mat materials such as matting made from cork, paper and the like may also be used.
In the forty-eight (48)×ten (10) inch sign referred to as an example herein, the width of lettering and design shapes is typically in the range of about one-half (0.5) to one (1.0) inch. The overcut of the mat containment layer with respect to the size of the display image is not critical. The overcut may, however extend approximately 50 to 100% or more from the sharply defined edge of the stencil pattern. FIG. 2 shows the relationship of the mat cut-out to the display design as the mat is applied to the reverse side of the panel. For example, with reference to FIG. 2 if the size of the "L" image 7 were one-half (0.5) inch, the dimension of the overcut mat opening 7 m could be from about one and one-half (1.5) to about two and one-half (2.5) inches. The thickness of the containment mat likewise is not critical and a thickness of 0.0625 inch (1/16") to 0.125 inch (1/8") is suitable to confine within its boundries a luminescent gel (often times assisted by surface tension) in the casting process. Again with reference to FIG. 2, casting gel is applied in the entire cut-out area 7 m shown by the solid line in the figure. Thus, the luminescent material applied to the reverse side of the sign, may extend beyond the side edges of the actual boundries of the stencil design for the display image. The gel in areas may have a thickness of one-eighth (0.125) to one-fourth (0.25) inch.
Signs and displays, of course, come in all shapes, sizes and colors and given the guidelines and examples set forth herein, it should be within the skill of the art to adapt a particular signage application to the method of the invention. | Signage and a method of making a sign which produces the visual effect of a pleasant "glow" to an observer whereby the brilliance of a back-lighted design image subtly fades out from a uniformly illuminated central image to a diffusion. | 6 |
FIELD OF THE INVENTION
[0001] The present invention relates to a urinary catheter assembly comprising a package allowing for storage of the catheter and for contamination free insertion of the catheter into a natural or an artificial urinary canal of an individual.
BACKGROUND OF THE INVENTION
[0002] Catheters for draining the bladder are increasingly used for intermittent as well as indwelling or permanent catheterisation. Typically catheters are used by patients suffering from urinary incontinence or by disabled individuals like para- or tetraplegics who may have no control permitting voluntary urination and for whom catheterisation may be the way of urinating e.g. permitting the individual to stay seated in a wheel chair or lying in bed.
[0003] Typically, catheters are provided to the user enveloped in a completely sealed and sterilised package. During use and prior to insertion, the catheter is typically removed completely from the package whereby a potential contamination of the catheter may occur, e.g. if the user unintentionally touches the catheter or if the catheter touches surrounding obstacles, toilet seat, wash basin etc. Catheter packages and assemblies of catheters and packages exist, wherein both a proximal end and a distal end of the package may be opened, thus allowing for draining the urine through a catheter which is still at least partly enveloped in the package. Thereby, the user may urinate without completely exposing the catheter and the risk of contamination is reduced. However, since there is a clearance between the inner surface of the catheter package and the outer surface of the catheter itself, urine may flow backwards in the package in a direction opposite to the flow direction inside the catheter. An unwanted situation is that the user of the catheter and/or the surroundings gets contaminated by urine or other liquid substances, e.g. a lubricant or water applied to the catheter for the purpose of reducing the surface friction.
[0004] Since only the inserted part of the catheter is exposed from one end of the package prior to insertion of the catheter, another unwanted situation may be that the user unintended forgets to open the other end of the catheter package. An amount of urine may thereby build up in the catheter package and possibly cause a back-flow in the catheter tube. In this case there is a risk of severe contamination of the surroundings and also a possibility of back-flow into the bladder.
[0005] Moreover, existing catheters are provided in various sizes. As an example, catheters, which are relatively long, are offered for male individuals whereas relatively short catheters are offered for female individuals. The at least two variants, imply problems and costs for the providers of urinary catheters.
[0006] Catheter assemblies comprising a catheter and a package which includes an amount of a liquid substance, e.g. a lubricant for a conventional catheter or a liquid swelling medium for a hydrophilic catheter, exist. Some of the existing packages provide a combination between a storage volume for sterile storage of the catheter and a reservoir for collection of liquid substances, e.g. for collection of friction reducing substances or for collection of urine. Typically there is a large disproportion of the storage capacity necessary for storing the friction-reducing substance and the urine, respectively. Accordingly, the known catheter assemblies of this kind are provided with a relatively small storage container for storing the friction-reducing substance inside the relatively large urine reservoir. It is a disadvantage of the known assemblies that the user, prior to insertion of the catheter into the urinary canal, will have to rupture the storage container in order to achieve a reduced surface friction of the catheter. Especially, it is a disadvantage in the event that the catheter is a hydrophilic-coated catheter. In this event, the user would need to open the storage container to allow a liquid swelling medium stored therein to activate the coating and then wait for at least 30 seconds in order to complete the activation prior to insertion of the catheter.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to overcome the above-described disadvantages of the known catheter assemblies by providing a urinary catheter assembly which, according to a first aspect of the invention, allows for non contaminated insertion of a catheter into a urinary canal, said assembly comprising a urinary catheter defining a conduit and having a proximal end adapted for insertion into a urinary canal of an individual and an opposite distal end, and a catheter package having a generally tubular body such as a hose with a cavity for accommodation of the catheter. The proximal end of the package includes a catheter outlet through which the proximal end of the catheter can be “dismantled” or projected from the catheter package upon opening thereof. The assembly further includes sealing means adapted to provide a substantially liquid tight seal between the catheter package and the urinary catheter, while the catheter is being dismantled or projected from the package.
[0008] The sealing means may be provided in the proximal end of the package, e.g. constituting a closure for the proximal end of the package. As an example, the closure may have a rupturable portion with a shape which matches the outer cross-sectional shape of the catheter. When the catheter is removed through the rupturable portion, the closure will sealingly surround the catheter while the catheter is being dismantled. The cavity is thereby defining a receptacle between the catheter and the hose. The receptacle may e.g. be used for storage of a friction-reducing substance.
[0009] The sealing means may also be arranged between an outer surface of the urinary catheter and an inner surface of the hose. As an example, the sealing means may be provided in the form of a sliding seal adapted to move in relation to either one of the inner surface of the hose, the outer surface of the catheter or both, while still providing a substantial liquid tight passage therein between. The cavity thereby defines an upper receptacle located near the proximal end of the package and an oppositely located lower receptacle between the catheter and the hose. Especially the upper receptacle may advantageously be used for storing a friction reducing substance for treatment of at least the proximal end of the catheter in the package.
[0010] The catheter or at least a part of the catheter could be made from silicone or from a thermoplastic elastomeric material, other thermoplastic materials, curable elastomeric materials, polyamide resins or elastomers or any mixture thereof, i.e. the group may comprise materials like, PVC, PU, PE, latex, and/or Kraton™.
[0011] Preferably the catheter is provided with a bending moment defined as the product between E-modulus and moment of inertia of at least 1 MPamm 4 .
[0012] Since the proximal (insertable) end of the catheter, for male individuals, must pass prostate in a curved passage, the proximal end portion of the catheter, e.g. the first 10-50 mm. such as 20-40 mm., such as 25-35 mm, such as the first 30 mm. of the catheter may be provided with an even lower bending moment defined as the product between E-modulus and moment of inertia of less than e.g. 0.6 MPamm 4 or even less than 0.3 MPamm 4 . Other parts of the catheter, e.g. a distal end portion where the urine is drained into the toilet, a bag or place of disposal, may similarly be provided with a different bending moment.
[0013] The cross-sectional flow area or the hydraulic radius defined as the ratio of the cross-sectional flow area to the wetted perimeter, may be selected independently upon the length, e.g. on the basis of the size of the urinary canal, which size preferably differs between the individuals.
[0014] Preferably, the catheter is provided in an insertable length in the range of 50-90 mm., such as in the range of 55-85 mm., such as in the range of 60-80 mm. such as with a length in the size of 70 mm. which length has been found to be a suitable insertable length for most female individuals. For male individuals, the insertable length of the catheter may preferably be provided in the range of 180-250 mm., such as in the range of 190-240 mm., such as in the range of 200-230 mm. such as in the size of 220 mm. For the male individuals it may further be preferred to provide at least a part of the inserted end of the catheter in a material or in dimensions so that a the tube becomes very flexible in order to easy the passage of the catheter past prostate.
[0015] The inner cross-sectional shape of the catheter should preferably be substantially circular with a cross-sectional area in the range of 0.5 mm 2 -50 mm 2 .
[0016] The outer cross-sectional shape and size of the catheter should be provided with regards to the size of the urinary canal and/or the passage into the bladder so that the catheter around the outer surface thereof seals liquid-tightly.
[0017] The catheter or at least a section thereof may be provided with a hydrophilic surface. When treated with a liquid swelling medium, such a surface will provide an excellent lubrication for the insertion and also provide compatibility with the body tissue.
[0018] However, the catheter may also be of the traditional type wherein the low friction character is obtained by application of a lubricant different from water, e.g. a silicone based lubricant, the lubricant being applied to at least a section of the catheter.
[0019] The liquid swelling medium for a hydrophilic surface may be provided in the package, especially in the upper storage compartment, near the proximal end of the catheter, when the catheter is arranged in the package. Thereby, the low friction character will be initiated already when the catheter is being arranged in the package. The liquid swelling medium may simply be a saline solution, a bactericidal solution capable of swelling the hydrophilic surface and capable of keeping the surface in a sterile condition or it may be any suitable liquid swelling medium. The swelling may also be initiated already before packaging of the catheter, the catheter then being packed in a substantially gas impermeable package for conservation of the moistened surface. Furthermore, the liquid swelling medium may be provided in a capsule or container directly within the hose member together with the catheter for swelling of the hydrophilic material immediately prior to the insertion.
[0020] It is an advantage to provide the catheter package in a material which is at least substantially gas and water impermeable, which is durable to at least moderate external conditions, such as temperature variations and light. The material should at least substantially maintain its properties over a period of up to 12 or more months, e.g. up to 24 month. The catheter package and/or the hose member could therefore preferably be made from silicone or a thermoplastic elastomeric material, other thermoplastic materials, curable elastomeric materials, polyamide resins or elastomers or any mixture thereof, i.e. the group may comprise materials like, PA, PP, PVC, PU, PE, latex, and/or Kraton™. All parts of the catheter package may be made from two foils of a sheet material joined along edges, e.g. by melting or gluing the foils together or the package may be made from an extruded substantially tubular member being closed in both ends. The foil may advantageously be made from laminates of different materials. One layer may e.g. be a layer of aluminium or similar metal for provision of a completely gas-impermeable package.
[0021] The proximal end and the distal end of the catheter package could be provided with an even structure. However, it will be preferred that the proximal end of the package is provided with opening means adapted to remove the proximal end of the catheter. Similarly, the distal end of the package may be provided with opening means adapted specifically for draining fluid substances from the package. The fluid substances may either be a friction-reducing medium or urine.
[0022] Preferably, the hose member is an elongate and/or tubular member adapted to accommodate at least a major part of the catheter. If the catheter is of the kind which develops a low friction surface character upon treatment with a liquid medium or substance, it may be an advantage to provide the liquid medium in the package and preferably in the hose member. The catheter will thereby be treated already upon removal of the catheter from the package. For this purpose, the hose member may preferably be adapted to relatively closely enclose the catheter. As an example, the inner diameter of the hose member may preferably be in the range of 1.1-2 times the outer diameter of the catheter, such as 1.2-1.9 times, such as 1.3-1.8, such as 1.4-1.7, such as 1.5-1.6, such as in the size of 1.55 times the outer diameter of the catheter. Alternatively, the liquid medium may be contained in a pouch connected to the package. The pouch may e.g. constitute a closure for closing either the proximal or the distal end of the package. Preferably, the pouch is integrated in a closure for closing the proximal end of the package, which end is located near the proximal end of the catheter.
[0023] If the catheter is a hydrophilic catheter, i.e. if the catheter is either coated with a hydrophilic coating or made completely from a hydrophilic material, the liquid substance may be water or a water/saline solution. If the catheter is of the traditional type having a primarily hydrophobic surface, the liquid substance may be a lubricant, e.g. based on silicone.
[0024] The sealing means could be provided in the form of an obstruction which substantially prevents a liquid substance to pass between the inner surface of the package and outer surface of the catheter. The sealing means thus divides the space confined between the catheter and the hose member into an upper receptacle, in the direction towards the proximal end of the catheter and package and a lower receptacle, in the direction towards the distal end of the catheter and package.
[0025] As an example, the sealing means could be provided as a radially outwardly extending protrusion of the outer surface of the catheter or as an inwardly extending protrusion of the inner surface of the hose member, e.g. in the form of a resilient vane adapted to contact the inner surface of the hose member or outer surface of the catheter, respectively. The outwardly extending protrusion of the catheter should in this respect be understood either as a protrusion connected to the catheter or a protrusion formed directly on the surface of the catheter. As an example, the catheter may be connected with a plug member, which plug member is provided with vanes adapted to slide along the inner surface of the hose or at least parts thereof. Similarly, the inwardly extending protrusion of the hose should be understood either as a protrusion connected to the hose or a protrusion formed directly on the inner surface thereof.
[0026] Two or more radially outwardly or inwardly extending protrusions of the outer or inner surfaces of the catheter and/or the hose member, will provide an even better sealing against flow of liquid substances between the two compartments. By providing the at least two radially inwardly extending protrusions of the inner surface of the hose member with different radial sizes, a further sealing effect will be achieved.
[0027] According to a preferred embodiment, the sealing means comprises a ring shaped member arranged between the inner surface of the hose member and the outer surface of the catheter. As an example, a regular ring-shaped gasket may be placed inside the hose member. Preferably, the member is loosely arranged so that it is allowed to move back and forth inside the hose. As an example, the ring shaped member may be provided with a clearance against the hose member and against the catheter so that liquid substances are substantially prevented from passing the ring shaped member and so that the ring shaped member is still allowed to be shifted longitudinally back and forth in the catheter package.
[0028] The ring shaped member may preferably be adapted to co-operate with an inwardly extending protrusion of the inner surface of the hose member or with an outwardly extending protrusion of the catheter.
[0029] The distance from the distal end of the urinary catheter to the position of the sealing means may preferably be provided between 0 and 100% of the total distance between the distal end of the catheter and the proximal end of the catheter, such as 0%, such as 10%, such as 20%, such as 30%, such as 40%, such as 50%, such as 60%, such as 70%, such as 80%, such as 90%, such as 99%.
[0030] In general, the problems of introducing a catheter into the urethra depend not only of the size of the introduced part of the catheter but also on the slipperiness of the introduced part. As previously mentioned, the catheter or at least a part of the catheter adapted for insertion into the urethra or an artificial urinary canal may often be provided with a surface slipperiness for easy and safe insertion. However, it has been found that the slippery surfaces are difficult to handle, not least for a user having reduced dexterity. It is therefore an important aspect of the present invention to allow the user to manipulate the catheter by touching only the catheter package and only to “dismantle” or expose a length of the catheter which is necessary for opening the bladder. Preferably, the sealing means is arranged so as to seal between the outer surface of the catheter and the inner surface of the hose over a certain dismantling or projecting length. This will allow the user of the catheter to withdraw the catheter at least partly from the package, e.g. by pulling the proximal end of the catheter out of the catheter package, meanwhile the sealing between the catheter and the package remains. The feature allows that a catheter type of one length can be supplied both to male and female users. The user only needs to withdraw a length of the catheter from the catheter package necessary for opening the bladder, i.e. approximately 50-90 mm. for female users and approximately 180-250 mm. for male users.
[0031] The sealing means and/or the hose member may preferably be provided so that a passage between the outer surface of the catheter and the inner surface of the hose member remains sealed while the catheter is being dismantled or projected from the package over a first dismantle period, thus preventing fluid from passing between the urinary catheter and the hose member when the sealing means is positioned within said first period.
[0032] In order not to contaminate the surroundings with friction-reducing substances, it is an advantage to allow such a substances which may possibly be stored in the upper receptacle to drain down into the lower receptacle before dismantling or projecting the catheter through the proximal end of the package. The sealing means and/or the hose may therefore preferably be provided so that a clearance is defined between the outer surface of the urinary catheter and the inner surface of the hose member over a second dismantling period, thus allowing a fluid to pass between the urinary catheter and the hose member when the sealing means is positioned within said second period. As the catheter is being removed from the package, the catheter enters the second dismantling period. Any liquid substance contained in the upper receptacle is thereby drained down into the lower receptacle and it is thereby avoided that the substance might otherwise be unfortunately released though the proximal end of the package.
[0033] The length of the first dismantling period may preferably constitute between 0 and 100% of a total length of the package, such as 0%, such as 10%, such as 20%, such as 30%, such as 40%, such as 50%, such as 60%, such as 70%, such as 80%, such as 90% or such as 100%.
[0034] According to one embodiment, the substantially liquid tight seal is provided continuously between the catheter package and the catheter over the first dismantle period. However, the liquid tight seal may also be provided discontinuously.
[0035] Most catheters are provided with a surface which, when treated with a friction-reducing substance, exhibits a low friction surface character. Accordingly, it is an advantage that the package defines a liquid tight wetting pocket for treatment of the surface part with such substances. In the case that the catheter is hydrophilic or at least is provided with a hydrophilic surface coating on at least the proximal end thereof, the substance would typically be a water based solution, e.g. a saline solution. If the catheter is not hydrophilic, the substance may e.g. be a silicone based solution.
[0036] It is a further advantage to provide the assembly with an amount of the substance which is sufficient for effecting a treatment of at least a part of the catheter surface. As an example, the treatment may be performed on a first part of the catheter, which part is adapted for insertion into the urethra. The treatment may advantageously take place in the upper receptacle.
[0037] According to a preferred embodiment of the invention, the substance is contained in a pouch connected to the assembly. The pouch may as an example constitute a closure for closing one of either the proximal or distal ends of the package, which end is preferably the proximal end of the package which end is located near the proximal end of the catheter. According to another preferred embodiment, the substance is applied to the receptacle or at least the upper receptacle during the assembling process. The low friction surface character of the catheter is thereby initiated already from the time when the catheter assembly is produced. The package is therefore preferably formed with a wall of a substantially gas impermeable material so as to allow long time preservation of the catheter and a liquid substance in the package.
[0038] It is an advantage to provide the package with an opening for draining a liquid substance out of the package. As an example, the opening may be used for draining out surplus liquid swelling medium remaining in the package after treating a hydrophilic catheter. As another example, the opening may be used for draining urine out of the package. For this purpose, the opening is preferably provided in the distal end of the package. During use, the individual may simply have to withdraw a length of the catheter which is sufficient for causing the urine to flow from the bladder. The urine will flow through the catheter conduit and into the package. The urine is allowed to drain out of the package, e.g. into the toilet or into a collection bag or reservoir connected to the package, through the opening. Preferably the opening is closed by closing means connected to the catheter for causing opening of the package upon removal of the catheter from the package. As an example, the opening may closed by the distal end of the catheter itself.
[0039] According to a preferred embodiment of the invention, the closing means connected to the urinary catheter is provided with a flow channel co-operating with an outlet provided in the package. In a first position of the closing means in relation to the outlet, liquid substances are allowed to flow from the conduit of the catheter and out of the package. In another position, liquid substance are prevented to flow from the conduit of the catheter and out of the package. The two positions corresponding to a catheter respectively taken out of the package or being taken out of the package and a catheter arranged in the package.
[0040] The flow channel of the closing means may further comprise at least one inlet allowing a liquid substance to flow between the one of either the lower or upper storage compartments and the conduit of the catheter. In order to prevent urine, drained through the catheter, from running out through the inlet, the inlet may be provided with means adapted to allow a liquid substance only to flow in the direction from one of either the lower or upper storage compartments and into the conduit.
[0041] Preferably, the hose is formed with a wall of a flexible material so as to allow the hose wall to be squeezed into contact with the catheter by finger pressure. This will allow a user of the assembly to use the hose as an applicator for guided non-contaminating insertion of the catheter into the urinary canal. For that purpose, it is an advantage to provide the hose so that the user may vary the length of the hose. This will allow the user to contract the hose for exposing the proximal end of the catheter through the catheter outlet.
[0042] The variable length may be provided by a telescopic arrangement of a first part of the hose in relation to a second part of the hose or it may be provided via a concertina folded wall part of the hose.
[0043] The package may preferably be closed in the proximal end by a detachable closure, e.g. by a thin foil glued onto an opening of the proximal end of the package. This will allow the user to open the proximal end of the package by pushing the proximal end of the catheter though the foil, thereby letting the foil be penetrated by the catheter tip.
[0044] According to a preferred embodiment, the catheter assembly is provided with a compartment being closed in a first end whereas in a second opposite end it is detachably connected with the hose member. The compartment may preferably be formed with a wall of a flexible material allowing the compartment wall to be squeezed into contact with the catheter by finger pressure. Thereby, the compartment may be used as an applicator for guided non-contaminating insertion of the catheter into the urethra after opening the first closed end and detachment of the compartment from the hose member. The compartment may preferably be tubular and preferably, the hose member and compartment in combination forms a tubular member of a length which allows for accommodation of at least a mayor part of the catheter. Preferably, the catheter is arranged inside the package so that it extends from the hose member and into the compartment. Thereby, the user may grip the proximal end of the catheter by squeezing the compartment into contact with this part of the catheter and, upon detachment of the compartment from the hose member, insert the catheter into the urethra.
[0045] A detachable cover member may preferably close the other end of the compartment. After removal of the cover member, the user may draw the proximal catheter end out of the compartment, e.g. by squeezing the compartment into contact with the catheter, withdrawing a piece of the catheter from the hose member, releasing the squeezing grip of the compartment and by moving the compartment down to a part of the catheter now laid open from the hose member. For this purpose, it is an advantage to provide at least a first part of the hose member with a wall of a flexible material so as to allow the first part of the hose wall to be squeezed into contact with the catheter by finger pressure. Thereby, the user can hold the catheter through the compartment wall while the catheter is moved out of the hose member and then hold the catheter through the hose member wall, while the compartment is moved down to a part of the catheter now being exposed. At this point, the compartment may be used for holding the catheter while the catheter is inserted into the urethra. Only a certain length needed for the opening of the bladder is withdrawn from the hose member while the other part of the catheter remains inside the hose member. So as to avoid contamination of the surroundings, the detachable cover member may preferably be provided so that it can be re-connected to the compartment after catheterisation, thus leaving at least the proximal end of the package closed.
[0046] In order to facilitate coordinated operation of the hose member and the compartment for non-contaminated insertion of the catheter into the urethra, at least a first part of the hose member and preferably the part enveloping the proximal end of the catheter, may be formed with a concertina folded wall. This will allow the length of the hose wall to be extended and shortened respectively which again will facilitate easy removal of the proximal end of the catheter from the hose member. As an example, the proximal end of the catheter may be enveloped in the hose member. In order to be able to squeeze the compartment into contact with the catheter, the user will first have to move the catheter out of the hose member and into the compartment. With the concertina folded wall of the hose member, the user may simply press the compartment against the concertina folded hose member. The length of the hose member is thereby being reduced and the proximal end of the catheter is moved into the compartment. The user may now grip the catheter through the compartment wall and thus pull the proximal end of the catheter out of the catheter package without touching and possibly contaminating the catheter.
[0047] In order to provide a catheter assembly which is uncomplicated to use even for persons with a reduced dexterity, the compartment, the cover member and/or at least a part of the hose member may be provided with a gripping zone for easing the grip during use of the compartment for insertion of the catheter into the urethra.
[0048] The gripping means may be provided as a radially extending flange or flanges of the compartment, cover member and/or the hose member or as a zone or zones of the compartment, cover member and/or the hose member having a large outer cross sectional diameter. The compartment, cover member and/or the hose member may also be provided with means for engaging an external handle. As an example, the compartment, the cover member and/or the hose member may be provided with a ring-shaped bulge for attaching a handle.
[0049] The connection between the compartment and the hose member may preferably be provided by a weakening line for tearing off the compartment from the hose member.
[0050] The connection between the second compartment and the hose member may be provided so that the connection can be re-established by twisting and/or pushing the second compartment onto the hose member.
[0051] The second compartment may be provided with a weakening line for opening the first end by tearing off a first end part of the compartment.
[0052] For disabled users there may be severe difficulties in entering available toilet rooms. It is therefore an advantage to make the use of the catheter totally independent of the availability of toilet rooms by connecting a distal end of the package with a reservoir for accommodation of a liquid substance. In this case, the catheter package or at least the hose member thereof, may even be integrated in the reservoir.
[0053] It is an advantage to provide the reservoir in a material which is durable to at least moderate filling with a liquid without causing destruction of the reservoir or evaporation of the liquid substance through the walls of the reservoir. Moreover, the walls of the reservoir should at least substantially maintain its properties over a period of up to 12 or more month, e.g. up to 24 month. The reservoir could therefore preferably be made from a thermoplastic elastomeric material, other thermoplastic materials, curable elastomeric materials, polyamide resins or elastomers or any mixture thereof, i.e. the group may comprise materials like, PA, PP, PVC, PU, PE, latex, and/or Kraton™. Preferably, the reservoir is made from two foils of a sheet material joined along edges, e.g. by melting or gluing the foils together. The foils may e.g. be laminated from various materials and may e.g. comprise one layer of aluminium or a similarly metallic layer for providing a completely gas impermeable package.
[0054] It is an advantage if the reservoir is provided with a volume so that it will never be filled to its limit. Accordingly, the reservoir may preferably be provided with a volume in the range of 500-5000 ml, such as 600 ml, such as 700, such as 800, such as 900 ml, such as 1000, such as 1500 ml, such as 2000, such as 2500, such as 3000 ml, such as 3500, such as 4000 ml, such as 4500, such as 5000.
[0055] It is an advantage if the liquid substances, e.g. urine, is prevented from leaking out of the reservoir. Therefore, the connection between the distal end of the package and the reservoir may be adapted to allow the liquid substance to flow only in a direction from the package to the reservoir. As an example, the connection may be provided with a one way valve or closure of the kind known in the art.
[0056] After catheterisation, many users would prefer to empty the reservoir before the catheter assembly or reservoir is disposed. It is therefore an advantage to provide a draining spout or valve for emptying the reservoir. The valve should at least be operable between a closed and an open position. As an example, the valve could be a formed as a spout with a passage which is closed. The passage may as an example be closed by melting the reservoir together along a tear-off line. After completion of the catheterisation, the user simply tears off the tip of the spout and empties the reservoir.
[0057] In some cases, the user may have to carry a used catheter assembly with an emptied reservoir until an appropriate place of disposal is available. It is therefore an advantage to provide a draining spout with a closure enabling the user, after emptying the reservoir, to close it tightly. As an alternative to a detachable closure, a valve having an open and closed position may be connected to the spout. As an example, the valve may be a regular valve 2-way-valve with an open and closed position.
[0058] According to a second aspect, the present invention relates to a catheter assembly comprising a urinary catheter defining a conduit and having a proximal end adapted for insertion into the urinary canal of an individual and an opposite distal end, and a catheter package having a generally tubular body such as a hose with a cavity for accommodation of the catheter. A proximal end of the catheter package includes a catheter outlet adapted to dismantle or project the proximal end of the catheter from the catheter package. In an opposite distal end of the package is an opening being closed by closing means connected to said catheter for causing opening of the package upon removal of the catheter from the package. This aspect may be combined with any combination of embodiments and aspects described for the first aspect of the present invention.
[0059] According to a third aspect, the present invention relates to a catheter assembly comprising a urinary catheter defining a conduit and having a proximal end adapted for insertion into the urinary canal of an individual and an opposite distal end, and a catheter package having a hose with a cavity for accommodation of the catheter and, in a proximal end thereof, a catheter outlet adapted to dismantle or project the proximal end the catheter from the catheter package. The hose is provided with a variable length, allowing the hose to be contracted for exposing the proximal end of the catheter through the catheter outlet, and any combination of embodiments and aspects described for the first aspect of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0060] Preferred embodiments of the invention will now be described in details with reference to the drawing in which:
[0061] FIG. 1A shows cross-sectional view of a catheter assembly according to a preferred embodiment of the present invention,
[0062] FIG. 1B is a perspective view of one embodiment of a plug coupled to a catheter,
[0063] FIG. 1C is a cross-sectional view of one embodiment of the catheter assembly illustrated in FIG. 1A ,
[0064] FIG. 1D is a cross-sectional view of the catheter assembly illustrated in FIG. 1C ,
[0065] FIG. 2A is a perspective view of an alternative embodiment of a plug coupled to a catheter,
[0066] FIG. 2B is a perspective view of the plug illustrated in FIG. 2A ,
[0067] FIG. 2C is a cross-sectional view of one embodiment of a catheter assembly,
[0068] FIG. 2D is a cross-sectional view of one embodiment of a catheter assembly,
[0069] FIG. 3A is a perspective view of a catheter assembly,
[0070] FIG. 3B is a perspective view of a catheter assembly,
[0071] FIG. 3C is a perspective view of a catheter assembly,
[0072] FIG. 3D is a perspective view of plug for a catheter assembly,
[0073] FIG. 3E is a perspective view of plug for a catheter assembly,
[0074] FIG. 4A is an embodiment of a plug of a catheter assembly, where a passage between the catheter and a hose is sealed over a first dismantling period and open over a second dismantling period,
[0075] FIG. 4B is a perspective view of plug for a catheter assembly,
[0076] FIG. 4C is a perspective view of a catheter assembly,
[0077] FIG. 4D is a perspective view of a catheter assembly,
[0078] FIG. 4E is a perspective view of a catheter assembly,
[0079] FIG. 5A though FIG. 5G illustrates seven sequences of the removal of a catheter from a catheter assembly,
[0080] FIG. 6A through FIG. 6C illustrates three different embodiments of the invention wherein a compartment for non-contaminated insertion of the catheter into a urinary canal is attached to the hose member,
[0081] FIG. 7A shows a perspective view of one embodiment of the invention, wherein the distal end of the package is closed by the distal end of the catheter itself,
[0082] FIG. 7B is a perspective view of the package illustrated in FIG. 7A ,
[0083] FIG. 7C is a perspective view of the package illustrated in FIG. 7A ,
[0084] FIG. 8A shows an embodiment of the assembly shown in FIG. 7A , wherein the distal end of the package is closed by a detachable closure,
[0085] FIG. 8B shows an embodiment of the assembly shown in FIG. 8A , wherein the distal end of the package is open,
[0086] FIG. 8C is a perspective view of one embodiment of a detachable closure,
[0087] FIG. 9 is a perspective view of one embodiment of a catheter assembly and a reservoir for storage of urine and other liquid substances,
[0088] FIG. 10 is a perspective view of one embodiment of a catheter assembly and a reservoir for storage of urine and other liquid substances,
[0089] FIG. 11 is a perspective view of one embodiment of a catheter assembly and a reservoir for storage of urine and other liquid substances.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0090] Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
[0091] Referring to FIG. 1A , FIG. 1B , FIG. 1C , and FIG. 1 d a catheter assembly according to the present invention comprises a urinary catheter 1 defining a conduit 2 for transportation of urine and other liquid substances, a catheter package 3 and sealing means 4 . In this respect the catheter is defined by a hose and by additional parts connected to the hose, e.g. the plug 25 . The plug combines the sealing between the catheter and the package and the closing means adapted to close the distal end of the package—see the following description. The catheter is provided with a proximal end 5 , adapted for insertion into the urethra of an individual. The catheter is provided with holes 6 arranged peripherally around the proximal end part of the catheter for draining urine from the bladder and into the conduit of the catheter. The catheter is further provided with at least one opening 7 in the opposite distal end for draining liquid substances out of the conduit. The package is provided with a hose 9 defining a cavity 10 for accommodation of the catheter.
[0092] The sealing means 4 is arranged between the outer surface 11 of the catheter and the inner surface 12 of the hose member and provides a substantially liquid tight division of the space confined between the hose member and the catheter into a lower receptacle 13 and an upper receptacle 14 .
[0093] As shown in FIG. 1C , the sealing means may preferably be provided in the form of a radially outwardly extending protrusion 4 , e.g. in the form of a soft, resilient vane of the catheter or attached to the catheter and provided in a length which enables the vane to contact the inner surface of the hose member.
[0094] FIG. 1A shows a preferred embodiment of the assembly, wherein a flow channel 15 is provided in order to allow a liquid substance to flow from the upper receptacle 14 and into the conduit 2 , e.g. water or a water/saline solution contained in the upper receptacle for treatment of a hydrophilic catheter or a lubricant for causing a low friction surface character of a conventional catheter.
[0095] FIG. 1B shows one embodiment of the sealing means connected to the catheter.
[0096] FIG. 1C shows a situation wherein an opening 16 provided in the distal end of the package, allows liquid substances comprised in the lower receptacle to drain out of the package.
[0097] FIG. 1D shows a situation wherein closing means 17 of the catheter liquid tightly seals the opening 16 . Preferably, the closing means is provided with a number of resilient and/or soft bulges 18 adapted to contact the inner surface of the opening 16 .
[0098] FIGS. 1C and 1D further show a detachable closure 19 of the catheter outlet 22 at the proximal end of the package. The closure may, as indicated in FIGS. 1C and 1D , preferably be attached to the package via a strip 20 , so that the assembly remains as one unit. The closure may be provided with a radially extending gripping handle 21 , easing the removal of the closure, not least for individuals with a reduced dexterity.
[0099] FIGS. 2A, 2B, 2C and 2D shows an alternative embodiment of the plug 25 and an alternative embodiment of the distal package end, wherein an open distal end of the package is closed by a closure 26 . The closure may either be detachable or glued onto the hose member 9 . The plug is preferably provided with at least one outlet opening 27 allowing urine flowing from the bladder and into the proximal end of the catheter to drain out of the catheter through the plug. The plug may further be provided with an inlet 28 for draining a liquid substance from the upper receptacle 14 and into the conduit 2 . The closure 26 is further provided with an opening 29 for draining liquid substances out of the lower receptacle, e.g. urine.
[0100] FIG. 2C shows a situation wherein the closing means of the catheter is withdrawn from the closure, whereby the passage 29 is opened.
[0101] FIG. 2D shows a situation wherein the closing means of the catheter, closes the passage 29 and thereby prevents a liquid substance to drain out of the package.
[0102] The catheter and package shown in FIG. 2C and FIG. 2D are not drawn in its full length. The proximal ends of both have been omitted in order to focus only on the differences between the embodiment of FIG. 1C and FIG. 2C .
[0103] FIG. 3A shows an embodiment of the invention wherein the plug 35 is provided with features similar to the plug 25 of FIG. 2A . The plug further comprises a groove 36 adapted to engage a ring shaped sealing member 37 . The ring shaped sealing member is provided inside the package 38 , either fixed to the inner surface of the hose or movably arranged so that it is allowed to slide back and fourth in the hose.
[0104] FIG. 3C shows a situation wherein the ring shaped member engages the groove
[0105] Like FIG. 2C , the proximal ends of both the catheter and the package have been left out, in order to focus only on the differences between the embodiment of FIG. 2C and FIG. 3C .
[0106] FIG. 4A shows an embodiment of the invention where the plug 45 comprises is provided with resilient vanes 46 provided with a diameter so that they over a first section 47 of the hose may contact the inner surface, when the plug is positioned within this section of the hose. However, the hose is provided with two different radial sizes. Accordingly, since the radial size of a second section 48 of the hose is larger than the radial size of the first section of the hose, the vanes 46 cannot contact the inner surface of the hose, when the plug is positioned within the second section.
[0107] FIG. 5A shows an embodiment of the invention wherein the hose 9 is provided with a variable length. The variable length is provided via a concertina folded wall part 50 of the hose. The hose further forms two gripping zones 51 , 52 allowing the user to firmly grip the hose and shorten the length thereof, see e.g. FIG. 5 b . As shown in the FIGS. 5A, 5B, 5C, 5D, 5E, 5F and 5G , the variable length allows the user to push the proximal catheter end out of the package by shortening the hose length, gripping the catheter through the hose wall, extending the hose length while the catheter is being gripped, releasing the grip and again shortening the length and vice versa. Accordingly, the hose wall 53 may preferably be made from a flexible material allowing the wall to be squeezed into contact with the catheter by finger pressure.
[0108] FIG. 6A shows an embodiment of the invention, wherein a compartment 60 is closed in a first end 61 , whereas in a second opposite end 62 it is detachably connected with the hose member 63 . The compartment is provided with two gripping zones 64 , 65 enabling the user to firmly grip the compartment. Moreover, the compartment is provided with a concertina folded wall section 66 enabling the user to reduce the length of the compartment, in order to push the proximal end of the catheter 67 out of the proximal end of the package. The closure 69 for closing the first end, is provided so that the package may be closed after the catheterisation. This will allow the user to store the used catheter assembly without any risk of contamination of the surroundings. However, as previously described, the first end 61 may also be closed by a tear-off compartment end, e.g. in the form of a thin foil glued to the end of the compartment.
[0109] The compartment may be detachably connected to the hose over a tear-off line, see FIG. 6A or alternatively, the compartment may be connected to the hose member telescopically, by inserting one of either the hose or the compartment into the other one of the hose or the compartment, see FIGS. 6B, 6C .
[0110] FIG. 7A shows a simple embodiment of the invention wherein the package, in its distal end is provided with an opening 75 . The opening may be closed by the distal end 76 of the catheter itself, whereby the distal end of the package is automatically opened upon removal of the catheter from the catheter package. As indicated, a liquid substance comprised in the package, e.g. a liquid swelling medium for treatment of a hydrophilic catheter, is allowed to drain out of the package through the holes 77 provided in the proximal end of the catheter. The proximal end of the catheter and package is, for simplification of the drawing, left of the FIGS. 7A and 7B . In FIG. 7C , the proximal end of the package is left out. However, the proximal end of the package may be closed e.g. by a closure of any kind.
[0111] FIG. 8A shows an embodiment of the invention, wherein the distal end of the package is closed by a detachable closure 80 . The closure is provided with an outlet 81 for draining liquid substances out of the package. In a first position of the catheter in relation to the package and the closure, see FIG. 8A , the outlet is closed by the distal end of the catheter. When the catheter is removed from the package, the outlet is opened, whereby liquid substances is drained out of the package.
[0112] FIGS. 9-11 shows different embodiments of the invention wherein the hose member is connected to a reservoir for collection of liquid substances, e.g. for collection of urine and/or a saline solution having been used for establishing a low friction surface character of the catheter prior to use.
[0113] Referring to FIG. 9 , the valve 90 may preferably be provided as a one-way closure, so as to ensure that liquids drained into the reservoir does not flow back through the hose member and/or through the catheter. The reservoir is provided with a draining spout or valve 91 for draining the liquid substances out of the reservoir. As an example, the draining valve may be opened by tearing off a top part of the valve. For this purpose the reservoir may preferably be provided with a weakening line 92 . The reservoir may preferably be formed as a bag with a substantially flat bottom part 93 .
[0114] Thereby it will be possible for the user to leave the reservoir on a flat surface, e.g. on the floor, while catheter is inserted into the urethra and while urine is drained into the reservoir. Instructions relating to the opening of the draining valve may preferably be printed on the reservoir. The handles 94 , 95 gives the user a better grip, e.g. when emptying the reservoir. For this purpose, it will be specifically appropriate to use both handles in combination, so that the reservoir is lifted in the top handles 95 , while the rear handle 94 is used to rotate the reservoir. In this respect it should be kept in mind that the user would typically be at least partly motorically disabled. The assembly further comprises a closure 96 for opening and closing the assembly, respectively. FIG. 9 shows an embodiment of the combined assembly and reservoir, wherein a compartment 97 , in the joint 98 is telescopically joined to the hose 99 .
[0115] FIG. 10 shows an embodiment of the assembly of FIG. 9 , wherein a compartment 100 is attached to the hose member 101 by means of a coupling 102 .
[0116] FIG. 11 shows an embodiment of the assembly of FIG. 10 , wherein the compartment 100 is attached to the hose member 101 by means of a weakened tear-line 103 .
[0117] It should be understood that the shown embodiments of the assembly wherein the catheter assembly and a reservoir. However, the reservoir may be used independently from the catheter assembly. As an example, a similar reservoir as shown in FIGS. 10-13 may be used in connection with indwelling catheters or in connection with any other kind of catheters, e.g. as a leg-bag, attached to the leg via. leg-straps.
[0118] The invention being thus described, it will be apparent that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be recognized by one skilled in the art are intended to be included within the scope of the following claims. | A packaged catheter assembly includes a urinary catheter, a package, and a seal. The urinary catheter has a tube section connected between a proximal end and a distal end, and the proximal end of the urinary catheter is insertable into a urinary bladder. The package contains the urinary catheter and has a proximal compartment section that is removable from a distal section of the package to provide an outlet in the distal section of the package. The seal is arranged between an outer surface of the urinary catheter and an inner surface of the distal section of the package. The seal provides a nearly or truly liquid tight interface between the urinary catheter and the inner surface of the distal section of the package. | 1 |
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 60/642,017, filed Jan. 7, 2005. This application is related to application Ser. No. 29/224,679 entitled “J-BANDS”, filed Mar. 3, 2005. These above applications are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] People have used rubber bands, strings and the like for years to hold their pant legs in place, whether to hold their pant legs off the ground, out of the way to allow riding a bike without a chain guard or to help keep the pant legs up to prevent the shoes or boots from staining the pant legs. This presents an unsightly appearance to the viewing public.
[0003] There is therefore a need for a device or apparatus that will perform this function while providing a colorful style in different sizes without having the person present an unsightly appearance. Such an apparatus has to be simple to use, and be an accessory to the style of clothing a person may wear. Therefore, to meet this style requirement there is a need for an improved apparatus for providing this style requirement.
BRIEF SUMMARY OF THE INVENTION
[0004] The J-Band is a pant accessory that allows the person to display the tongue of his or her boot or shoe. The J-Band can also be worn over the entire pant legs, to prevent long pants from dragging under a heel of the shoe. A company logo may be placed or engraved on the center portion of the J-Band or along the bar. The advantage of the J-Band over the use of rubber bands and the like is that the J-Band allows the person to add to their style rather than detract from it.
[0005] In an aspect, the J-Band supports the ankle-shin area of pant legs. The J-Band has a “W” shaped bar with a first loop and a second loop on each end. A strap has each end connected to each loop respectively. The strap has an adjustment buckle coupled to it for adjusting the tension on the strap, thereby allowing tightening and loosing of the J-Band against the leg of the person.
[0006] Additional embodiments and advantages of the present invention will become apparent from the following description and the appended claims when considered with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 shows a cross-sectional view of an embodiment of a J-Band, according to the present invention;
[0008] FIG. 2 shows a perspective front view of a J-Band of FIG. 1 , according to the present invention;
[0009] FIG. 3 shows a perspective side view of a J-Band of FIG. 1 , according to the present invention;
[0010] FIG. 4 shows a perspective top view of a J-Band of Fig.1 , according to the present invention;
[0011] FIG. 5 shows a side-view perspective of a J-Band 100 of Fig. 1 in use, according to the present invention;
[0012] FIG. 6 shows a side-view perspective of a J-Band 100 of FIG. 1 in another use, according to the present invention; and,
[0013] FIG. 7 shows a front view perspective of a J-band in use, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 shows a perspective view of a J-Band 100 , according to the present invention. FIG. 2 shows a perspective front view of a J-Band, according to the present invention. The J-Band 100 includes a bar 101 and a strap 102 .
[0015] The bar 101 includes a loop 103 having a loop hole 104 , and loop 105 having a loop hole 106 . In the present invention, bar 101 is cast in a “W” shape having a center portion 107 and an interior elbow 108 and an interior elbow 109 . Typically, the center portion 107 is cast in such a way as to accommodate a decal, such as, a manufacture's decal or sport decal and the like. Likewise, the decals may be placed on the sides of the bar 101 or the strap 102 . Typically, the bar 101 is made of harden plastic but may be made of rubber, metal or the like.
[0016] The strap 102 includes an adjustment buckle 110 . Typically, strap 102 is made of an elastic material but it may be made of rubber or a non-elastic material. In the present invention, the adjustment buckle 109 is made of plastic but may also be made of metal or be formed by using a Velcro assembly (not shown), which is known in the art. How the J-Band 100 is assembled will be discussed next.
[0017] As stated above, the bar 101 has a loop 103 having a loop hole 104 , and loop 105 having a loop hole 106 . Loop holes 105 and 106 are cast to accommodate Strap 102 . Strap 102 has an end 111 that is threaded through loop hole 104 and then attached to strap 102 . Typically, end 111 is attached to strap 102 by sewing it to strap 102 . Another end 112 of strap 102 is threaded through loop hole 106 and then through the adjustment buckle 109 , by a method known in the art, and then attached to strap 102 . Typically, end 112 is attached to strap 102 by sewing it to strap 102 , as shown in FIG. 4 .
[0018] FIG. 3 shows a perspective side view of a J-Band, according to the present invention. Center portion 107 angles away from interior elbows 108 , 109 (not shown) and loops 103 , 105 (not shown).
[0019] FIG. 5 shows a side-view perspective of a J-Band 100 in use, according to the present invention. FIG. 7 shows a front view perspective of a J-band in use, according to the present invention. As shown in theses views a person may place the strap 102 of J-Band 100 directly against a leg 113 and then place a front of a pant leg 114 on the interior elbows 108 , 109 and behind center portion 107 . The person may also place a front portion 114 of the pant legs 115 in front (not shown) or behind a tongue 116 of a shoe 117 . By wearing the J-Band 100 in this way the person only shows the center portion 107 and the interior elbows 108 , 109 and is also allowed a freedom of style in what is displayed to the public.
[0020] FIG. 6 shows a side-view perspective of a J-Band 100 in another use, according to the present invention. The person may also place the strap 102 of the J-Band 100 on the out side of a pant leg 1 15 . Used in this way, the J-Band 100 is completely visible. The person may also place a front portion 114 of the pant legs 115 in front (not shown) or behind the tongue 116 of the shoe 117 .
[0021] The J-Band 100 is a pant accessory that allows the person to display the tongue 116 of his or her shoe 117 . The J-Band can also be worn over the entire pant legs 115 , to prevent long pants from dragging under a heel 118 of the shoe 117 . A company logo may be placed or engraved on the center portion 107 or along the bar 101 .
[0022] The foregoing detailed description is merely illustrative of several physical embodiments of the invention. Physical variations of the invention, not fully described in the specification, may be encompassed within the purview of the claims. Accordingly, any narrower description of the elements in the specification should be used for general guidance, rather than to unduly restrict any broader descriptions of the elements in the following claims. | An apparatus for supporting the ankle-shin area of pant legs having a “W” shaped bar with a first loop and a second loop on each end and a strap having each end connected to each loop respectively. The strap has an adjustment buckle coupled to it for adjusting the tension on the strap. | 0 |
FIELD OF THE INVENTION
This invention relates to a method and apparatus for manufacturing an outer housing for use as a part of an underground perforating gun of the sort used in the oil and gas industry.
BACKGROUND OF THE INVENTION
A perforating gun is typically used in the oil and gas industry by insertion downhole into a cased borehole for perforating the casing at a location adjacent a hydrocarbon containing formation. Such a gun is generally elongate and includes a number of charges spaced along its length. The charges are oriented such that when detonated, explosive forces are directed radially outwardly through the casing and into the formation.
A gun can be of any practical length but is typically between 0.5 and 10 meters. The overall diameter of a gun must be small enough such that the gun can be inserted into the borehole casing. The number and spacing of charges can vary and is determined by the requirements of a particular site.
A particular type of gun is expendable, i.e., is discarded after use, and this is the type of gun to which the invention described here pertains. Such a gun is also described in co-pending U.S. patent application Ser. No. 08/517,674 filed Aug. 22, 1995, which application names the same co-inventors as named for this invention and the specification of which co-pending application is incorporated herein by reference. The gun includes a charge holder on which the charges are mounted and an external housing. The charge holder with its mounted charges is sealed inside the housing so as to preclude the entry of dampness.
The outer housing of an expendable gun is typically of metal and is usually cylindrical having a circular outer cross-section to generally match the shape of the inside surface of the borehole casing. The housing, or carrier wall is generally between about 0.75 cm (0.3 inches) and about 1 cm (3/8 inches) thick. It is common for the carrier wall to have thinned or scalloped areas each being located to be aligned with a charge. Less explosive force is required to break through the thinned portion of the wall housing wall when the gun is detonated, as opposed to an unthinned portion. The scalloping thus improves the performance of a gun by increasing the amount of explosive force which makes its way through to the borehole casing and the formation.
As known to the inventors of the invention described in this specification, current methods for manufacturing a gun housing is a relatively labor intensive process. Stock pipe is cut to length, transported to a lathe, threads are turned in to a first end of the pipe, the pipe is re-positioned with respect to the headstock of the lathe, and threads turned in to the second end of the pipe. The pipe is then mounted in a clamp of a milling machine and the thinned areas described above are milled into the external side of the pipe wall.
The present invention is directed to improving this currently used system for producing an external housing in the manufacture of an underground gun.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for manufacturing a machined article from a stock piece. The apparatus includes:
a machining device movable within a work area of the apparatus;
a movable base having first and second spaced apart clamps, mounted to the base, for securing the piece in a first clamped position in which a first section of the piece is located between the clamps; and
a stationary third clamp mounted independent of the base, located to clamp onto the piece when the piece is secured in a the first clamped position, for holding the piece in a stationary position with respect to the base, to permit unclamping of the first and second clamps from the piece and movement of the base, to reposition the piece with respect to the first and second clamps, and securing of the piece by the first and second clamps in a second clamped position in which a second section of the piece is located between the first and second clamps; and wherein,
the base is movable to permit positioning of the first and second sections of the piece in the work area, when clamped in the first and second clamped positions, respectively, for machining thereof by the machining device.
The invention permits a relatively automated, including pre-programmed computer controlled, manufacturing process.
In a particular embodiment, the apparatus is adapted for manufacturing a machined article from a tubular stock piece having a longitudinal axis wherein, the first and second clamps are oriented and the third clamp is located to permit mutual alignment of the first, second and third clamps when the piece is secured in the stationary position by the first, second and third clamps.
Preferably, the article of manufacture is a housing for an underground perforating gun.
Preferably, the base of the apparatus is rotatable about a generally upright axis and the first and second clamps are located such that, when the piece is in a the clamped position, the axis of the piece forms an angle of about 90° with the upright axis;
the apparatus further comprises a conveyor for the piece;
the conveyor has a first position which permits conveying of the piece in a direction parallel with the axis of the piece for receipt within the first and second clamps, when each of the first and second clamps is in an open position, in a first working position coincident with a clamped position in which a leading first end of the piece is located in the work area of the apparatus for machining by the machining device; and
the conveyor has a second position to provide clearance for movement of the piece past the conveyor when the piece is secured in a clamped position and the base is rotated about the upright axis.
Preferably, the machining device includes a rotatable spindle for mounting of machining tools thereon, the spindle being rotatable about a generally horizontal spindle axis, and the conveyor, when in the first position, is located to orient the longitudinal axis of the piece so as to be parallel with the spindle axis.
More preferably, the base of the apparatus is rotatable about the upright axis by about 90° so as to move the piece from the first working position to a second working position in which a section of the piece is in the working area; and
the third clamp is in a location remote from between the first and second clamps and the first, second and third clamps are in the mutually aligned arrangement, to permit step by step the repositioning of the piece from the second working position into a third working position in which a second end of the piece is, after rotation by the base by a further 90°, located in the work area.
In an alternative type of embodiment, the invention is a method for manufacturing a machined article from a stock piece. Method steps include:
(A) (i) clamping a tube with first and second spaced apart clamps, the clamps being spaced apart and affixed to a movable base of a manufacturing apparatus, with a first end of the tube proximate the first clamp;
(ii) positioning the base to locate a first end of the clamped tube in a work area of the apparatus and machining the first end of the tube with a machining device of the apparatus;
(B) (i) clamping the tube with the first and second clamps, with a first portion of the tube between the clamps;
(i) positioning the base to locate the first portion of the tube in the work area and machining the first portion of the tube with the machining device;
(C) (i) clamping the clamped tube with a third clamp mounted to the apparatus in a fixed position separate from the movable base, unclamping the first and second clamps from the clamped tube, positioning the base to locate a second portion of the tube between the first and second clamps, clamping the tube with the first and second clamps and unclamping the third clamp from the tube;
(ii) positioning the base to locate the second portion of the clamped tube in the work area;
(iii) machining the second portion of the tube with the machining device;
(D) (i) repeating steps (C)(i), (C)(ii) and (C)(iii) N times, as necessary, to machine N second portions of the tube, where N is a whole number;
(ii) repeating steps (C)(i) and C(ii), as necessary to position a second end of the tube proximate the second clamp, and clamping the tube with the first and second clamps; and
(E) (i) positioning the base after step (D)(ii) to locate the second end of the tube in the work area of the apparatus and machining the first end of the tube with the machining device of the apparatus.
Again, it is preferable for the machining steps and movement of the article of manufacture between various positions within the work area of the apparatus to be under computer control.
BRIEF DESCRIPTION OF THE DRAWINGS
A description of the preferred embodiment of the invention is described below, reference being had to the accompanying drawings, in which:
FIG. 1 is a schematic plan view showing locations of major components of a preferred embodiment system;
FIG. 2 is plan view of an outdoor storage area for stock tubing;
FIG. 3 is a partial elevational view of a storage rack taken along line 3--3 of FIG. 2;
FIG. 4 is a partial elevational view of a storage rack and conveyor system taken along line 4--4 of FIG. 2;
FIG. 5 is a partial sectional view taken along line 5--5 of FIG. 4;
FIG. 5a is a detail of a plunger for loading a stock pipe onto the conveyor system, viewed from the angle of FIG. 5, showing the plunger in an upper position;
FIG. 5b is similar to FIG. 5b, showing the plunger in a lower position;
FIG. 5c is a detail of the pair of plungers as viewed from the vantage point of FIG. 4;
FIG. 5d is a partial detail of the conveyor system taken along line 5d--5d of FIG. 5;
FIG. 6 is a plan view of the interior portion of the apparatus;
FIG. 7 is a side view of the indoor portion of the conveyor system and location of the cutting station;
FIG. 8 is a side view of the apparatus for measuring and cutting stock tubing to length;
FIG. 9 is a partial section of the measuring apparatus taken along line 9--9 of FIG. 7;
FIG. 10 is a sectional view taken along line 10--10 of FIG. 7, showing a plunger used in draining a stock tube immediately after cutting;
FIG. 11 is a sectional view taken along 11--11 of FIG. 7;
FIG. 12 is a sectional view taken along 12--12 of FIG. 6 and is an elevational view of the apparatus for loading a pipe from the in-feed rack temporary storage area onto the conveyer for transport to the work area;
FIG. 12a is an elevational view of a roller conveyer running between the in-feed rack (internal storage) area and work stations;
FIG. 13 is an elevational view taken along 13--13 of FIG. 6 of the apparatus for selectively queuing, if desired, a pipe on the in-feed rock.
FIG. 14 is a side view of the apparatus shown in FIG. 13 as viewed from the right hand side of FIG. 13;
FIG. 15 is a side view of a rotatable first clamping device for securing a pipe in the work station;
FIG. 16 is a side view of a rotatably fixed second clamping device for securing a pipe in the work station;
FIG. 17 is a partial sectional view of the second clamping device taken along line 17--17 of FIG. 16;
FIG. 18 shows a third clamping apparatus for securing the position of the pipe during repositioning of the first and second clamping devices, jaws of the apparatus being in an open position;
FIG. 19 shows the third clamping device having a pipe of 7" outer diameter secured by its jaws;
FIG. 20 shows the third clamping device having a pipe of 1 9/16" outer diameter secured by its jaws;
FIG. 21 shows a detail of a support apparatus for a portion of a pipe when the pipe is located in the work station;
FIG. 22 shows the support apparatus of FIG. 21, as viewed from the right hand side of FIG. 21;
FIGS. 23a to 23e illustrate a broach tool used for machining a key way into the end of a tube. FIG. 23a is a side view of the base of the tool;
FIG. 23b is an end view of the base shown in FIG. 23a;
FIG. 23c is an end view of a plate for attachment to the end of the tool shown in FIG. 23b;
FIG. 23d is a side view of the plate shown in FIG. 23c;
FIG. 23e is an end view, similar to that of FIG. 23b, of the completely assembled tool;
FIG. 24a shows the three clamping devices of the apparatus, the pipe being in an initial position with respect to the first and second clamping devices;
FIG. 24b is similar to FIG. 24a, the pipe being in an axially translated position with respect to the clamping devices;
FIG. 24c shows a pipe backing unit of an alternative embodiment of the invention as would be viewed from the left hand side of FIG. 24a;
FIG. 24d shows the pipe backing unit of FIG. 24c as viewed looking into FIG. 24a;
FIG. 25 illustrates scallops machined into the outer curved surface of a pipe;
FIG. 26 is a cross section of a finished pipe having scallops machined thereinto;
FIG. 26a is a cross section of a finished pipe of a "port plug" gun housing; and
FIG. 27 is a longitudinal sectional view of the end of the finished pipe of FIG. 26.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Turning to the drawings, FIG. 1 is an overall schematic representation showing the various components of an apparatus 10 of the present invention. Generally speaking, a stock tube is moved from storage area 12, located out of doors, along conveyor system 14, cut to length at cutting station 16, as necessary, conveyed along roller conveyor 71 and then fed to temporary interior storage area 18. A given tube is selected as desired by a crane (not illustrated in FIG. 1) and fed onto conveyor 19 and into either of work stations 20. Finished tubular housings are conveyed along conveyor 19 away from work station 20 and transferred to storage area 22. The dashed line 24 represents the perimeter of the building in which the work stations are located.
FIGS. 2 to 5d illustrate the storage area 12 and conveyor 14 in greater detail. Stock tubes 26 are stored on racks 28a, 28b, 28c, 28d. Each rack includes three elevated, slightly sloping rails 30 in respective storage areas 12a, 12b, 12c, 12d. The rails are mounted on legs 32. Only one piece of stock tubing is illustrated in FIG. 2, for the sake of simplicity, but generally several tubes would be stored on each rack, and because of the slope of rails 30, tubes gravitate toward conveyor 14. The illustrated apparatus can process pipe having an outer diameter of from about 1 9/16 inches to about 8 inches. Stock tubing is typically 42 or 45 feet in length. A person skilled in the art could readily modify details of the apparatus described herein to process a workpiece outside this range of dimensions.
Conveyor 14 runs between paired racks 28a, 28b, and paired racks 28c, 28d. Conveyor system 14 includes carriage 34, which is pulled along rail assembly 36 by cable 38 connected at each end of the carriage. Cable 38, which is actuated by pulley 40, is pulled in the desired direction by operation of motor 44 in the appropriate rotational direction.
Generally speaking, for conveyance of a stock piece from either of racks 28a, 28b of the outdoor storage area into the building, the empty carriage is moved into the position shown in FIG. 2. Plungers 48a, 48b, 48c, associated with rack 28b, only one plunger 48b being visible in FIG. 5, operate simultaneously with each other. Further details of the plungers can be seen in FIGS. 5a to 5c. Piston 42 of each plunger is moved from it extended (upper) position shown in FIG. 5a into a lower position, i.e. retracted position, into its housing 50 as shown in FIG. 5b. This permits a stock tube 26c (shown in phantom in FIG. 4) to roll under the force of gravity into position atop the housings 50. The plungers are vertically extended into the position shown in FIGS. 4, 5, 5a and 5c, and the tube then rolls under the force of gravity into position on the carriage 34, illustrated for tube 26d in FIG. 4. Motor 44 is then actuated to move the carriage and the tube loaded therein, through an opening of the building wall 24 into the interior of the building.
Turning to FIGS. 4 to 5d, the arrangement of plungers 48a, 48b, 48c is described in greater detail. Only one of these, plunger 48b, is illustrated in FIG. 5, but the operation of all three is identical. Hydraulic cylinder 52, which operates reciprocally in the horizontal, is connected to horizontal member 54. Horizontal members 54, 56 are connected by tie member 58, which is pivotally connected at either end to respective members 54, 56. Member 57 is in turn rigidly connected (welded) to tie member 58 and the lower end of piston 42 as shown in FIGS. 5a and 5b. Extension of hydraulic cylinder 52 thus, through the pivotal connections, causes a lowering of piston 42 from the extended position of FIG. 5a into the retracted position of FIG. 5b. The pistons of plungers 48a, 48b, 48c, being similarly connected at their lower ends to member 54 are thus lowered simultaneously with each other. Correspondingly, retraction of hydraulic cylinder 52 leads to a raising of all three plungers 48a, 48b, 48c. A similar arrangement is provided for each set of three plungers associated with each rack.
Horizontal member 54 is connected through member 55 to cross-member 59 so as to stabilize longitudinal member 54 against deformation as it moves back and forth in the horizontal.
Turning to FIGS. 2, 4 and 5d, the arrangement of conveyor 14 is described in greater detail. Carriage 34 is mounted on wheels 60 mounted externally of C-channel members 62, the wheels riding in rails 64. Mounted on the carriage are three pairs of rollers 65, upon which the tube rests. Generally speaking, a pipe is greater in length than the carriage and in operation, the carriage is positioned prior to loading of the pipe so that a pipe will be axially centered on the carriage. A pipe is thus loaded with its leading edge overhanging the edge of the carriage. Rail stand 66 includes legs 68 and cross-members 70 to which rails 64 are mounted. Movement of carriage 34 along the rails is controlled by motor 44 connected through cable 38 to either end of the carriage. Operation of the motor to rotate pulley 40 in the clockwise direction as shown in FIG. 5 thus pulls the carriage toward the motor. Conversely, operation of the motor to rotate pulley 40 in the counter-clockwise direction pulls the carriage away from the motor.
FIGS. 6 to 11 illustrate that portion of apparatus 10 which cuts a raw tube to a desired length. A rubber bung is manually inserted into the leading end of the tube to contain fluids that flow into the tube during the subsequent cutting operation. Carriage 34 having a tube loaded thereon thus moves from right to left as viewed in FIGS. 7 and 8. The leading end of the pipe, moves onto roller conveyor 71, rollers of the roller conveyor being at the same height of those of the carriage for acceptance of the leading edge of the pipe thereon. Mounted at the side of roller conveyor 71 (to the left of the conveyor as viewed in FIG. 11) is a 360 inch glass scale measuring device 72 which operates in conjunction with the roller conveyor to position the stock tube with respect to cutting station 16 for cutting the tube to the desired length. Device 72 includes member 74 having transverse arm 76 located to be in the path of the tube as it travels along the roller conveyor. Member 74 is slidingly connected at the side of the roller conveyor so that when the forward moving end of the pipe comes into contact with the arm, the member travels along with the end of the pipe. Member 74 is connected to the glass scale contact 78 which tracks the distance traveled by member 74 along the conveyor, and thereby determines the distance travelled by the tube. Member 74 slides on chrome rods 80 which is moved forward by the powered rollers of the roller conveyor, and when the tube has travelled the distance required to bring the pipe into the desired position with respect to cutting station 16, an operator stops the motor. The glass scale measuring device 72 is commercially available and is manufactured by Acu-Rite Corporation, Model AR-10 of the United States. The measurement from the scale is relayed to the work station computer 160 for use in finishing the tube, farther details being described below.
The tube is secured in the cutting position by a clamp device which is a part of saw 84. The cutting operation is performed by saw 84. Saw 84 is commercially available under the name Hyd-Mech Model S-20 from Hyd-Mech Saws Ltd., Ontario, Canada.
Once the cutting operation is complete, the clamp is released to free the tube. The forward end of the tube is then raised by cylinder 86 to drain cutting fluids that may have entered into the tube during the cutting operation. The tube is then lowered back onto conveyor 71, and any remaining debris is vacuumed from the tube interior after which a second bung is inserted in the back end of the tube.
Ejector 88 is then actuated. Extension of ejector hydraulic cylinder 90 causes rotation of "V"-shaped arm 92 in the clockwise direction, as viewed in FIG. 9, which pushes the tube sideways into in-feed storage rack 18.
FIGS. 6 and 12 through 14 illustrate temporary storage area 18 and cranes 96, which together are capable of selecting any tube stored in the area for queuing for loading onto conveyor 19 for delivery of the tube to work stations 20. Although the various components of each crane 96 are driven by hydraulic motors, the individual operations involved in loading a tube onto conveyor 19 are operator controlled. Cranes 96 are mounted for travel along rails 94 secured to the floor. Cranes 96 are driven by a hydraulic motor connected to a common axle (not shown). An operator thus actuates the device for movement along the rails to bring arms 98 connected to chain sliding apparatus 100 mounted on cross-member 101 into vertical alignment with the tube to be re-queued on in-feed rack ready for elevation onto conveyor 19. Each upper portion 102 of crane 90 is under the control of hydraulic motors for vertical movement while each arm 98 is also under independent control of electric motors. By appropriate vertical movement of upper portions 102 and horizontal movement of arms 98 along cross-member 101 the arms are inserted into respective ends of the desired tube. See FIG. 6. The selected tube is then raised and cranes 96 are moved toward conveyor 19 to bring the tube into a position nearest the conveyor and the tube is then deposited upon rails 104 of the storage area. The rails 104 slope gently downward in the direction from conveyor 14 to conveyor 19. The rails are inclined sufficiently for tubes deposited into the storage area to roll into position adjacent conveyor 19. See FIG. 12.
Elevator 106 is brought by hydraulic motor 114 into a lower position, (shown in phantom in FIG. 12) if not already in such position, such that it is located below the tube adjacent the conveyor. The elevator is then raised into the upper position shown in FIG. 12. Surface 108 is inclined gently toward conveyor 19 so that once elevator 106 reaches its upper position, the tube resting thereon rolls under the force of gravity onto conveyor 19. Sprockets 116 are driven through chain 118, the sprockets being gearingly connected to drive rollers 110, 112. Upward or downward operation of the motor causes the elevators 106 and 176 (see below) to move in synchrony with each other: as one elevator moves up the other moves down.
Conveyor 19 includes a series of rollers 110, 112, horizontally aligned with each other and running the length of the conveyor, upon which the tube sits, the rollers being paired and shaped to hold the tube therebetween, as seen in FIG. 12. The rollers are connected by chains and are under separate control of an hydraulic motor.
The height of conveyer rollers 110, 112 can be adjusted, the entire series of rollers being movable together to retain their horizontally aligned position. Hydraulic arm 120 controls the height of rack 122 on which the rollers are mounted.
Turning to FIG. 6, work table 124 is positioned for delivery of a tube into a work station 20. Work table 124 is included as part of a commercially available milling machine sold by Toshiba Machine Co. under Model BTD-200QE with a thirty-tool ATC (Automatic Tool Changer) and 1600 r.p.m. spindle and Tosnuc T-777.2 computer controller. Work table 124 is driven by an electric stepper motor which is part of the milling machine, and is not illustrated. Work table 124 has mounted thereon, a rotary table 129 which is mounted with assembly 126 (FIG. 15) and clamping assembly 127 which is an air operated chuck and tube securing assembly, "steady rest" 128 (FIGS. 16 and 17). Table 129 is rotatable about a vertical axis centered in the circle containing arc 131 shown in FIG. 6. For receipt of a tube through assemblies 126, 127, 128, 129 work table 129 is rotated into position with its lengthwise axis parallel with that of conveyor 19, in which assembly 126 is nearest conveyor 19. Generally speaking, a tube is to be received into assemblies 126, 127, 128, 129 so as to be centered therein, as illustrated in FIGS. 15 to 17, as described in more detail immediately below.
Prior to insertion of the tube into assembly 126, the positions of lower supports 130, 132 are adjusted, as necessary, to accommodate the diameter of the tube. Pins 134 are thus removed and the height of each support adjusted, apertures 136 of the supports being aligned with apertures 138 of support block 140 and pins being inserted therein.
Upper arms 142 of assembly 126 are hydraulically retracted to permit insertion through the center of the assembly.
In a similar manner, the height of lower support members 144, 146 of non-rotatable (steady rest) securing assembly 128 are adjusted as for assembly 126, as necessary, to accommodate the outer diameter of the tube, and upper, hydraulically controlled cylinders 148, 150 are retracted to permit insertion of the tube through the center of clamping assembly 128.
Supports 130, 132, 144, 146 having been suitably positioned, and table 129 being rotated into position and height adjusted appropriately, so that clamps are aligned for receipt of the tube, rollers 110, 112 are activated and the tube conveyed through the clamp assembly apertures. Eventually, the leading end of the leading end of the tube comes into contact with "home plate" 152, which is installed as one of many "tools" installed on the driver of the apparatus, described further below. See FIG. 6. The rollers are deactivated and conveyor 19 is lowered vertically to bring the pipe to rest upon rail-guided supports 151, (FIGS. 21 and 22) which supports are vertically aligned with the lower support members of clamping assemblies 126, 128 by adjustment of the height of the work table. Rollers 153 of supports 151 rest upon and are guided by arcuate rails (I-beams) 155 for rotation of the pipe as indicated in FIG. 6 (arrow 131), the purpose of which is explained below. Cylinders 142, 148, 150 are extended to secure the tube in place. Home plate 152 is then removed. The arrangement is such that the programmed computer knows the location of the leading end of the tube with respect to the contact position with home plate and the tube is thus in a secured position for a first series of computer-controlled machining operations to be carried out. Once clamped into the apparatus, all further operations involving tables 124, 129 and the milling machine are generally under the control of computer 160. Operations can be pre-programmed, a sample programme developed for the production of a particular gun housing is given in Appendix A.
Pipe leading end 26a is thus suitably positioned for processing of the rim of the pipe by milling tools sourced from the ATC of apparatus 154, the rotational axis of the driver 156 of the machining apparatus being generally parallel to the longitudinal axis of the pipe. Appropriate milling tools are used to shape the end of the pipe with threads, chamfers, etc. Machining apparatus 154 includes magazine 157 for storage of the various tools which can be secured to the drive mechanism 156 as needed. Tools are moved between magazine 157 and driver 156 of the machining apparatus by a tool changer which is provided as part of the Toshiba apparatus (not illustrated) and is under motorized control of computer 160 through drive mechanism 162. All motor actuated movements of driver 156 of the machining apparatus, i.e., translational movements of the device as well as rotation of the tools are under control of computer 160. The driver and computer form part of the commercially available unit sold by Toshiba Machine Co. Work table 124 is capable of motorized movement, under control of the computer, in the horizontal directions indicated by arrows 125a, 125b while machining apparatus (and its rotating spindle) is movable vertically for machining operations. It is thus possible, through cooperative movements of the table and the machining apparatus to shape the end of the pipe as desired. For example, viewing the end of the pipe to be machined as oriented in FIG. 26, a simple chamfer could be machined onto the lower portion of the pipe end by downward and then upward movement (y-axis) of machining apparatus as the table moves from left to right (x-axis). Threads could be machined onto the lower portion of the pipe end by similar movement with the additional movement of the table into or out of the page (z-axis), as appropriate. Generally, at least milling of threads into the interior of the end of the pipe is carried out.
In the manufacture of a particular embodiment housing, a seal bore is rough cut into the end of the pipe with a thread bore. Following this, a seal finish bore, and the radius, face and chamfer on the end of the pipe are milled into the end. The magazine of the milling machine includes pockets that hold the tools used for the various milling operations and the machining apparatus moves between the work area "W" and the magazine as necessary for installation of a tool on the driver and insertion of a tool into its pocket for storage when not in use. Included are tools: for boring a diameter in preparation for threading; for preparing a seal bore; for milling down the flat end of the pipe to obtain the finished pipe length; for chamfering (e.g. a 0.03×45' chamfer); and for milling an internal radius (e.g. 0.12 radius). The next action may be to broach a keyway down the inside wall of the pipe. The keyway aids in alignment of internal components of the gun and is cut with tool 163. Alternatively, holes may be milled through the wall of the pipe to for joining finished pipes end-to-end without threaded devices (e.g. with non-threaded 4 pin 2×O-ring devices or combinations of both). Following this, an assortment of grooves may be cut round the inside and outside of the pipe to further accommodate alignment and security of internal components to be installed later and to aid in identification.
Broach tool 163 is shown in FIGS. 23a to 23e. End 180 is suitably shaped for receipt thereonto of a conical piece, the same for all tools, having housing a standard end for receipt within the jaws of a chuck of the driver. The tool includes plate 182 which fits onto the base 184 of the tool at end 186. Cutting bit 188 is secured to the base against the plate by clip 190 fastened to the base by bolt 192. In use, bit 188 is brought into contact with an interior surface of the pipe end by reciprocating motion of the tool, material is removed from the pipe on the backstroke.
Once the machining operations to the end of the pipe are complete, a pipe extension 164 (FIG. 24a) bearing external threads complementary to those on the interior work piece is screwed onto the end the pipe. Table 129 is then rotated 90° in the counterclockwise direction (i.e., from the three o'clock position to the twelve o'clock position) in the direction of arrow 131 as viewed in FIG. 6, into the position shown in FIG. 24a.
The pipe is positioned for machining operations on that portion of its outer curved surface located between the clamping apparatuses 127, 128. By movement of table 124 in a direction parallel to arrow 194b (FIG. 24a) the pipe is positioned axially with respect to machining apparatus 156 for milling of a scallop 127 (FIG. 25) (or drilling and tapping a hole 196 extending through the pipe, as in the case (FIG. 26a) of a "port plug" gun housing) into the outer curved surface of the pipe. The pipe is rotated about longitudinal axis 169 for circumferential positioning of the pipe for installation of a scallop by releasing of clamps 128 and 126 and rotation of clamp 127. Thus, the tube is released from clamp 128 by retraction of upper cylinders 148, 150 and from clamp 126 by retraction of upper cylinders 142 and the tube is rotated by rotation of clamping apparatus 125. Once in the desired position for the next machining operation, the tube is resecured by re-extension of the upper cylinders of clamps 128 and 126. In this way, access is provided to any circumferential area of the tubular surface to machining apparatus 156.
Once all the portions of the tube located in the work area between clamps 126, 128 are machined, the table is positioned to bring the pipe extension so as to be located between open jaws 168, 170 of clamping apparatus 166 which are closed onto the pipe through extension of hydraulic cylinder 172. See the position of the table shown in phantom in FIG. 24a. As illustrated, the jaws of clamping apparatus 166 are configured to accommodate pipe of any outer diameter that would typically be processed by the apparatus. After the pipe is secured by clamp 166, the hydraulic cylinders of clamping devices 126, 127, 128 are retracted to release the pipe therefrom. Work table 124 is then moved along the axial direction of the pipe, from right to left as viewed in FIG. 24a, and brought into the position shown in FIG. 24. In this way, a second section of the curved surface of the tube is brought into position between clamping devices 127, 128. The hydraulic cylinders of clamping devices 126, 127, 128 are re-extended to again secure the pipe by clamping devices 126, 127, 128 and the jaws of clamping device 166 are released from the pipe. Work table 124 is then moved axially back into position (i.e., toward the six o'clock position in FIG. 6) so as to locate the next section of tubing to be machined, i.e., that tubing portion located between clamps 127, 128, in the work area "W" of the machining apparatus. The next section of the curved surface between the two clamps is then processed, the tube shuttled along to move the next section to be finished into the work area, etc., until the tube is fully axially translated with respect to clamping devices 126, 128. Once the machining operations to be carried out on the curved outer surface portion of the tube are complete, work table 129 is again rotated in the clockwise direction as indicated in FIG. 6, to the three o'clock position. The pipe is now in the same location as it was upon its initial conveyance into the work area, but its position is reversed. That is, tube end 26b is now in the work area. The interior portion of tube end 26b is then machined as desired to complete the machining of the tube. The tube is then conveyed along conveyor 19 and lifted from the conveyor by arm 174 onto cradle 176 in an upper position (not shown in FIG. 12). The cradle then moves into the lower position shown in FIG. 12, and comes to rest on rails 105 (clockwise direction as viewed in FIG. 12) and the finished pipe rolls under the force or gravity into storage area 22.
Single conveyor 19 is used to deliver stock pipes to both work stations 20 and to convey finished pipes to storage area 22. When not conveying a pipe, the roller conveyor is lowered into a position which provides clearance for the pipe resting on track 151 to be rotated away from conveyor 19. When a pipe in one of the work stations is positioned away from conveyor 19 (e.g., when scallops are being milled into its sides) the conveyor can be freely operated for movement of another pipe between the other work station and storage areas 18, 22.
In an alternative embodiment, the apparatus does not include clamping apparatus 166 for securing the pipe in place while the work table is moved with respect to the pipe. Rather, the pipe is held in position using by a locating tool installed on the driver of the of machining apparatus 156. The locating tool enters the scallop (or hole) farthest downstream in the work area and presses the pipe against the backing units 171 clamping devices 125, 127, 128 are released from the pipe and the table moved in direction of arrow 194b (FIG. 24a). The clamping devices then re-secure the pipe, the locating tool is disengaged from the pipe and returned to the magazine. The work tool is then replaced onto the driver and machining operations on the side of the pipe continued. In the sense that this embodiment requires time for deinstallation of a milling tool (e.g. scalloping tool), installation of the locating tool for the shuttling operation, deinstallation of the locating tool and reinstallation of the milling tool, this embodiment does not have the full time saving advantage of the previously described embodiment involving clamp 166. Further, of course, this embodiment requires a scallop or similar worked area on the side of a pipe for engagement of the pipe by the locating tool.
Appendix B, below, provides exemplary manufacturing times achievable with the invention disclosed herein.
It will be understood that a person skilled in the art would be capable of varying the embodiments described herein while remaining within the scope of this invention. Preferred embodiments having been described, claims which define the desired scope of protection for the invention follow.
APPENDIX A______________________________________G-Code for GUN Program______________________________________02S414(4" GUN 2 METER 14 SPM)(PRIME PERF.)(4" SCALLOPED CARRIER)(DO NOT CHANGE VARIABLES MARKED THUS)(DO NOT CHANGE ORDER OF VARIABLE INTRO)(SET O/D /2) [SV, V37=4.0/2](METERS LONG-2)(FINISHED LENGTH-93.12)(SCALLOPS PER METER) [SV, V57=14](TOTAL SCALLOPS) [SV, V67=27](SCALLOP DEPTH -.008) [SV, V42=.242](DEGREE OF PHASING-90)(SCALLOP PITCH) [SV, V52=3.0](DEPTH OF BROACH-.375) [SV, V31=3.462)(THREAD MAJ DIA) [SV, V32=3,437/2](BORE DIA/2 MID LIMIT) [SV, V47=3.5/2](THREAD MIN DIA/2 TOP LIMIT) [SV, V48=3.279/2](.102 GROOVE DIA FOR) [SV, V36=3.56/2](DEPTH OF .102 GROOVE) [SV, V50=3.40](START POINT OF FIRST SCALLOP IN POS.) [SV, V38=7.56](*DEPTH OF THREAD CALC.) [SV, V33=V50-.135](*START POINT OF SECOND THREAD PASS) [SV,V35=[V33-.1667]](*LOOP COUNT TO SKIP FIRST SCALLOP) [SV, V39=0](*W AXIS EXTENSION T1)[IF, V37<2.125/2, GO, 2][IF V37<3.4/2 GO, 3][IF V37<4.125/2, GO, 4][IF V37<5.1255/2, GO, 5][IF V37<6.125/2, GO, 6]N2[SV, V40=14.1875] [GO, 7]N3[SV, V40=13.5] [GO, 7]N4[SV, V40=12.875] [GO, 7]N5 [SV, V40=12.375] [GO, 7]N6 [SV, V40=11.875] [GO, 7]N7(*W AXIS T9 PLUNGER) [SV, V41=[V40-1.267+V42+.25+.06]](*VARIABLE PULL IN SCALLOP END) [SV, V44=V38](*LAST PULL ABS. POS. CALCULATION)(*ROTARY TABLE PUSH ERROR, SET TO JAW ERROR)[IF, V37<3.4/2, GO, 9][IF, V37<4.125/2, GO, 10][IF, V37<5.1255/2, GO, 11][IF, V37<6.125/2, GO, 12]N9[SV, V46=.0035] [SV, V64=.006] [SV, V60=17][SV, V62=1.] [SV, V63=1] [SV, V70=12][GO, 13]N10[SV, V46=.004] [SV, V64=-.306] [SV, V60=18][SV,V62=1.] [SV, V63=.9] [SV, V70=13] [SV, V72=4.845][GO, 13]N11[SV, V46=.003] [SV, V64=-.871] [SV, V60=19][SV, V62=1.58] [SV, V63=.8] [SV, V70=14][G0, 13]N12[SV, V46=.006] [SV, V64=[SV, V60=20]SV, V62=1.] [SV, V63=.7][GO, 13]N13(RADIAL PLUS FACTOR IN THREAD) [SV, V49=.02][IF, V57=14, GO, 14][IF, V57=17, GO 15][IF, V57=20, GO, 16][IF, V57=26, GO, 17]N14[SV, V56=6] [SV, V66=7][SV, V58=12] [GO, 18]N15[SV, V56=7] [SV, V66=8][SV, V58=14.4] [GO, 18]N16[SV, V56=9] [SV, V66=10][SV, V58=12] [G0, 18]N17[SV, V56=12] [SV, V66=13][SV, V58=12] [GO, 18]N18(V67 IS NUM OF SCAL)[SV, V81=V67-V66](V81 IS NUM OF SCAL AFTER 1ST PULL)[SV, V82=V8 1/[V66-1]](V66-1 IS NUMBER OF SCALS IN FULL CYCLES OTHER THANFIRST CYCLE)(V82 IS NUM FULL CYCLES IN V81)[SV, V55=FOMT[V82]](ABOVE LINE REMOVES DECIMAL PORTION OF V82)[SV, V84=V82-V55](V84 IS FRACTION OF FULL CYCLE LEFT)[SV, V85=[V66-1]*V84](V85 IS SCAL LEFT TO DO)[SV, V51=FRND[V85]](VS1 NEEDS TO BE AN INTEGER)(SV, V53=V56*V52)[SV, V45=54.532-[V38+V56*V52]-[V38+V58] + [V38+V53-V581]][IF, V52*V56+V38>25.6, GO, 9999][IF, V38<7, GO, 9999][IF, V37<1.65, GO, 9999]G72$MAINNEWN9999M30%OMAINEW(MAIN PROG. FOR 3+4" GUNS)G25G73Z45.25G 53[IF, V57=26, GO, 2][IF, V57=39, GO, 2]N1G57H901[GO, 3]N2G57H909N3G0G90X.440M96M97M00 (LOAD PIPE)(LOWER LIFTING ROLLERS)T[V60]N1(6"STOP)G43H20GOX.440Y0Z1.M19Z.06M00 (PUSH PIPE UP TO STOP)M90 (LOCK ENDS)M94 (CLAMP CHUCK)M00 (MAKE SURE LIFTING ROLLERS ARE DOWN)(START)Z2.M06[IF, V57=26, GO, 4][IF, V57=39, GO, 4][SV, V61=901] [SV, V65=1][SV, V71=0][IF, V37=5.0/2, GO, 5]G72$ENDNEW[GO, 6]N4[SV, V61=909] [SV, V65=1][SV, V71=0]N5G72$ENDSTN6M51M93M00(SCREW MANDREL INTO END OF GUN)[IF, V57=26, GO, 8][IF, V57=39, GO, 8]N7GS7H902[GO, 9]N8G57H910N9GOX-25.G91B-90T[V60]G90G24X39.506Y31.545Z45.75119.677J-.01K17.675(TABLE AT ZERO)G72$SCALLOP, L[V55](V44=ABS.PULL POS. FOR LAST SCALLOPS)[SV, V44=V38+V53-[51*V52]]G72$SCALLOP, L1[IF V84=0, GO, 49](SCALLOP FINISH)[IF V57=26, GO, 11][IF V57=39, GO, 11]N10G58W-[V40]H902G58Z[V37-.025]H902G57H902[GO, 12]N11G58W-[V40]H910G58Z[V37-.025]H910G57H910N12G90MEG43H1Z.25W-[V40]Y0M8[IF, V66=4, GO, 13][ff, V66=7, GO, 14][IF, V66=8, GO, 15][IF, V66=10, GO, 16][IF, V66=13, GO, 17][IF, V66=15, GO, 18][IF, V66=19, GO, 19]GO, 20]N13G72$4SCAL[GO, 20]N14G72$7SCAL[GO, 20]N15G72$8SSCAL[GO, 20]N16G72$10SCAL[GO, 20]N17G72$13SCAL[GO, 20]N18G72$15SCAL[GO, 20]N19G72$19SCALN20M01N49N99M9(PULL BACK TO MACHINE LAST END)[IF, V57=26, GO, 22][IF, V57=39, GO, 22]N21G57H902[GO, 23]N22G57H910N23G010G73W0M5M00G0X-[V38+V53-V58]G73Z22.62M92M95 (OPEN CHUCK)G1X-[V38+V53+V46]F100.M94M93G04P2[IF, V67=17,GO, 220]X-[V3 8+V53-V58][GO, 221]N220X-[V3 8+V53-V58+2.4]N221M92M95[IF, V67=17, GO, 300]G1X-[V45+V46]F100.[GO, 301]N300G1X-[V45+V46+2.4]F100.N301M94M93 OPBN GRIPPERG04P2. DWELLM06 TOOL CHANGEX-25.G0G90B-270M92M90(LOCK ENDS)[IF, V57=26, GO, 25][IF, V57=39, GO, 25]N24[SV, V61=903][GO, 26]N25[SV, V61=911]N26[SV, V65=20]G25[IF, V57=26, GO, 28][IF, V57=39, GO, 28][IF, V37=5.0/2, GO, 28]N27G72$ENDNEW[GO, 29]N28072$ENDSTN29M00G57H901G0G90X.44M95M51 (UNLOCK)M00 (UNLOAD)M00 (LAST CALL TO UNLOAD)G0090B90M30%______________________________________
APPENDIX B______________________________________Examples of total carrier manufacturing times.Carrier Number of ManufacturingDiameter Shot per Meter Carrier Length Scallops time______________________________________3 3/8" 14 (4 spf) 1 m 14 24.7 minutes 3 m 40 33.43 3/8" 20 (6 spf) 2 m 40 32.1 4 m 80 39.24.0" 14 1.5 m 21 32.1 3 m 40 39.3 6 m 80 55.1 17 (5 spf) 1 m 17 29.9 3 m 50 39.4 6 m 100 57.4 20 (6 spf) 1 m 20 30.2 3 m 60 39.3 6 m 120 56.9 30 (9 spf) 1 m 31 32.4 3 m 90 45.6 4 m 120 52.15.0" 14 1 m 14 34.0 3 m 40 34.0 6 m 80 59.1 17 1 m 17 34.0 3 m 50 43.8 6 m 100 61.2 26 (8 spf) 2 m 54 41.8 3 m 81 48.5 5 m 133 60.9 39 (12 spf) 2 m 79 46.3 3 m 118 52.8 6 m 196 68.0______________________________________ | An apparatus for manufacturing a machined article from an elongated tubular workpiece is disclosed. A machining device is movable within a work area of the apparatus and a movable base having first and second spaced apart clamps secure a section of the article. A stationary third clamp is mounted independent of the movable base for holding the article in a stationary position relative to the movable base. A conveyor permits positioning of the article relative to the clamps. | 8 |
FIELD OF THE INVENTION
[0001] The invention relates to an assembly of a substrate measurement system as defined in the preamble of claim 1.
PRIOR ART
[0002] Such a cluster tool is known from WO 99/49500, in which, in order to reduce cycle time overhead, an inspection tool (e.g. a optical microscope) and one or more review tools (e.g. a scanning electron microscope and/or an atomic force microscope) are linked by an automation platform that handles wafer transport between the tools and a substrate container interface. Although the cluster tool is designed to be optimised with respect to the throughput from one tool (e.g. inspection) to another (e.g. one of the provided review tools), the flexibility of the cluster in terms of maintenance and repair of one of the tools is low: in such a case the complete cluster will be out of order. Also, flexibility in terms of reconfiguring a cluster tool on-site for a different type of wafer analysis, by just a simple replacement of the measurement tools is low.
SUMMARY OF THE INVENTION
[0003] It is the objective of the present invention to provide a solution for these problems by a more flexible arrangement of the measurement tools and the substrate transfer means involved.
[0004] The present invention relates to an assembly of a substrate measurement system as defined in the preamble of claim 1, characterised in that a second measurement chamber is provided, which fits within the same dimensions as said first measurement chamber and is provided with the same identical interface as said first measurement chamber to replace said first measurement chamber.
[0005] The present invention provides a substrate measurement system comprising a central substrate handling chamber which is provided with substrate transfer means, at least one substrate container interface with a standardised interface and arranged to receive a matching substrate container, and a mechanical interface to receive a measurement chamber comprising a measurement instrument. The measurement chamber has a standardised size and is provided with standardised mechanical interface, in order to connect to the corresponding interface of the substrate handling chamber. Because of the standardisation of the measurement chamber, the modular substrate measurement system can easily be configured with different types of measurement instruments for a certain application by a simple replacement of one measurement chamber by another chamber.
[0006] According to a preferred embodiment of the present invention, the central substrate handling chamber comprises two or more measurement chambers of standardised size and provided with a standardised mechanical interface. In this embodiment, the substrate transfer means are shared by the two or more measurement instruments inside their respective measurement chambers and the substrate container interface, resulting in savings in cost and floor space. Moreover, two or more measurements on a single wafer can be executed sequentially without time delay. In this embodiment, more than one substrate container interface can be connected to the substrate handling chamber. The measurement chambers can be distributed in a substantially horizontal plane but they can also be stacked in a substantially vertical direction.
[0007] According to a embodiment of the present invention, the substrate measurement system comprises a substrate container stocker system arranged to store a plurality of substrate containers, each containing a batch of wafers awaiting measurements, and substrate container transfer means. The substrate container transfer means transfer substrate containers between the stocker system and the substrate container interface of the substrate handling chamber. In this manner, a further increase in efficiency is possible by providing a wafer storage buffer in the stocker system. Due to the physical separation of the functionality of process tools and measurement tools, the delay times in both the process tools and the measurement tools may be reduced since their respective cycle times are no longer dependent on each other.
[0008] According to a further embodiment of the preset invention, the substrate container interfaces and the mechanical interface of the substrate handling chamber arranged to connect to a measurement chamber are standardised, so that at choice a station can receive either a substrate container or a measurement chamber. In this way, the flexibility of a modular substrate measurement system is increased even further. The system can be adapted to specific needs within a short time. Also, replacement and repair of a measurement chamber containing a defective measurement instrument may be strongly simplified due to the modularity of the system.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Below, the invention will be explained with reference to the drawings, which are intended for illustration purposes only and not to limit the scope of protection as defined in the accompanying claims.
[0010] [0010]FIG. 1 is a schematic top view diagram showing a substrate measurement system according to a first embodiment;
[0011] [0011]FIG. 2 is a schematic top view diagram showing a substrate measurement system according to a second embodiment;
[0012] [0012]FIG. 3 is a schematic top view diagram showing a substrate measurement system according to a third embodiment;
[0013] [0013]FIG. 4 a is an exploded perspective view of a substrate measurement system according to the fourth embodiment;
[0014] [0014]FIG. 4 b is a schematic top view diagram showing a substrate measurement system according to a fourth embodiment;
[0015] [0015]FIG. 5 a is an exploded perspective view of a substrate measurement system according to the fifth embodiment;
[0016] [0016]FIG. 5 b is a schematic top view diagram showing a substrate measurement system according to a fifth embodiment.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] [0017]FIG. 1 shows a substrate measurement system comprising a centrally mounted substrate handling chamber 7 , provided with wafer transfer means 10 . The substrate handling chamber is provided with a substrate container interface 1 and a mechanical interface 50 on which a measurement chamber 30 is connected. Substrate container interface 1 is connected to substrate handling chamber 7 . On substrate container interface 1 a substrate container 8 is mounted. Substrate container interface 1 provides a standardised mechanical interface on which the substrate container 8 is connected by means of a corresponding interface.
[0018] In the measurement chamber 30 a measurement instrument 35 is provided for a certain application, e.g. measurement of the thickness of a film on a wafer. Both substrate handling chamber 7 and measurement chamber 30 comprise standardised mechanical interfaces; the mechanical interface 50 provided on the substrate handling chamber 7 and the matching interface 51 on the measurement chamber 30 are standardised.
[0019] The mechanical interface 50 and the matching interface 51 both provide matching coupling parts 52 and 53 , respectively, for coupling the measurement chamber 30 to the substrate handling chamber 7 . The coupling provides a gaslight sealable coupling between the measurement chamber 30 and the substrate chamber 7 . In this manner, the measurement chamber 30 can be used under controlled vacuum pressure conditions. Also, the mechanical interface 50 provides a mechanical support area 54 for supporting the measurement chamber 30 on a matching support area 55 of the mechanical interface 51 . The support areas 54 , 55 may be arranged as a substantially horizontal area, a substantially vertical area, or a combination of both. The fit of such a mechanical support area 54 and a matching support area 55 may provided in any conceivable way as known in the art.
[0020] Thus, by the arrangement of the mechanical interface 50 and the matching interface 51 as described above, the measurement chamber 30 can easily be replaced by another measurement chamber such as 39 or 40 , each also provided with the standardised mechanical interface 51 and its respective measurement instrument 41 or 42 , specific to their respective desired application. The replacement of measurement chambers is schematically indicated in FIG. 1 by arrows R 1 , R 2 , R 3 and R 4 .
[0021] To permit easy replacement of a measurement chamber 30 , 39 , 40 , and to have truly portable measurement chambers, a measurement chamber with its contents, preferably, does not weigh more than about 15-30 kilograms and, preferably, has a maximum size of about 50 centimetres in length, width and height. In this way, a measurement chamber can be replaced quickly within a few minutes, and a very flexible measurement procedure is obtained.
[0022] In a particular embodiment, the measurement interfaces 50 and 51 can be designed and dimensioned as Front-Opening Unified Pod (FOUP) interfaces according to SEMI standard E47.1. In this design a pod is supported on a platform by three support pins, which fit in three recessions in the bottom of the pod, everything dimensioned in prescribed dimensions.
[0023] [0023]FIG. 2 shows a second embodiment of the present invention of a substrate measurement system wherein a plurality of stations is distributed in a substantially horizontal plane around a centrally mounted substrate handling chamber 7 , provided with wafer transfer means 10 . The substrate handling chamber has the shape of a regular hexagon, but other shapes, including shapes with less or more sides, and/or irregular shapes are also possible. Two substrate container interfaces 1 and 2 are shown with substrate container 8 and 9 installed on substrate container interface 1 and 2 , respectively. Four measurement chambers 30 , 31 , 32 , 33 are shown, each connected to substrate handling chamber 7 . The measurement chambers 30 , 31 , 32 , 33 comprise a respective measurement instrument 35 , 36 , 37 and 38 , specific to the application of each measurement chamber. The measurement chambers 30 , 31 , 32 , 33 have standardised dimensions and standardised mechanical interfaces 51 matching the standardised interfaces 50 of the substrate handling chamber 7 in such a manner that any of the measurement chamber 30 , 31 , 32 or 33 , can be interchangeably mounted on any one position of the measurement chambers 30 , 31 , 32 or 33 .
[0024] The substrate transfer means are capable of transferring a substrate from any of the substrate containers 8 , 9 , located on substrate container interfaces 1 , 2 , by means of their interfaces 80 , 81 , in any required sequence along any number of the measurement chambers 30 , 31 , 32 , 33 and of returning the substrate in either, the same substrate container or the other substrate container, respectively.
[0025] During measurement of a substrate in any of the measurement instruments 35 , 36 , 37 , 38 , located in one of the measurement chambers 30 , 31 , 32 , 33 , the substrate can be supported by the substrate means 10 . But, most preferably, the substrate is supported on substrate support means (not shown) inside the measurement chamber 35 , 36 , 37 , 38 and the substrate transfer means 10 are retracted from the measurement chamber 30 , 31 , 32 , 33 . In this way, during measurement of one substrate in one measurement instrument, the substrate transfer means 10 is available to transfer other substrates to and from one of the other measurement instruments.
[0026] The substrate handling chamber 7 can also be equipped with a station for substrate aligning or for substrate identification, as known in the art. Alternatively, one of the measurement chambers can be equipped with a station for substrate aligning and/or for substrate identification. When two or more substrate container interfaces 1 , 2 are provided, one of the substrate containers could be used for substrates that are rejected on the basis of the results of the measurement(s) performed on them.
[0027] In the embodiment of FIG. 2, each measurement chamber 30 , 31 , 32 , 33 can easily be replaced by one of a plurality of other measurement chambers 39 , 40 , that are each provided with its respective measurement 41 or 42 , specific to the desired application.
[0028] [0028]FIG. 3 shows a modular substrate measurement system according to a third embodiment wherein the substrate container interfaces 1 , 2 , 3 and the measurement chambers 30 , 31 32 are grouped in linear arrays around an elongated substrate handling chamber 7 . Between substrate handling chamber and measurement chambers, mechanical interfaces 50 and 51 are provided as described in the previous embodiments. On the substrate container interfaces 1 , 2 , 3 substrate containers 8 , 9 , 11 are mounted. The substrate transfer means 10 comprise means for a linear translation in the substantially longitudinal direction of the substrate handling chamber 7 , as indicated by the arrows T 1 and T 2 .
[0029] In the embodiment of FIG. 3, due to the standardised mechanical interfaces 50 and 51 , each measurement chamber 30 , 31 , 32 can easily replaced by one of a plurality of other measurement chambers 39 , 40 , that are each provided with its respective measurement instrument 41 or 42 , specific to the desired application. Also, due to the standardised mechanical interfaces 50 and 51 , the measurement chambers 30 , 31 , 32 can be mutually exchanged in any way selected.
[0030] [0030]FIGS. 4 a and 4 b show a substrate measurement system according to a fourth embodiment. As shown in FIG. 4 a in an exploded perspective view of this embodiment, two substrate container interfaces 1 , 2 are provided, stacked on each other in a vertical direction. Substrate containers 8 , 9 are mounted on their respective substrate container interfaces 1 , 2 . Measurement chambers 30 , 31 , 32 , 33 provided with measurement instruments 35 , 36 , 37 , 38 are linked to a central substrate handling chamber 7 , by means of the standard mechanical interfaces 51 on the chambers 30 , 31 , 32 and one of the corresponding interfaces 50 of the chamber 7 . The measurement chambers are distributed here both in a substantially horizontal and a substantially vertical direction. The measurement chamber 30 is next to the station 31 at a right angle. The chamber 31 is on top of the chamber 32 , and the chamber 30 is on top of the chamber 33 (not visible).
[0031] In this embodiment, the substrate transfer means 10 of substrate handling chamber 7 is capable of transferring substrates to and from stations 1 , 2 , 30 , 31 , 32 , 33 both in a substantially horizontal and a substantially vertical direction.
[0032] In FIG. 4 b a top view of this embodiment of the present invention is shown. The measurement chambers 30 and 31 are located at a 90° angle with respect to their front sides. It is to be understood that any other suitable angle between the measurement chambers can be used as well.
[0033] In the embodiment of FIGS. 4 a and 4 b, due to the standardised mechanical interfaces 50 and 51 , each measurement chamber 30 , 31 , 32 , 33 can easily replaced by one of a plurality of other measurement chambers 39 , 40 (not shown), that are each provided with its respective measurement instrument 41 or 42 , specific to the desired application. Also, due to the standardised mechanical interfaces 50 and 51 , the measurement chambers 30 , 31 , 32 , 33 can be mutually exchanged in any way selected.
[0034] [0034]FIGS. 5 a and 5 b show the substrate measurement system according to a fifth embodiment, wherein the substrate measurement system is provided with a substrate container stocker and substrate container transfer means to transfer substrate container between the substrate container stocker and the substrate container interfaces.
[0035] As shown in FIG. 5 a in an exploded perspective view of this embodiment, two substrate container interfaces 1 , 2 are provided, stacked on each other in a vertical direction. Substrate containers 8 , 9 are mounted on their respective substrate container interfaces 1 , 2 . Measurement chambers 30 , 31 , 32 , 33 provided with measurement instruments 35 , 36 , 37 , 38 are linked to a central substrate handling chamber 7 , by means of the standard mechanical interfaces 51 on the stations 30 , 31 , 32 and one of the corresponding interfaces 50 of the chamber 7 . The measurement chambers are distributed here both in a substantially horizontal and a substantially vertical direction. The measurement chamber 30 is next to the chamber 31 at a right angle. The chamber 31 is on top of the chamber 32 , and the chamber 30 is on top of chamber 33 (not visible).
[0036] In this embodiment, the substrate transfer means 10 of substrate handling chamber 7 is capable of transferring substrates to and from stations 1 , 2 , 30 , 31 , 32 both in a substantially horizontal and a substantially vertical direction.
[0037] Substrate containers 8 , 9 mounted on the substrate container interfaces 1 , 2 , are transferred to and from the substrate container stocker 19 by transfer means 17 and 21 . In the substrate container stocker 19 , substrate containers are stored in a carrousel 14 which comprises a plurality of storage shelves 16 . Each shelf 16 can rotate around a central axis 20 in the carrousel and can contain a number of substrate containers. The substrate container stocking means 17 can transfer containers in both a substantially horizontal and substantially vertical direction to reach certain locations in the carrousel. Substrate containers can be entered in the system by means of the substrate container entrance stations 12 , 13 which provide interfaces for mounting substrate containers which can be simplified as compared to the substrate container interfaces 1 and 2 . The transfer means 17 and 21 transfer the substrate containers from the substrate container entrance stations 12 and 13 to the substrate container stocker 19 . Also, the transfer means 17 and 21 can transfer a substrate container directly from a substrate container entrance station 12 , 13 to a substrate container interface 1 , 2 and vice versa.
[0038] As is known in the art, it is possible to provide just on entrance station 12 or more than two entrance stations. An operator 18 can monitor and operate the system by means of a control unit comprising means for displaying and entering commands, e.g., a touch screen 15 . The control unit may comprise other means (not shown) as required for its function, as is known in the art.
[0039] Alternatively, the substrate container stocker may comprise a linear storeroom, in which containers are stored on rectangular shelves instead of inside the carrousel 14 , and linear substrate container transfer means instead of the substrate container transfer means 17 and 21 .
[0040] In the embodiment of FIGS. 5 a and 5 b, due to the standardisation of the mechanical interfaces 50 and 51 , each measurement chamber 30 , 31 , 32 , 33 can easily replaced by one of a plurality of other measurement chambers 39 , 40 (not shown), that are each provided with its respective measurement instrument 41 or 42 , specific to the desired application. Also, due to the standardised mechanical interfaces 50 and 51 , the measurement chambers 30 , 31 , 32 , 33 can be mutually exchanged in any way selected. The substrate handling chamber 7 can have a dust-free air atmosphere but also a controlled or protective atmosphere of an inert gas like nitrogen N 2 or a noble gas like argon Ar may be provided. Alternatively, it is possible to have the substrate handling chamber 7 evacuated. In that case, the substrate container interfaces 1 , 2 , 3 provide a load-lock to transfer substrates from the substrate containers 8 , 9 , 11 to and from vacuum.
[0041] Similarly, the measurement instrument 35 , 36 , 37 , 38 may require specific atmospheric conditions like a protective ambient (nitrogen or argon), or vacuum. In that case, the measurement chamber 30 , 31 , 32 , 33 and/or the substrate handling chamber 7 provide means to supply, maintain and confine the ambient within the measurement chamber. It will be understood that the measurement instrument 35 , 36 , 37 , 38 as mounted on the measurement chamber 30 , 31 , 32 , 33 comprises the essential parts to facilitate the measurement. However, other parts like e.g. a power supply, a vacuum pump, or a computer system linked to a measurement instrument, can be mounted at some distance of the measurement instrument 35 , 36 , 37 , 38 and/or the measurement chamber 30 , 31 , 32 33 , as will be known to persons skilled in the art. These other parts may be placed remotely from the substrate measurement system, if required.
[0042] It will be understood that, in particular when the sensor of the measurement instrument is small, a measurement chamber can comprise more than one sensor.
[0043] It will also be clear that for the first three embodiments the stations can also be stacked in a substantially vertical direction.
[0044] Typically, one desire to perform measurements at a number of locations spread over the substrate surface area. This can be realised by translating the substrate in two horizontal and orthogonal directions. However, this requires a lot of space: about two times the dimension of the substrate in both directions. By keeping the dimensions of each measurement chamber small the modularity of the system can be exploited to the full extent by connecting a plurality of measurement chambers to the substrate handling chamber while keeping the overall dimensions of the system within acceptable limits. To this end, the measurement chambers 30 - 33 , 39 , 40 are preferably provided with rotating means to rotate the substrate support means which support the substrate. In the measurement chamber 30 - 33 , 39 , 40 a sensor of a measurement instrument 35 - 38 , 41 , 42 is provided with sensor transfer means to translate the sensor relative to the substrate, in order to facilitate substrate mapping measurements.
[0045] The sensor transfer means may provide a linear displacement of the sensor, for example in a horizontal direction, perpendicular to the coupling part 53 of the interface 51 , or diagonally across the measurement chamber 30 - 33 , 39 , 40 . Also, for example, the sensor transfer means may provide a displacement of the sensor in a horizontal direction along a curved trace, when the sensor is attached to a sensor transfer means that can rotate around a mounting point.
[0046] Alternatively, the measurement sensor can be mounted at a fixed position within the measurement chamber 30 - 33 , 39 , 40 . In that case, the substrate support means are provided with support transfer means to displace the substrate relative to the sensor in a horizontal direction, preferably in the direction in which loading/unloading of the substrate takes place.
[0047] Also, it may be possible that sensor transfer means and support transfer means are provided which can displace both the measurement sensor and the substrate relative to each other, in two horizontal and orthogonal directions.
[0048] In this way the outside dimensions of the measurement chamber need to be only slightly larger than the dimensions of the substrate to allow mapping of the wafer. When the substrate is circular, with a diameter of 300 mm or greater, the measurement chamber can fit within a horizontal square or rectangular cross section with the smallest dimension less than 100 mm larger than the substrate diameter. For the compactness of the system it is advantageous to have this smallest dimension at the side that is mounted against the substrate handling chamber. | Substrate measurement system including a measurement chamber ( 30 ), and a substrate handling chamber ( 7 ) possessing substrate transfer means ( 10 ) and a substrate container interface ( 1 ) arranged two receive a substrate container ( 8 ), the handling chamber ( 7 ) containing a first interface ( 50 ) to connect the measurement chamber ( 30 ), the measurement chamber ( 30 ) containing a second interface ( 51 ) to connect the handling chamber ( 7 ), and the transfer means ( 10 ) being arranged to transfer substrates between the container ( 8 ) and the measurement chamber ( 30 ) through the handling chamber ( 7 ), in which system a second measurement chamber ( 39 ) is provided, having the same second interface ( 51 ) as the first measurement chamber ( 30 ) to replace the latter chamber ( 30 ). | 7 |
FIELD OF THE INVENTION
[0001] The present invention relates to sulfur containing fluoroalkyl amines, methods for making the same, and isocyanate/isothiocyanate derivatives of the same.
BACKGROUND OF THE INVENTION
[0002] Sulfur containing fluoroalkyl amines are useful as intermediates for compounds which are in turn useful for imparting water and oil repellency to textiles. Sulfur containing fluoroalkyl amines used in this manner may be found in Example 8 of Rondestvedt et al. (U.S. Pat. No. 3,655,732) wherein they are made by reacting an iodo-fluoroalkyl with an aminoalkyl thiol. Specifically, Rondestvedt et al. teaches reacting CF 3 (CF 2 ) 5 (CH 2 ) 2 I (an iodo-fluoroalkyl) with HS—CH 2 CH 2 —NH 2 (an aminoalkyl thiol) to make CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 CH 2 —NH 2 (a sulfur containing fluoroalkyl amine).
[0003] One disadvantage of preparing sulfur containing fluoroalkyl amines according to the method disclosed by Rondestvedt et al. is that crude product obtained by such a method can contain up to 29 mole percent of impurities. To increase yield and reduce the amount of these impurities, tert-butanol has been used as reaction solvent ( J. Org. Chem. 1977, 42, 2680-2683); however, tert-butanol is relatively expensive and subsequent isolation of the product can be unpredictably tedious due to foam and emulsion formation.
[0004] In addition to problems of poor yield, another disadvantage of preparing sulfur containing fluoroalkyl amines according to the method disclosed by Rondestvedt et al. is that such a method is incapable of producing oxidized forms of sulfur containing fluoroalkyl amines. While Rondestvedt et al. disclose a method of making sulfur containing fluoroalkyl amines such as CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 CH 2 —NH 2 , the method of Rondestvedt et al. cannot produce corresponding oxidized forms such as CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O)—CH 2 CH 2 —NH 2 or CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O) 2 —CH 2 CH 2 —NH 2 .
BRIEF SUMMARY OF THE INVENTION
[0005] The present invention provides a method of making sulfur containing fluoroalkyl amines which overcomes the problems of previously known methods such as the one described by Rondestvedt. For example, unlike previously known methods, the method of the present invention can achieve higher yields of sulfur containing fluoroalkyl amines without resorting to costly solvents. Furthermore, unlike previously known methods, the method of the present invention can produce oxidized forms of sulfur containing fluoroalkyl amines wherein the sulfur atom thereof is oxidized.
[0006] In the method of the present invention, a fluoroalkyl thiol is reacted with a N-vinylamide resulting in an amide intermediate which is then subjected to deacylation to make corresponding sulfur containing fluoroalkyl amine. Optionally, the amide intermediate can be subjected to oxidation prior to deacylation thereby producing an oxidized form of sulfur containing fluoroalkyl amines wherein the sulfur atom thereof is oxidized.
[0007] Fluoroalkyl thiols useful in the present invention are represented by R f -Q-SH wherein R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl can be optionally replaced by hydrogen, and/or ii) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene; Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group.
[0008] N-Vinylamides useful in the present invention are represented by H 2 C═CH—(CH 2 ) y —NR—C(O)—R wherein y is an integer chosen from 0 to 16, preferably 1, and most preferably 0; and each R is independently chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H.
[0009] When the aforementioned fluoroalkyl thiols and the aforementioned N-vinylamides are reacted, in accordance with the present invention, the result is an amide intermediate of the present invention represented by R f -Q-S—C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R wherein each R is independently chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H; i is 1 or 2, j is 0 or 1; provided that i+j=2. More preferably i=1, j=1, and z=O, Still even more preferably i=2, j=0, and z=0.
[0010] Except where otherwise noted, the aforementioned definitions for R f , Q, R, i, j, y and z are applied consistently throughout the specification and claims.
[0011] The amide intermediate of the present invention can be subjected to deacylation to produce a sulfur containing fluoroalkyl amine represented by R f -Q-S—C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NHR wherein R is chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H. Optionally, prior to removal of the acyl group, the amide intermediate of the present invention can be subjected to oxidation to produce a sulfur oxide intermediate of the present invention represented by R f -Q-S(O) x —C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R wherein x is 1 or 2. Except where otherwise noted, the aforementioned definition x is used consistently throughout the specification and claims. The sulfur oxide intermediate can then be subjected to deacylation to produce a sulfur containing fluoroalkyl amine of the present invention represented by R f -Q-S(O) x —C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NHR. Previously known methods were not capable of making sulfur containing fluoroalkyl amines having the —S(O) x — moiety.
[0012] Advantageously, the amide intermediate of the present invention of the present invention represented by R f -Q-S—C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R can be subjected to oxidation such that the sulfur atom thereof is selectively oxidized while the amide group, NR—C(O)—R, remains unoxidized. After oxidation, deacylation can be conducted to convert the amide group, NR—C(O)—R, into an amine group, —NHR, thereby resulting in a sulfur containing fluoroalkyl amine wherein the sulfur thereof is oxidized. Previously known methods do not form any intermediate wherein the sulfur atom thereof can be selectively oxidized. In contrast to the present invention, previously known methods only make compounds wherein both a sulfur group, —S—, and an amine group, —NHR, are present thereby rendering the selective oxidation of the sulfur group impossible because of the potential oxidation of the amine group.
DETAILED DESCRIPTION OF THE INVENTION
[0013] Unless otherwise stated, the R f moiety referred to throughout this disclosure is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene; and/or ii) one fluorine atom of the perfluoroalkyl can be optionally substituted by one hydrogen when the perfluoroalkyl is not interrupted by methylene or ethylene. Examples of R f moieties which are chosen from a perfluoroalkyl without substitutions or interruptions include (CF 3 ) 2 CF, and CF 3 (CF 2 ) m wherein m is an integer from 1 to 11. Examples of R f moieties which are chosen from a perfluoroalkyl substituted by one hydrogen include (CF 3 ) 2 CH, CF 3 (CF 2 ) 2 OCFHCF 2 , and HC m F 2m wherein m is 2 to 12. Examples of R f moieties which are chosen from a perfluoroalkyl which is interrupted by at least one oxygen include CF 3 (CF 2 ) 2 OCF 2 CF 2 and CF 3 (CF 2 ) 2 OCFHCF 2 , and CF 3 CF 2 CF 2 [OCF(CF 3 )CF 2 ] m OCRF wherein m is an integer from 6 to 15 and R can be F, CF 3 , or H. Examples of R f moieties which are chosen from a C 2 -C 12 perfluoroalkyl which is interrupted by at least one methylene include CF 3 (CF 2 ) 3 (CH 2 CF 2 ) m and CF 3 (CF 2 ) 5 (CH 2 CF 2 ) m wherein m is 1, 2, or 3. Examples of R f moieties which are chosen from a perfluoroalkyl which is interrupted by at least one ethylene include F[(CF 2 CF 2 ) n (CH 2 CH 2 ) m ] k CF 2 CF 2 wherein n=1, 2, or 3 preferably 1; and m=1, or 2 preferably 1; and k=1, 2, or 3.
[0014] Unless otherwise stated, the term “fluoroalkyl thiol” or “thiol” as used throughout this disclosure means a compound represented by R f -Q-SH wherein Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group. The fluoroalkyl thiols useful in the present invention can be made by any known method. For example, Lantz (U.S. Pat. No. 4,845,300) discloses the following reaction scheme for making thiols useful for the present invention: RfCH 2 CH 2 I+S═C(NH 2 ) 2 →[R f CH 2 CH 2 S—(NH 2 ) 2 ] + I 31 +NaOH→R f CH 2 CH 2 SH+NaI+O═C(NH 2 ) 2 +MeOH wherein R f is defined therein. Alternatively, Jacobson (U.S. Pat. No. 5,728,887) discloses hydrogenation for making thiols useful for the present invention: R f CH 2 CH 2 SCN+H 2 →R f CH 2 CH 2 SH+HCN wherein R f is defined therein. Alternatively, a thioacetate intermediate ( J. Fluorine Chem. 2000, 104, 173-183) can be used according to the following reaction: R f CH 2 CH 2 I+KSOCMe→(saponification)→R f CH 2 CH 2 SH+KOAc.
[0015] Unless otherwise stated, the N-vinylamides referred to throughout this disclosure and useful in the present invention are represented by H 2 C═CH—(CH 2 ) y —NR—C(O)—R wherein y is an integer chosen from 0 to 16, preferably 1, and most preferably 0; and each R is independently chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H. N-Vinylamides useful in the present invention include well known compounds which are commercially available such as N-vinylformamide, N-vinylacetamide, N-vinyl-N-methyl-acetamide, N-vinylpyrrolidone, and N-allyl formamide.
[0016] In the method of the present invention, a fluoroalkyl thiol is reacted with a N-vinylamide resulting in an amide intermediate which is then subjected to deacylation to make a corresponding sulfur containing fluoroalkyl amine. Optionally, the amide intermediate can be subjected to oxidation prior to deacylation thereby producing an oxidized form of sulfur containing fluoroalkyl amines wherein the sulfur atom thereof is oxidized.
[0017] Unless otherwise stated, the amide intermediates referred to throughout this disclosure are represented by R f -Q-S—C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R wherein each R is independently chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H. The amide intermediates of the present invention are made by reacting a fluoroalkyl thiol, R f -Q-SH, with a N-vinylamide, H 2 C═CH—(CH 2 ) y —NR—C(O)—R.
[0018] Specifically, the amide intermediates of the present invention can be made by the free-radical addition of a fluoroalkyl thiol, R f -Q-SH, to a N-vinylamide, H 2 C═CH—(CH 2 ) y —NR—C(O)—R. Reaction conditions for free-radical conditions are well known in the art. An example of a method for conducting free-radical addition involves dissolving one equivalent of a chosen thiol, one equivalent of a chosen N-vinylamide, and an initiator. The solution is then heated to a temperature (typically about 65° C.) which activates the reaction which is stirred until complete consumption of the thiol as determined by gas chromatography-mass spectrometry (GC/MS) monitoring.
[0019] Useful initiators for free-radical addition are well known in the art and include: azo compounds, such as azobisisobutyronitrile and azo-2-cyanovaleric acid; hydroperoxides, such as cumene, t-butyl and t-amyl hydroperoxide; dialkyl peroxides, such as di-t-butyl and dicumylperoxide; peroxyesters, such as t-butylperbenzoate and di-t-butylperoxy phthalate; and diacylperoxides, such as benzoyl peroxide and lauryl peroxide; peroxide such as persulfate; and metals such copper. Examples of useful organic solvents for free-radical addition include: ethers, such as tetrahydrofuran, dimethoxyethane, 1,4-dioxane; acetates, such as ethyl acetate, butyl acetate, and isopropyl acetate; alcohols, such as 2-methanol, ethanol, methylpropan-2-ol, isopropanol, 2-methoxyethanol (monoglyme), 2-methoxypropan-2-ol; and ketones, such as acetone, methylisobutyl ketone, and methylethyl ketone, such as N-methyl-2-pyrrolidone, and mixtures thereof. Also hydrocarbon solvents such as toluene are suitable.
[0020] As an alternative to free-radical addition, the amide intermediates of the present invention can be made by the Michael addition of a fluoroalkyl thiol, R f -Q-SH, to a N-vinylamide, H 2 C═CH—(CH 2 ) y —NR—C(O)—R, using catalytic amounts of a base, such as tertiary ammonium hydroxide or sodium hydride.
[0021] The sulfur oxide intermediates of the present invention are made by the oxidation of an amide intermediate using an oxidizing agent, such as peroxides. The oxidation may optionally include catalysts such as sodium tungstate, phenyl phosphonate, trioctylmethyl ammonium bisulfate, and mixtures thereof. When such catalysts are used during oxidation, the —S(O) x — moiety of the resulting sulfur oxide intermediate is —S(O) 2 —. One example us the use of such catalyst is in Tetrahedron 2005, 61, 8315-8327 and Sato et al. reference [27] therein. When no catalysts are used during oxidation, the —S(O) x — moiety of the resulting sulfur oxide intermediate is —S(O)—. An example of a method for conducting oxidation of an amide intermediate involves adding about one mol equivalent of an oxidizing agent (preferably hydrogen peroxide) to about one mol equivalent of an amide intermediate (optionally in the presence of catalyst) in solvent (preferably an alcohol such as ethanol) at a low temperature (typically about 0° C.) and stirring the mixture while allowing to warm (typically to about 50-60° C.) to activate the oxidation reaction. The progress of the reaction can be monitored via gas chromatography. Upon complete conversion (about 5 hours) any excess oxidizing agent is destroyed; for example hydrogen peroxide can be destroyed with a solution of sodium sulfite. The solvent can then be removed by distillation and the resulting residue containing crude product can be washed (e.g. with water) and dried in vacuum.
[0022] The sulfur containing fluoroalkyl amines of the present invention can be made by deacylation of an amide intermediate or a sulfur oxide intermediate. Deacylation of an amide intermediate can be performed by acid catalyzed or base catalyzed deacylation. Deacylation of a sulfur oxide intermediate can be performed by acid catalyzed deacylation.
[0023] Acid catalyzed deacylation can be conducted by adding to an amide intermediate or a sulfur oxide intermediate in solvent (preferably an alcohol such as ethanol) at a low temperature (typically 0° C.), a molar excess (typically about a six-fold excess) of concentrated acid (e.g. hydrochloric acid). This mixture is stirred and allowed to warm to ambient temperature and after an initial formation of foam the reaction mixture is slowly heated and held at reflux temperature (about 85° C.) for about 5 hours. The progress of the reaction can be monitored via gas chromatography. Upon complete conversion, the pH of the solution is brought to about 8-10 by carefully adding aqueous base (e.g. sodium hydroxide solution). The resulting sulfur containing fluoroalkyl amine in crude form separates as a bottom layer and can be isolated, e.g. with a separatory funnel. Alternatively, if the ammonium salt is desired, no aqueous base is added.
[0024] Base catalyzed deacylation can be conducted by adding an excess (typically about a five-fold excess) of concentrated base (e.g. sodium hydroxide) to the amide intermediate in solvent (preferably an alcohol such as ethanol) at a low temperature (typically 0° C.). This mixture is stirred and allowed to warm to ambient temperature and the reaction mixture is slowly heated and held at reflux temperature (about 85° C.) for about 8 hours. The progress of the reaction can be monitored via gas chromatography. The resulting sulfur containing fluoroalkyl amine in crude form separates as a bottom layer and can be isolated, e.g. via a separatory funnel.
[0025] One of the advantages of the formation of an amide intermediate of the present invention, R f -Q-S—C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R, is that the sulfur atom therein can be selectively oxidized while the acyl group —C(O)—R is remains unoxidized thereby forming a sulfur oxide intermediate represented by R f -Q-S(O) x —C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NR—C(O)—R wherein x is 1 or 2. The sulfur oxide intermediate can then be subjected to deacylation to convert the amide group, NR—C(O)—R, into an amine group, —NHR, thereby resulting in a sulfur containing fluoroalkyl amine wherein the sulfur thereof is oxidized. Previously known methods do not form any intermediate wherein the sulfur atom thereof can be selectively oxidized. In contrast to the present invention, previously known methods only make compounds wherein both a sulfur group —S— and an amine group —NHR (R is chosen from H or a C 1 to C 4 alkyl, preferably methyl, and most preferably H) are present thereby rendering the selective oxidation of the sulfur group impossible because of the potential oxidation of the amine group.
[0026] Accordingly, it was previously unknown how to make a sulfur containing fluoroalkyl amine of the present invention represented by R f -Q-S(O) x —CH 2 —C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —NH 2 wherein:
[0027] R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl can be optionally replaced by hydrogen, and/or ii) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene;
[0028] Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group; and
[0029] x is 1 or 2;
[0030] z is 0 or 1;
[0031] i is 1 or 2, j is 0 or 1; provided that i+j=2.
[0032] It was also previously unknown how to make isocyante and isothiocyante derivatives of the sulfur containing fluoroalkyl amine of the present invention, said isocyante and isothiocyante derivatives represented by R f -Q-S(O) x —C(H) i (CH 3 ) j —(CH 2 ) z+(i−1) —N═C═X 1 wherein:
[0033] X 1 is O or S;
[0034] R f is chosen from a C 2 -C 12 perfluoroalkyl provided that: i) one fluorine atom of the perfluoroalkyl can be optionally replaced by hydrogen, and/or ii) the perfluoroalkyl can be optionally interrupted by at least one oxygen, methylene, or ethylene;
[0035] Q is chosen from the group consisting of a C 2 -C 12 hydrocarbylene optionally interrupted by at least one divalent organic group; and
[0036] x is 1 or 2;
[0037] z is 0 or 1;
[0038] i is 1 or 2, j is 0 or 1; provided that i+j=2.
[0039] Isocyante and isothiocyante derivatives of the sulfur containing fluoroalkyl amine of the present invention can be made be made by any suitable process which converts a primary amine group (—NH 2 ) to an isocyanate group (—N═C═O) or isothiocyante group (—N═C═S). An example of a method of converting a primary amine group (—NH 2 ) to an isocyanate group (—N═C═O) may be found in Kornek et al. (DE10108543) consistent with the following reaction scheme: R f —CH 2 CH 2 —S—CH 2 CH 2 —NH 2 +EtOC(O)Cl+Cl 3 SiMe+2 NEt 3 →R f —CH 2 CH 2 —S—CH 2 CH 2 —N═C═O+EtOSi(Me)Cl 2 +2 Et 3 NHCl. An example of a method of converting a primary amine group (—NH 2 ) to an isothiocyante group (—N═C═S) may be found in J. Org. Chem. 1956, 21, 404-405 consistent with the following reaction scheme: R f —CH 2 CH 2 —S—CH 2 CH 2 —NH 2 +CS 2 +EtOC(O)Cl+2 NEt 3 →R f —CH 2 CH 2 —S—CH 2 CH 2 —N═C=S+COS+EtOH+2 Et 3 NHCl.
EXAMPLES
[0040] Table 1 below shows the fluoroalkyl thiols used throughout the examples numbered as Thiol #1, Thiol #2, and Thiol #3. Table 2 below shows amide intermediates made from the thiols in Table 1. Table 3 shows sulfur oxide intermediates made from the amide intermediates of Table 2. Table 4 shows sulfur containing fluorinated amines made from the amide intermediates or sulfur oxide intermediates which are labeled Fluorinated Amine #1, Fluorinated Amine #2, Fluorinated Amine #3, and Fluorinated Amine #4. Table 4 also shows a sulfur containing fluorinated amine salt labeled Fluorinated Amine Salt #1. Table 4 further shows isocyante and isothiocyante derivatives which respectively labeled Fluorinated Isocyanate #1 and Fluorinated Isothiocyanate #1.
[0000]
TABLE 1
Thiol
IUPAC Name
Structure
Thiol #1
3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-thiol
CF 3 (CF 2 ) 5 (CH 2 ) 2 SH
Thiol #2
3,3,4,4-tetrafluoro-4-heptafluoropropyloxy-butane-1-
CF 3 (CF 2 ) 2 O(CF 2 ) 2 (CH 2 ) 2 SH
thiol
Thiol #3
3,3,5,5,6,6,7,7,8,8,8-undecafluoro-octane-1-thiol
CF 3 (CF 2 ) 3 CH 2 CF 2 (CH 2 ) 2 SH
[0000]
TABLE 2
Made
from this
Amide Intermediate
Structure
Thiol
Made from this N-vinyl amide
Amide Intermediate #1A
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 —CH 2 —NH—C(O)—CH 3
Thiol #1
CH 2 ═CH—NH—C(O)—CH 3
Amide Intermediate #1B(*)
CF 3 (CF 2 ) 5 (CH 2 ) 2 S—CH 2 —CH 2 —N(CH 3 )—C(O)—CH 3
Thiol #1
CH 2 ═CH—N(CH 3 )—C(O)—CH 3
CF 3 (CF 2 ) 5 (CH 2 ) 2 S—CH(CH 3 )—N(CH 3 )—C(O)—CH 3
Amide Intermediate #1C
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 —CH 2 —NH—C(O)—H
Thiol #1
CH 2 ═CH—NH—C(O)—H
Amide Intermediate #1D
Thiol #1
Amide Intermediate #2
CF 3 (CF 2 ) 2 O(CF 2 ) 2 (CH 2 ) 2 S—CH 2 —CH 2 —NH—C(O)—H
Thiol #2
CH 2 ═CH—NH—C(O)—H
Amide Intermediate #3
CF 3 (CF 2 ) 3 CH 2 CF 2 (CH 2 ) 2 S—CH 2 —CH 2 —NH—C(O)—H
Thiol #3
CH 2 ═CH—NH—C(O)—H
(*)isomeric mixture of N-methyl-N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-acetamide and (R,S)-N-methyl-N-[1-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-acetamide
[0000]
TABLE 3
Made from oxidation of Amide
Sulfur oxide intermediate
Structure
Intermediate
Sulfur oxide intermediate #1A
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O)—CH 2 —CH 2 —NH—C(O)—H
Amide Intermediate #1C
Sulfur oxide intermediate #1B
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O) 2 —CH 2 —CH 2 —NH—C(O)—H
Amide Intermediate #1C
[0000]
TABLE 4
Ex.
Product
Structure
Intermediate used to make product
1
Fluorinated Amine #1
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 —CH 2 —NH 2
Amide Intermediate #1A*
2
Amide Intermediate #1C*
3
Amide Intermediate #1A**
4
Amide Intermediate #1C**
5
Fluorinated Amine #2
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O)—CH 2 —CH 2 —NH 2
Sulfur oxide intermediate #1A*
6
Fluorinated Amine #3
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S(O) 2 —CH 2 —CH 2 —NH 2
Sulfur oxide intermediate #1B*
7
Fluorinated Amine #4
CF 3 (CF 2 ) 2 O(CF 2 ) 2 (CH 2 ) 2 S—CH 2 —CH 2 —NH 2
Amide Intermediate #2*
8
Fluorinated Amine Salt #1
[CF 3 (CF 2 ) 3 CH 2 CF 2 (CH 2 ) 2 S—CH 2 —CH 2 —NH 3 + ]Cl −
Amide Intermediate #3
9
Fluorinated Isocyanate #1
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 —CH 2 —N═C═O
Fluorinated Amine #1
10
Fluorinated Isothiocyanate #1
CF 3 (CF 2 ) 5 (CH 2 ) 2 —S—CH 2 —CH 2 —N═C═S
Fluorinated Amine #1
*made by procedure for acid catalyzed deacylation
**made by procedure for base catalyzed deacylation
Thiol #1
[0041] Thiol #1 was 3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-thiol which was made as follows. Under nitrogen thiourea (1.1 equivalents) and 1-iodo-2-perfluorohexylethane (1 equivalent) were added to a degassed mixture of dimethoxyethane (DME, 9 parts) and water (1 part). The reaction mixture was held at reflux temperature for 8 hours. Most of the DME was distilled off and the distillation residue was allowed to cool to ambient temperature. Under stirring a solution of sodium methoxide in methanol (1 molar, 1.1 equivalents) was added to the suspension. Degassed water was added to the mixture. Thiol #1 was collected quantitatively as the fluorous bottom layer.
[0042] The spectroscopical data for the product were in agreement with those published elsewhere ( J. Fluorine Chem. 1985, 28, 341-355 and J. Fluorine Chem. 1989, 42, 59-68).
Thiol #2
[0043] Thiol #2 was 3,3,4,4-tetrafluoro-4-heptafluoropropyloxy-butane-1-thiol which was made as follows. 1,1,1,2,2,3,3-heptafluoro-3-[(1,2,2-trifluoroethenyl)oxy]-propane (available from E. I. du Pont de Nemours and Company as PPVE) was reacted with iodine monochloride and subsequently treated with boron trifluoride to furnish 1,1,1,2,2,3,3-heptafluoro-3-[(1-iodo-1,1,2,2-trifluoroethenyl)oxy]-propane (U.S. Pat. No. 5,481,028A). 1,1,1,2,2,3,3-Heptafluoro-3-[(1-iodo-1,1,2,2-trifluoroethenyl)oxy]-propane was then reacted with ethylene in the presence of a peroxide initiator to yield 1,1,2,2-tetrafluoro-1-(1,1,2,2,3,3,3-heptafluoropropyloxy)-4-iodo-butane (US20080113199A1). Under nitrogen, thiourea (1.1 equivalents) and 1,1,2,2-tetrafluoro-1-(1,1,2,2,3,3,3-heptafluoropropyloxy)-4-iodo-butane were added to degassed 1,4-dioxane. The reaction mixture was heated at reflux temperature for 8 hours. The dioxane was distilled off and the distillation residue was allowed to cool to ambient temperature. Under stirring, a thoroughly degassed solution of sodium hydroxide in methanol and water 1:1 (1 molar, 1.1 equivalents) was added to the suspension. The mixture was heated at 50-60° C. for 5 hours. Additional degassed water was added to the mixture. Thiol #2 was collected quantitatively as the fluorous bottom layer and purified via distillation. NMR of Thiol #2 was obtained as follows.
[0044] 1 H-NMR (CDCl 3 ): 1.60 (t, J=17 Hz, 1H, SH), 2.45 (m, 2H, CF 2 CH 2 ), 2.86 (m, 2H, CH 2 S).
Thiol #3
[0045] Thiol #3 was 3,3,5,5,6,6,7,7,8,8,8-undecafluoro-octane-1-thiol which was made as follows. Under nitrogen, potassium thioacetate (1.1 equivalents) was added to a solution of 1,1,1,2,2,3,3,4,4,6,6-undecafluoro-8-iodo-octane (1 equivalent) in THF. The reaction mixture was stirred at 50° for 5 hours. The THF was removed under reduced pressure. The distillation residue was dissolved in methanol (25 mL/0.1 mol) and treated with hydrochloric acid (37 w/% in water, three fold excess). Additional degassed water was added to the mixture. Thiol #3 was collected as the fluorous bottom layer and purified via distillation. NMR of Thiol #3 was obtained as follows.
[0046] 1 H-NMR (CDCl 3 ): 1.55 (s, br, 1H, SH), 2.32 (m, 2H, CF 2 CH 2 ), 2.74 (m, 4H, CH 2 S and CF 2 CH 2 CF 2 ).
Table 1
[0047] The following table shows the thiols that were made above.
Thiol #1
Procedure for Amide Intermediate Synthesis
[0048] When amide intermediate synthesis was used to make a chosen amide intermediate in the examples below, amide intermediate synthesis was conducted in the following manner. All amide intermediates in the examples were made according to the following procedure. A solution of one equivalent of a chosen thiol, one equivalent of a chosen N-vinylamide, and 0.04 parts (mol equivalents) VAZO 64 (available from E. I. du Pont de Nemours and Company of Wilmington, Del., USA) in inhibitor-free tetrahydrofuran (THF) was slowly warmed to 65° C. At about 45° C. an exotherm occurred, increasing the reaction temperature briefly to 70° C. The reaction was stirred at 65° C. until complete consumption of the thiol was indicated as determined by gas chromatography-mass spectrometry (GC/MS) monitoring for 5 hours.
Amide Intermediate #1A
[0049] Amide Intermediate #1A was N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-acetamide which was made using amide intermediate synthesis wherein Thiol #1 was the chosen thiol and N-vinylacetamide was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish the desired crude amide free of its regioisomer as a light orange oil. NMR of Amide Intermediate #1A was obtained as follows.
[0050] 1 H-NMR (CDCl 3 ): 1.98 (s, 3H, COCH 3 ), 2.36 (m, 2H, CF 2 CH 2 ), 2.70 (m, 4H, CH 2 SCH 2 ), 3.43 (m, 2H, CH 2 N), 5.98 (s, br, 1H, NH).
Amide Intermediate #1B
[0051] Amide Intermediate #1B was an isomer mixture of N-methyl-N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-acetamide (I) and (R,S)—N-methyl-N-[1-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-acetamide (II) which was made using amide intermediate synthesis wherein Thiol #1 was the chosen thiol and N-vinyl-N-methyl-acetamide was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish crude Amide Intermediate #1B as a mixture of regioisomers of I and II (3:2) as a light orange oil. The crude Amide Intermediate #1B was about 99% pure and was suitable for further use without further purification. The isomers were not separated. NMR of Amide Intermediate #1B was obtained as follows.
[0052] 1 H-NMR (CDCl 3 ): (I): 1.98 (s, 3H, COCH 3 ), 2.35 (m, 2H, CF 2 CH 2 ), 2.68 (m, 4H, CH 2 SCH 2 ), 2.96 (s, 3H, NCH 3 ), 3.47 (m, 2H, CH 2 N); (II): 2.03 (s, 3H, COCH 3 ), 2.35 (m, 2H, CF 2 CH 2 ), 2.65 (m, 5H, CF 2 CH 2 CH 2 S and CHCH 3 ), 2.80 (s, 3H, NCH 3 ), 3.43 (m, 1H, CHN).
Amide Intermediate #1C
[0053] Amide Intermediate #1C was N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-formamide which was made using amide intermediate synthesis wherein Thiol #1 was the chosen thiol and N-vinylformamide was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish the desired amide as an off-white solid. NMR of Amide Intermediate #1C was obtained as follows.
[0054] 1 H-NMR (CDCl 3 ): 2.33 (m, 2H, CF 2 CH 2 ), 2.70 (m, 4H, CH 2 SCH 2 ), 3.39 (m, 1H, 3.42 (m, 2H, CH 2 N), 6.66 (s, br, 1H, NH), 8.12 (s, 1H, CHO).
Amide Intermediate #1D
[0055] Amide Intermediate #1D was 1-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethyl]-pyrrolidin-2-one which was made using amide intermediate synthesis wherein Thiol #1 was the chosen thiol and N-vinylpyrrolidone was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish the desired amide as an off-white solid (Mp 64° C.). NMR of Amide Intermediate #1D was obtained as follows.
[0056] 1 H-NMR (CDCl 3 ): 2.02 (m, 2H, CH 2 CH 2 CH 2 ), 2.37 (m, 4H, CF 2 CH 2 and CH 2 C═O), 2.71 (m, 2H, SCH 2 CH 2 N), 2.77 (m, 2H, CF 2 CH 2 CH 2 S), 3.41 (m, 1H, 3.42 (m, 2H, SCH 2 CH 2 N), 3.48 (m, 1H, 3.42 (m, 2H, NCH 2 CH 2 CH 2 ).
Examples 1-4
[0057] In examples 1-4 below, Fluorinated Amine #1 was 2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octylsulfanyl)-ethylamine and was made by the deacylation of an amide intermediate as indicated. The NMR obtained in the examples below for Fluorinated Amine #1 is represented as follows.
[0058] 1 H-NMR (CDCl 3 ): 1.28 (br, 2H, NH 2 ), 2.38 (m, 2H, CF 2 CH 2 ), 2.65 (m, 2H, SCH 2 ), 2.73 (m, 2H, CH 2 S), 2.89 (m, 2H, CH 2 N).
[0059] 1 H-NMR (DMSO-d 6 ): 1.46 (br, 2H, NH 2 ), 2.48 (m, 2H, CF 2 CH 2 ), 2.58 (m, 2H, SCH 2 ), 2.72 (m, 4H, CH 2 S and CH 2 N).
[0060] 13 C-NMR (CDCl 3 ): 22.3 (s, CH 2 S), 32.1 (m, CF 2 CH 2 ), 35.8 (s, SCH 2 ), 40.5 (s, CH 2 N).
Procedure for Acid Catalyzed Deacylation
[0061] When acid catalyzed deacylation was used to make a chosen fluorinated amine in the examples below, acid catalyzed deacylation was conducted in the following manner. Concentrated hydrochloric acid solution (37.5 w/% in water, five to six-fold molar excess) was added to a solution of one equivalent of a chosen amide intermediate in ethanol at 0° C. The reaction mixture was allowed to warm to ambient temperature while being stirred. After the initial foam formation ceased the reaction mixture was slowly heated and held at reflux temperature for 5 hours at about 85° C. The progress of the reaction was monitored via Gas Chromatography. Upon complete conversion, the pH of the solution was brought to 8-10 by carefully adding aqueous sodium hydroxide solution. The chosen fluorinated amine in crude form separated as the bottom layer and was isolated as a brownish slightly viscous liquid via a separatory funnel. The aqueous phase was extracted with diethyl ether. The residue of the dried ether phase was combined with the initial first crop. The chosen fluorinated amine in crude form was washed with water and dried using molecular sieves (4 Å) and was purified by distillation to obtain a colorless liquid in 80 to 95% yield as either a colorless solid or pail yellow liquid.
Example #1
[0062] Fluorinated Amine #1 was made by the acid catalyzed deacylation of Amide Intermediate #1A.
Example #2
[0063] Fluorinated Amine #1 was made by the acid catalyzed deacylation of Amide Intermediate #1C.
Procedure for Base Catalyzed Deacylation
[0064] When base catalyzed deacylation was used to make a chosen fluorinated amine in the examples below, base catalyzed deacylation was conducted in the following manner. An aqueous solution of sodium hydroxide (five equivalents) was added to one equivalent of the chosen fluorinated amine at ambient temperature and the mixture was slowly brought to reflux temperature. After about 8 hours of reaction time, the chosen fluorinated amine in crude form separated as the bottom layer and was isolated as a brownish slightly viscous liquid via a separatory funnel. It was washed with water and dried using molecular sieves (4 Å). The chosen fluorinated amine in crude form was purified by distillation and obtained as a colorless liquid in 80 to 95% yield as either a colorless solid or a pail yellow liquid.
Example #3
[0065] Fluorinated Amine #1 was made by the base catalyzed deacylation of Amide Intermediate #1A.
Example #4
[0066] Fluorinated Amine #1 was made by the base catalyzed deacylation of Amide Intermediate #1C.
Sulfur Oxide Intermediate #1A
[0067] Sulfur oxide intermediate #1A was N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-sulfinyl)-ethyl]-formamide which was made by oxidation of Amide Intermediate #1C as follows. Hydrogen peroxide (35 w/% in water, 1.1 mol equivalents) was added to a solution of one equivalent of Amide Intermediate #1C in ethanol at 0° C. The reaction mixture was allowed to warm to ambient temperature while being stirred. The progress of the reaction was monitored via Gas Chromatography. Upon complete conversion (5 hours) any excess peroxide was destroyed by adding a solution of sodium sulfite (negative peroxide test). The ethanol was distilled off; the residue was washed with water and dried in vacuum. The Sulfur oxide intermediate #1 was obtained quantitatively as a colorless solid. Mp 179° C. NMR of Sulfur oxide intermediate #1A was obtained as follows.
[0068] 1 H-NMR (CDCl 3 ): 2.59 (m, 2H, CF 2 CH 2 ), 2.93 (dm, J=170 Hz, 2H, SOCH 2 CH 2 N), 2.96 (m, 2H, CF 2 CH 2 CH 2 SO), 3.84 (m, 2H, CH 2 N), 6.50 (s, br, 1H, NH), 8.19 (s, 1H, CHO).
[0069] 13 C-NMR Spectrum of Sulfur oxide intermediate #1A could not be obtained due to its insufficient solubility most common organic deuterated solvents.
Sulfur Oxide Intermediate #1B
[0070] Sulfur oxide intermediate #1B was N-[2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-sulfonyl)-ethyl]-formamide which was made by oxidation of Amide Intermediate #1C as follows. A solution of sodium tungstate (0.01 equivalents), phenyl phosphonate (0.01 equivalents), and trioctylmethyl ammonium bisulfate (0.01 equivalents) in hydrogen peroxide (35 w/% in water, 2.2 equivalents) was prepared. This solution was slowly added to a solution of one equivalent of Amide Intermediate #1C in ethanol at 0° C. The reaction mixture was allowed to warm to ambient temperature and then heated to 60° C. while being stirred. The progress of the reaction was monitored via Gas Chromatography. Upon complete conversion any excess peroxide was destroyed by adding a solution of sodium sulfite (negative peroxide test). The ethanol was removed under reduced pressure. The residue was washed with water and dried in vacuum. Sulfur oxide intermediate #1B was obtained quantitatively as a colorless solid. Mp 108° C. NMR of Sulfur oxide intermediate #1B was obtained as follows.
[0071] 1 H-NMR (CDCl 3 ): 2.62 (m, 2H, CF 2 CH 2 ), 3.28 (m, br, 4H, CH 2 SO 2 CH 2 ), 3.83 (m, br, 2H, CH 2 N), 6.25 (s, br, 1H, NH), 8.19 (s, 1H, CHO).
[0072] 13 C-NMR (CDCl 3 ): 22.3 (s, CF 2 CH 2 ), 33.3 (s, CH 2 N), 43.4 (s, SO 2 CH 2 ), 51.6 (s, CH 2 SO 2 ), 161.7 (s, CHO).
Example 5
[0073] Fluorinated Amine #2 was (3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-sulfinyl)-ethylamine which was made by acid catalyzed deacylation of Sulfur oxide intermediate #1A. After acid deacylation, the crude Fluorinated Amine #2 was filtered, washed with water, and dried. The drying step is important because Fluorinated Amine #2 forms adducts with both polar protic and non-protic solvents, respectively. Ethanol was removed from the filtrate under reduced pressure and the residue was washed with water and dried in vacuum. Fluorinated Amine #2 was obtained quantitatively as a colorless solid. Mp>250° C. NMR of Fluorinated Amine #2 was obtained as follows. NMR analysis was performed on crystals obtained from dimethoxyethane (DME) with the following results.
[0074] 1 H-NMR (DMSO-d 6 ): 2.59 (m, 2H, CF 2 CH 2 ), 2.80 (m, 2H, CH 2 N), 2.88 (m, 2H, SOCH 2 ), 2.98 (m, 2H, CH 2 SO).
Example 6
[0075] Fluorinated Amine #3 was 2-(3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluoro-octane-1-sulfonyl)-ethylamine which was made by acid catalyzed deacylation of Sulfur oxide intermediate #1B as follows. Example 5 was duplicated except Sulfur oxide intermediate #1B was used instead of Sulfur oxide intermediate #1A. Fluorinated Amine #3 was obtained quantitatively as a colorless solid, mp>250° C. NMR (in CDCl 3 ) and IR analysis was performed on crystals obtained from dimethoxyethane (DME) with the following results.
[0076] 1 H-NMR (CDCl 3 ): 1.76 (br, 2H, NH 2 ), 2.68 (m, 2H, CF 2 CH 2 ), 3.14 (m, 2H, CH 2 N), 3.28 (m, 2H, SO 2 CH 2 ), 3.39 (m, 2H, CH 2 SO 2 ), 3.63 (m, 4H, OCH 3 ), 3.75 (m, 4H, OCH 2 ).
[0077] 1 H-NMR (DMSO-d 6 ): 2.71 (m, 2H, CF 2 CH 2 ), 2.97 (m, 2H, CH 2 N), 3.27 (m, 2H, SO 2 CH 2 ), 3.52 (m, 2H, CH 2 SO 2 ).
[0078] 13 C-NMR (CDCl 3 ): 24.5 (s, CF 2 CH 2 ), 36.2 (m, CH 2 SO 2 ), 43.1 (s, CH 2 N), 46.6 (s, SO 2 CH 2 ), 56.8, 61.9, 71.3, 72.5 (s, DME).
[0079] IR Spectrum: 1070 cm −1 (sym. SO 2 ).
Amide Intermediate #2
[0080] Amide Intermediate #2 was N-[2-(3,3,4,4-tetrafluoro-4-heptafluoropropyloxy-butylsulfanyl)-ethyl]-formamide was made using amide intermediate synthesis wherein Thiol #2 was the chosen thiol and N-vinylformamide was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish the desired crude amide quantitatively with a purity of 97% as an off-white solid. Mp>250° C.
[0081] 1 H-NMR (CDCl 3 ): 2.38 (m, 2H, CF 2 CH 2 ), 2.77 (m, 4H, CH 2 SCH 2 ), 3.53 (m, 2H, CH 2 N), 6.88 (s, br, 1H, NH), 8.20 s, 1H, CHO).
Example 7
[0082] Fluorinated Amine #4 was 2-(3,3,4,4-tetrafluoro-4-heptafluoropropyloxy-butylsulfanyl)-ethylamine which was made by acid catalyzed deacylation of Amide Intermediate #2. NMR analysis was performed on crystals obtained from dimethoxyethane (DME) with the following results.
[0083] 1 H-NMR (CDCl 3 ): 1.92 (br, 2H, NH 2 ), 2.32 (m, 2H, CF 2 CH 2 ), 2.65 (t, 2H, SCH 2 ), 2.73 (m, 2H, CH 2 S), 2.92 (t, 2H, CH 2 N).
Amide Intermediate #3
[0084] Amide Intermediate #3 was N-[2-(3,3,5,5,6,6,7,7,8,8,8-udecafluoro-octylsulfanyl)-ethyl]-formamide which was made using amide intermediate synthesis wherein Thiol #3 was the chosen thiol and N-vinylformamide was the chosen N-vinylamide. All volatiles were removed under reduced pressure to furnish Amide Intermediate #3 quantitatively with a purity of 97% as an off-white solid. Mp>250° C. NMR of Amide Intermediate #3 was obtained as follows.
[0085] 1 H-NMR (CDCl 3 ): 2.33 (m, 2H, CF 2 CH 2 ), 2.73 (m, 6H, CH 2 SCH 2 and CF 2 CH 2 CF 2 ), 3.54 (m, 2H, CH 2 N), 6.16 (s, br, 1H, NH), 8.19 (s, 1H, CHO).
Example 8
[0086] Fluorinated Amine Salt #1 was 2-(3,3,5,5,6,6,7,7,8,8,8-undecafluoro-octylsulfanyl)-ethyl-ammonium chloride which was made by the deacylation of Amide Intermediate #3 as follows. Concentrated hydrogen chloride solution (37.5 w/% in water, five to six-fold molar excess) was added to a solution of one equivalent of Amide Intermediate #3 in ethanol at 0° C. The reaction mixture was allowed to warm to ambient temperature while being stirred. After the initial foam formation ceased the reaction mixture was stirred at 70° C. for 5 hours. The progress of the reaction was monitored via Gas Chromatography. The Fluorinated Amine Salt #1 was isolated in quantitative yield by stripping all volatiles under reduced pressure.
[0087] 1 H-NMR (MeOH-d4): 2.39 (m, 2H, CF 2 CH 2 ), 2.81 (m, 4H, CH 2 S), 2.90 (m, 2H, SCH 2 ), 3.05 (m, 2H, and CF 2 CH 2 CF 2 ), 3.19 (m, 2H, CH 2 N).
Example 9
[0088] According to DE10108543(C1), Fluorinated Isocyanate #1 was 1,1,1,2,2,3,3,4,4,5,5,6,6-tridecafluoro-8-(2-isocyanato-ethylsulfanyl)-octane which was made as follows. A solution of one equivalent of Fluorinated Amine #1 (0.1 mol) and one equivalent of triethyl amine (0.1 mol) in dry toluene (350 mL) is cooled to 0° C. (ice bath). Ethyl chloroformate (0.11 mol) is added dropwise within 20 min. The mixture, while stirring, was allowed to warm to room temperature. A second equivalent of triethyl amine (0.1 mol) is added followed by the dropwise addition of methyl trichlorosilane (0.12 mol) at 30-40° C. (addition time about 20-30 min). The mixture was then heated to 100° C. for 1 hour. After the mixture had cooled to ambient temperature the precipitated ammonium salts were filtered off. Under steady N 2 flow, both toluene and generated ethoxy methyl dichlorosilane were distilled off at 200 mm Hg. The residue was dried in vacuum to furnish Fluorinated Isocyanate #1 in 95% yield as a light red-brown liquid. NMR analysis yielded the following results.
[0089] 1 H-NMR (CDCl 3 ): 2.34 (m, 2H, CF 2 CH 2 ), 2.73 (m, 4H, CH 2 SCH 2 ), 3.45 (m, 2H, CH 2 N).
[0090] 13 C-NMR (CDCl 3 ): 23.1 (s, CH 2 S), 32.1 (m, CF 2 CH 2 ), 35.8 (s, SCH 2 CH 2 N), 40.5 (s, CH 2 N), 106-121 (m, CF 2 ), 123.8 (s, NCO).
Example 10
[0091] According to J. Org. Chem. 1956, 21, 404-405, Fluorinated Isothiocyanate #1 was 1,1,1,2,2,3,3,4,4,5,5,6,6-tridecafluoro-8-(2-isothiocyanato-ethylsulfanyl)-octane which was made as follows. A solution of one equivalent of Fluorinated Amine #1 (0.1 mol) and two equivalents of triethyl amine (0.2 mol) in dry methylene chloride (200 mL) was cooled to 0° C. (ice bath). Carbon disulfide (1.3 equivalents) was added drop-wise within 20 min. The mixture was allowed to warm to ambient temperature while stirring was continued for one hour. The reaction mixture was stirred for additional 8 hours at ambient temperature. Toluene (200 mL) was added and precipitated solids were filtered of (Buechner). The solvents of the filtrate were removed in vacuum to furnish the desired product in sufficient purity for further derivatization in 97% yield. NMR analysis yielded the following results.
[0092] 1 H-NMR (CDCl 3 ): 2.35 (m, 2H, CF 2 CH 2 ), 2.78 (m, 4H, CH 2 SCH 2 ), 3.68 (m, 2H, CH 2 N).
[0093] 13 C-NMR (CDCl 3 ): 23.1 (s, CH 2 S), 32.1 (m, CF 2 CH 2 ), 32.6 (s, SCH 2 CH 2 N), 45.0 (s, CH 2 N), 106-121 (m, CF 2 ), 133.4 (s, NCO). | The present invention provides a method of making sulfur containing fluoroalkyl amines which overcomes the problems previously known methods. Unlike previously known methods, the method of the present invention can achieve higher yields of sulfur containing fluoroalkyl amines without resorting to costly solvents. Furthermore, unlike previously known methods, the method of the present invention can produce oxidized forms of sulfur containing fluoroalkyl amines wherein the sulfur atom thereof is oxidized. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to a portable toilet of the type disclosed in U.S. Pat. No. 3,570,018, issued Mar. 16, 1971 to Sargent, et al., and is particularly directed to improvements in toilets of this character.
With the advent of the portable toilet disclosed in the aforesaid patent, a substantial advance was made over prior art portable toilets as then known, particularly with respect to those used in the travel and recreational fields. Because space often is at a premium where these units are stored or used, efforts have been made to make the toilets as small and compact as possible within limits permitted without impairing the functions and operations thereof. The dimensions have been dictated by minimum capacity requirements for the flush water chamber and the holding tank; the vertical dimensions required to accommodate the flat slide valve assembly associated with the holding tank for closing and opening the latter; and the lateral dimensions required, not only for the toilet but with respect to the location where the toilet may be mounted, so that the seat section, as well as the holding tank section, can easily be secured in place or removed for servicing, or the like. Further, the demands to conserve space have been made concurrently with other demands to reduce costs and to assure optimum operating conditions, such as to eliminate unwanted splashing or spitting at the flush nozzles, sometimes associated with bellows-type hand pump generally used with these toilets for flush purposes, and to eliminate servicing and cleaning problems sometimes arising in connection with the slide valve assembly.
Summary of the Invention
The present invention has overcome inadequacies of the prior art and has provided a portable toilet characterized by its compactness, low cost, ease of servicing, and convenience and efficiency of operation.
According to one form of the present invention, a portable toilet is provided comprising a portable lower holding tank section and a portable upper seat section removably supported thereon. The seat section has top, side and bottom walls with an outlet port in its bottom wall and defines a bowl extending between the top and bottom walls and opening at the bottom to said outlet port. The holding tank section has a top wall and side and bottom walls that form a closed receptacle with an inlet port in its top wall in registry with the outlet port. A flat slide valve assembly is mounted on the holding tank section and defines the inlet port. The slide valve assembly includes a flat blade supported within the confines of the holding tank for movement in a plane perpendicular to the axis of the inlet port for closing the inlet port and sealing the interior of the tank section from the environment. The inlet port of the holding tank section is defined by an elastomeric seal which serves to provide a sealing relationship with the outlet port of the upper seat section, a sealing relationship with the flat blade when the flat blade is in its closed position, and a sealing relationship with the top wall of the holding tank section. The valve body of the valve assembly is secured within the holding tank section and provides guide surfaces for movement of the flat blade between its open and closed positions. For the purpose of moving the flat blade, a shaft is connected to the blade and extends through the front wall of the holding tank section. By virtue of this construction and arrangement a valve assembly is provided which allows the vertical dimensions of the portable toilet to be maintained at a minimum while still making optimum utilization of the water storage capacity of the upper seat section and the waste storage capacity of the holding tank section.
Another feature of the present invention that facilitates use of the improved slide valve assembly includes the construction and arrangement wherein in the shaft of the slide valve assembly is provided with a protective bellows so that the shaft is not exposed to the contents of the holding tank. Still another feature of the slide valve assembly is the construction and arrangement of the flat blade and the arrangement wherein the front edge of the blade will move most effectively against the elastomeric annular seal when moved to a closed position and will avoid trapping solid particles between the forward edge of the blade and the seal or valve body.
Still another feature of the present invention which contributes to most effective utilization of space in the area where the portable toilet may be supported is the arrangement of holddown brackets for supporting the holding tank section on a supporting surface. In the preferred embodiment of the invention a pair of holddown brackets are provided which are adapted to be attached to a supporting surface on opposite sides of the holding tank section. Each bracket is shaped to extend upward from the point of attachment and to terminate at the upper end in an inwardly turned hook that fits over the top wall of the holding tank section. The top wall of the holding tank section has at its side edges recessed portions for receiving the ends of the hooks. The recessed portions extend to the rear of the holding tank section so that the holding tank section can be moved forward without obstruction from the hooks when the hooks are aligned in a selected location in the recessed portions. The top wall of the holding tank section has sockets offset from the aforesaid recessed portions into which the hooks normally can be seated to restrict movement of the holding tank section. However, when it is desired to remove the holding tank section, this can be accomplished merely by deflecting the holddown brackets into proper alignment with the recessed portions and the holding tank section can then be removed from its supported position merely by pulling the holding tank forward. Thus, the need for lateral space for releasing the brackets is substantially eliminated.
Still another feature of the present invention which contributes economy of space is the clasp mechanism which secures the holding tank section and the upper seat section together. The clasp mechanism includes a pair of straps positioned on opposite sides of the outlet and inlet ports which are secured to the bottom wall of the upper seat section for limited movement by a handle which extends to the front side of the portable toilet. The lower holding tank section has a pair of elevated screws located in the paths of movements of the straps, and each strap has a slot with an associated enlarged opening of a size sufficient to receive one of the heads of the retention screws. The straps have inclined portions adjacent to the slots so that movement of the straps by the handle to a closed position after the screw heads have been inserted into the enlarged openings will cause vertical movement of the sections relative to one another to be urged then together. Thus, the handle of the clasp mechanism, the handle of the valve assembly and the holddown brackets for securing the portable toilet on a supporting surface can all be actuated from a frontal position so that relatively little space is required on opposite sides of the portable toilet in the area where it may be mounted. Thus, economy of space is realized not only from the reduced vertical dimensions of the portable toilet, but also with respect to the vehicle or other structure in which the portable toilet is mounted because only very limited space is required on opposite sides of the portable toilet for operating and servicing the same.
Still another feature of the present invention which contributes to its minimum size and low cost is the construction and arrangement of the pump flush apparatus and the upper portion of the bowl where the flush water is discharged by the pump flush apparatus. To eliminate the need for a flush ring at the upper edge of the bowl and to avoid undesirable spitting or splashing which sometimes may occur when using conventional bellows-type hand pumps for discharging a measured volume of water into a bowl, a unique arrangement of a ramp is provided around the upper periphery of the bowl in conjunction with a unique arrangement of the discharge nozzle from the pump flush apparatus. In this arrangement the flush water is initially directed toward the rear of the toilet. Further, a flush-dampening reservoir means is incorporated in the pump flush apparatus so as to aid in providing a more uniform flow of flush water into the bowl which will minimize spitting or the like.
Thus, it is an object of the present invention to provide an improved portable toilet which has various features which contribute to the production of a relatively low cost portable toilet which is efficient in operation and convenient for servicing and which is characterized by the economy of space that is realized in connection with its construction and in the space of the supporting structure where the toilet may be mounted.
Other objects of this invention will appear in the following description and appended claims, reference being had to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a portable toilet embodying one form of the present invention, a portion being broken away to illustrate details of the supporting bracket for securing the holding tank section to a supporting surface;
FIG. 2 is a top plan view of the portable toilet with portions of the top cover and seat broken away to illustrate details of the toilet bowl;
FIG. 3 is a bottom plan view of the upper seat section;
Fig. 4 is an enlarged fragmentary section taken on the lines 4--4, illustrating the details of the clasp mechanism for securing the upper and lower sections together;
FIG. 5 is a top plan view of the lower holding tank section;
FIG. 6 is a fragmentary section taken through the upper seat section on a line illustrating details of the pump flush assembly;
FIG. 7 is an enlarged exploded view taken on the lines 7--7 of FIG. 5, showing details of the flat slide valve assembly;
FIG. 8 is a sectional view taken on the lines 8--8 of FIG. 7, showing the flat blade and the arrangement for mounting it on the front side wall of the lower holding tank section;
FIG. 9 is an enlarged sectional view taken on the lines 9--9 of FIG. 8;
FIG. 10 is an enlarged fragmentary section taken on the lines 10--10 of FIG. 8;
FIG. 11 is an enlarged bottom plan view of the valve body of the flat slide valve assembly;
FIG. 12 is an enlarged fragmentary section taken on the lines 12--12 of FIG. 11, showing the position of the outlet port of the upper seat section in sealing arrangement with the sealing ring of the flat slide valve assembly; and
FIG. 13 is an enlarged fragmentary section taken on the lines 13--13 of FIG. 11.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangement of parts illustrated in the accompanying drawings, since the invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
Referring now to the drawings, the invention will be described in greater detail. The portable toilet 10 comprises the lower holding tank section 12 and the upper seat section 14 removably supported thereon. The upper seat section 14 is molded of a suitable plastic material so as to have a top wall 16, side walls 18 and a bottom wall 20 with an opening 22 in the bottom wall providing an outlet port. The upper seat section also defines a bowl 24 extending between the top and bottom walls 16 and 20, which opens at the bottom to said outlet port 22. A flush water compartment 26 is provided in the space surrounding the bowl 24 within the side walls 18 and the top and bottom walls 16 and 20. A fill opening spout 28 is provided in the rear side wall 18 for filling flush water into the flush water compartment 26, and a closure cap 30 is provided for closing the spout 28. A handle 32 is also molded in the rear side wall 18 for carrying the upper seat section 14.
The upper seat section 14 also contains pump-flush apparatus 34 which includes the passageway 36, a discharge nozzle 38, a flushing plunger or bellows pump 40, a flush-dampening resevoir means 42, and the plurality of check valves 44 that are found in the passageway 36. The bellows pump 40 functions the same as the corresponding part disclosed in the aforesaid U.S. Pat. No. 3,570,018, to which reference is made for a more detailed description. In the conventional manner, depressing the bellows 40 will serve to discharge water from the flush water chamber 26 through the flush-dampening resevoir means 42 and out the nozzle 38 to the inclined spiral ledge 46 in the bowl 24. The flush-dampening reservoir means 42 has a pocket or chamber 48 in which an air cushion is provided to cushion the pressure of the water that is discharged by action of the bellows pump 40 to provide a more uniform pressure and elimination of air bubbles in the stream of water that is discharged from the nozzle 38, thereby tending to eliminate the spitting action that sometimes occurs in connection with pump apparatus of the type using a bellows pump 40. When using pumps of this character it is not uncommon for bubbles of air to exist in the water circuit and these bubbles become pressurized during the pumping so as to cause a spitting action of the water as it leaves the nozzle 38. To overcome this undesirable characteristic the chamber 48 will serve to trap such bubbles, and the air that is then trapped in the chamber 48 will act as an air cushion to cause a more uniform discharge of the water through the nozzle 38. The flush-dampening reservoir means 42 can easily be installed within the upper seat section 14 by passing it through the spout 28 after which the flush-dampening reservoir means can be secured in place by the nut which is threadedly connected to the nozzle 38 and when screwed in place the discharge end will clamp onto the inclined surface of the top wall 16 as shown best in FIGS. 2 and 6. The nozzle 38 also has a shield portion 50 which projects from the upper edge of the nozzle outlet for positively directing the water into the bowl and onto the spiral ledge 46. The nozzle is mounted so as to direct the stream of water toward the rear of the toilet bowl 24 in a direction to minimize splashing of any water from the bowl to the surrounding area.
Also forming a part of the upper seat section 14 is the toilet seat 52 and the cover 54. It will be noted that the toilet seat 52 extends over the spiral ledge 46. Positioned above the toilet seat 52 is the cover 54, both of which are supported on common hinge posts, not shown, located adjacent to the rear edge of the top wall 16.
One of the features of the present invention is the clasp mechanism 56 for releasably securing the upper seat section and the lower holding tank section together. A portion of this mechanism is mounted on the bottom wall 20 of the upper seat section 24 and the remainder of the clasp mechanism is secured to the top wall of the holding tank section 12, as will presently be described. With respect to the upper seat section 14, the clasp mechanism includes a handle 58 which is located in the cavity 60 defined by the front side walls of the upper seat section 14 and the holding tank section 12, as can be seen best in FIG. 4. The handle 58 is connected to a pair of straps or members 62 which are secured to the bottom wall 20 for limited movement by the plurality of screws or members 64. As can be seen in FIG. 3, the screws 64 extend through the slots 66 with the heads being held in spaced relationship to the bottom wall 20 by means of a plurality of spacers 68, FIG. 4, so that the straps 62 can move lengthwise the length of the slots 66. The straps 62 also have an additional pair of slots 70 which have enlarged openings 72 at one end and inclined surfaces 74 adjacent hereto for a purpose that will be described hereinafter.
The lower holding tank section 12 has a top wall 76, side walls 78 and a bottom wall 80 forming a closed receptacle with an inlet port 82 in its top wall in registry with the outlet port 22 of the upper seat section 14. A flat slide valve assembly 84 is mounted on the holding tank section 12 and defines the inlet port 82. The slide valve assembly includes the flat blade or valve element 86 which is supported within the confines of the holding tank section for movement in a horizontal plane perpendicular to the axis of the inlet port 82 for closing the inlet port and sealing the interior of the holding tank section 12 from the environment.
The rear side wall 78 includes the handle 88 for carrying the holding tank section and it also includes a spout 90 which may be used for evacuating the holding tank and which normally is closed by the closure cap 92.
Referring now to FIGS. 4 and 5, it can be seen that the top wall 76 of the lower holding tank section 12 includes a pair of screws 94 which have their heads spaced from the upper surface of the top wall 76 by the spacers 96. When it is desired to clasp the upper seat section 14 firmly to the lower seat section 12, this can readily be accomplished merely be placing the upper seat section 14 onto the lower seat section 12 so that the openings 72 of the straps 62 fit over the heads of the screws 94 after which the handle 58 can be moved inwardly causing the heads 94 to slide up the inclined surfaces 74 to the position shown in FIG. 4, thereby urging the two sections together. When it is desired to disconnect the two sections, this can readily be accomplished merely by lowering the handle 58 from the position shown in FIG. 4 and pulling it to the left until the heads of the screws 94 are in alignment with the openings 72, after which the upper seat section 14 can be removed from the lower holding tank section 12.
Another of the features of the present invention is the construction and the arrangement of the flat slide valve assembly 84. The flat slide valve assembly 84 includes the elastomeric annular seal 98, the upper annular seal cover 100, the annular valve 102, the flat blade 86, the shaft 104 that is connected at one end to the flat blade 86, the valve handle 105 connected to the other end of the shaft 104, and the protective bellows 106 which protects the shaft 104 from the contents of the holding tank section 12. The various details of these components of the flat slide valve assembly 84 will be described with particular reference to FIGS. 7--13, inclusive.
As can be seen best in FIG. 7, the elastomeric annular seal 98 has a lower lip 108 around its inner periphery which is adapted to be engaged by the upper surface of the flat blade 86 when the latter is in its closed position under the inlet port 82 defined by the annular seal 98. In its unstressed position the lower lip 108 will be in the position shown in FIG. 7, but when the flat blade 86 is moved to its closed position, shown in FIG. 12, the lip 108 will be deflected upward as there shown, to provide a tight seal between the blade and the lip 108.
The annular seal 98 also has an upper lip 110 around its inner periphery which is adapted to be engaged by the downwardly directed annular flange 112 that forms the lower end of the bowl 24 and defines the outlet port 22 from the upper seat section 14. As can be seen best in FIG. 12, when the upper seat section 14 is pressed into place on the lower holding tank section 12, the upper lip 110 will be stretched into sealing engagement with the outer surface of the annular flange 112 to provide a sealing relationship between the upper seat section 14 and the lower holding tank section 12 at the outlet port 22 and the inlet port 82. This arrangement also allows relatively flexible manufacturing tolerances in the upper and lower sections 14 and 12, because the extent of penetration of the annular flange 112 can vary while still providing a satisfactory sealed relationship.
The annular seal 98 also has a groove around its outer periphery at 114 so as to have overlapping edges 116 and 118 with respect to the top wall 76 of the holding tank section 12. The fastening screws 119 which extend through the cover 100 serve to clamp the cover 100 against the edge 118 to provide a tight seal at this joint. Similarly, the edge 116 is firmly clamped against the top wall 76 by the same screws 119 which are threadedly connected to the bosses 121 of the valve body 102 and hold the valve body 102 firmly to the underside of the top wall 76. Seal rings 123 fit around bosses 121 to assure leak proof joints. Similar seal rings 125 are provided under screws 94 to provide leak proof joints where the screws 94 connect to the valve body 102 at the posts 127. These posts serve as support structures which may, if desired, engage portions of the bottom wall of the holding tank section 12.
For installation purposes, the valve body 102 comprises two annular segments 120 and 122 to permit the valve body to be inserted into the holding tank section 12 during initial assembly. The arcuate segment 120 includes vertically spaced guide surfaces for supporting the upper and lower surfaces of the flat blade 86. The upper guide surfaces include the surfaces 124 and 126, and the lower guide surfaces comprise the surfaces 128 and 130. Similarly, the valve body segment 122 includes the upper guide surfaces 132 and 134, and the lower guide surfaces 136 and 138. Thus, it can be seen that the flat blade 86 can move between open and closed positions on the guide surfaces provided in the valve body 102. When the flat blade moves under the elastomeric annular seal 98 it will engage the depending lip 108 to provide an effective sealing closure. It is to be observed that there are no abuttments against which the inner end or edge 140 of the blade 86 must engage. This serves to eliminate any problems that might otherwise arise where solid matter may be engaged by the edge 140 and trapped against an abutting surface of the valve body. The edge 140 is also constructed so as to be substantially straight with a concave portion at 142. It is found that this arrangement causes a progressively smooth sliding action of the lip 108 on the blade, as shown in FIG. 10. Where the blade 86 has a conventional straight or convex leading end, it is found that the lip 108 tends to slide on the edge in an uneven non-progressive manner, so that a point is reached at which a long arc length of the lip 108 must abruptly slide up over the edge of the blade, which often results in the lip 108 rolling under, thus assuming a configuration which cannot seal against the blade 86.
In view of the fact that the shaft 104 is usually within the confines of the holding tank section 12, and the stem must slide out through the front wall 78 during opening of the valve assembly 84, a bellows 106 has been secured at one end by a spring clip 144, and the bellows has been secured to the front side wall 78 of the holding tank section 12 by the male retainer element 146 which is threadedly connected to the female retainer 148 to secure the bellows 106 in the manner shown in FIG. 9. This arrangement assures that the portion of the shaft that slides through the retainer element 146 will remain clean and uncorroded to assure easy movement and absence of leakage at this fitting.
It will be observed that the top surface of the flat blade 86 includes a small conical projection 150 which will function when the flat blade 86 is in its closed position to snap under the lower edge 152 of the body segment 120 to prevent the blade 86 from inadvertently moving to an open position, such as might occur if the portable toilet 10 were used, for example, in a recreational vehicle wherein vibration from the vehicle might be transmitted to toilet 10.
When it is desired to secure the portable toilet 10 to a supported structure, a pair of holddown brackets 154 may be employed. As shown best in FIGS. 1 and 5, each bracket is shaped to extend upward from the point of attachment at 156 upward to terminate at the upper end in an inwardly turned hook 158 that fits over the top wall 76 of the holding tank section 12. The top wall 76 has at its side edges recessed portions 160 for receiving the ends of the hooks 158, and the portions 160 extend to the rear of the holding tank section so that the latter can be moved forward from its supported area without obstruction from the hooks 158 when the hooks are aligned with the recessed portions 160. To prevent inadvertent movement of the holding tank section 12, sockets 162, which are offset from the recessed portions 160, are provided, and the resilient properties of the brackets 154 are such that they will normally be in the positions shown in FIGS. 1 and 5 preventing release of the holding tank section 12 for movement in a forward direction. When it is desired to release the holding tank section 12 from the brackets 154, this can be accomplished by an individual merely by making use of the finger holes l64 to urge the brackets outwardly to proper alignment with the recessed portions 160 and the holding tank section 12 can then be moved forward.
From the foregoing description it will be apparent that the handle 105 for the flat slide valve assembly 84 and the handle 58 for actuating the clamp mechanism 56 are both located on the front side of the portable toilet 10 for convenient actuation. Similarly, the brackets 54 can be operated for releasing the portable toilet from the front of the toilet and very little room on either side is required for this purpose. Thus, the portable toilet 10 can be supported in an area having relatively small width so as to conserve space in the recreational vehicle or the like. Furthermore, all of the dimensions in the toilet, by virtue of the construction and arrangement of the flat slide valve assembly 84 and the upper regions of the bowl 24 and the arrangement of the pump flush apparatus 34 are such as to provide maximum capacity while maintaining the vertical dimensions at a minimum. | A self-contained portable sanitation unit formed in two vertically stacked sections. The top section includes a seat and cover, a bowl having an outlet port at its bottom, walls defining with the bowl a flush water chamber surrounding the bowl, and pump flush apparatus for discharging flush water into the bowl. The pump apparatus and the bowl are constructed and arranged to assure that the flush water is discharged from a discharge nozzle in a stream against the bowl wall so as to substantially eliminate "spitting" or other undesirable splashing of water thereby eliminating need for a flush rim. The lower section functions as a holding tank and is sealed from the environment by a manually actuated slide valve assembly which has its valve body and valve blade located within the holding tank to conserve vertical space, and the handle for the valve blade is located at the front of the unit. The sections are releasably secured together by a clasp mechanism located between the sections and the clasp handle is also located at the front of the unit, thereby minimizing space requirements on opposite sides of the unit. Similarly, clamp brackets for clamping the holding tank section to a support surface can be released from a frontal position and the top section alone or the two sections can be removed from a frontal position. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates to motor speed controls suitable for use in controlling and varying the speed of a motor driven kitchen appliance. Although speed control circuits for household kitchen appliances are well known in the art, several of the prior art speed control circuits have suffered from certain disadvantages.
U.S. patent Aaplication No. 916,189 to Ponczek et al., filed June 16, 1978, now abandoned, and assigned to the assignee of the instant application discloses a speed control circuit for use in an electric kitchen appliance, such as a mixer, which employs a mechanical governor as the sensing element and controls a triac, which in turn controls current flow to an appliance motor. It is clear that such a hybrid mechanical-electrical arrangement, while an improvement over previous systems, still leaves much to be desired, in that mechanical components which are subject to wear are employed in the system.
Another speed control system, also assigned to the assignee of the instant application, is disclosed in U.S. Pat. No. 4,227,128 to Cockroft et al. Cockroft et al. is directed to another speed control arrangement wherein the motor speed at which a mechanical governor switches is simultaneously altered as the average conduction angle of a triac is changed by movement of a single control knob. This device also suffers from some of the same disadvantages as the first mentioned mechanical governor/triac hybrid controller.
A relatively complex speed control circuit employing a multiple toothed pulse or interrupter wheel in association with a magnetic pickup as a speed sensing element, which is assigned to the assignee of the present application, is disclosed in U.S. Pat. No. 4,326,153 to Contri. It should be noted, however, that the Contri circuit requires the use of a 24-tooth interrupter wheel which adds additional expense to the appliance.
Accordingly, there is a need for a relatively inexpensive speed control circuit which does not require modification of the mechanical drive components of a home appliance. The electronic control unit should be adapted to be assembled and tested separately from other appliance components, such as the drive motor before the final assembly.
SUMMARY OF THE INVENTION
A feedback motor speed control circuit for controlling the speed of an electric household kitchen appliance is herein disclosed. The feedback motor speed control circuit includes a magnetic coil sensor located in spaced proximity with a fan of an appliance motor for magnetic coupling therewith. The magnetic sensor produces a signal having a frequency substantially proportional to the rotational speed of the electric motor. The signal is clipped and attenuated by conditioning means and fed to a digitizer which produces a uniform amplitude rectangular wave signal having a frequency proportional to the frequency of the magnetic sensing coil signal. The rectangular wave signal is fed to clipping and differentiating means and converted to a pulse signal having a frequency equal to the frequency of the rectangular wave. The pulse signal is fed to integrating means having a relatively long time constant to produce a D.C. speed signal having amplitude proportional to the speed of the electric motor.
Regulated voltage producing means are also provided which supply a regulated voltage to a differential amplifier which also receives the D.C. speed signal. The differential amplifier produces an error signal output which drives an optical coupler to control a high voltage portion of the circuit. The optical coupler controls a charging rate of capacitance means connected to a triac, thereby determining the conduction angle of the triac which is connected to the electric motor for control thereof.
It is a principal object of the present invention to provide a low cost feedback motor control circuit which can be used with a conventional electric motor and fan to control the speed thereof.
It is another object of the instant invention to provide a feedback motor speed control circuit which digitizes a sensed signal prior to analog processing of the sensed signal.
It is still another object of the instant invention to provide a feedback motor speed control circuit which has a first low voltage sensing and conditioning means and a second high voltage motor control means isolated from one another by an optical coupler.
It is still a further object of the instant invention to provide a feedback motor speed control circuit which can be calibrated separately from an electric motor with which it is to be employed.
Other objects and uses of the present invention will become obvious to one skilled in the art by the perusal of the following specification and claims in light of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a a schematic diagram of a feedback motor speed control circuit embodying the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the only drawing Figure, a feedback motor speed control generally indicated by numeral 10 and embodying the present invention is shown therein. The feedback speed control circuit 10 is connected to a conventional alternating current or universal motor 12 having an armature 13 and a pair of field coils, respectively identified by numerals 14 and 16. The electric motor 12 provides mechanical energy for an electric household appliance of the type disclosed in U.S. Pat. No. 4,071,789, which is assigned to the assignee of the instant application, and has a cooling fan 11 coupled thereto which rotates at the same speed as the motor 12.
The motor 12 is energized from a suitable source of alternating current received at a plug 18 which is connected to a switch 20. The switch 20 is connected through a lead 22 to the field coil 14 to supply alternating current thereto. The field coil 16 is connected to another portion of the motor speed control circuit 10 for receipt of alternating current at substantially line voltage, as will be described in detail hereinafter.
A pickup or induction coil 24 is mounted to couple magnetically with the fan 11 so that when the motor 12 is operating the fan rotates past the pickup coil 24, thereby periodically varying the reluctance of the pickup coil 24 and causing the pickup coil 24 to generate a time varying coil signal having a frequency proportional to the speed of the rotation of the electric motor 12.
In order to condition the coil signal for processing by other portions of the speed control circuit 10 an attenuating resistor 26 is connected to one of the ends of coil 24 for receipt of the coil signal. A lead 28 is connected to the other end of coil 24. A clipping diode 30, in this case, a 1N4148, is connected at its anode to lead 28 and at its cathode to resistor 26. Diode 30 clips the coil signal to prevent the potential difference between resistor 26 and lead 28 from going above 0.7 volts during the negative half of the output of the pickup coil 24 time-varying coil signal. In the present embodiment, resistor 26 is a 10 kilohm resistor.
In order to provide a suitable supply of electrical energy to other portions of the speed control circuit 10, a power supply circuit 32 is provided therefor and includes a full wave rectifier bridge 34 connected to lead 22 and to a lead 36, which is also connected to plug 18. The rectifier bridge 34 is energized by A.C. line current either at 120 or 240 volts. One of the output terminals of the rectifier bridge 34 is connected to a 6.8 kilohm resistor 38. In a high voltage embodiment of the instant speed control circuit, that is, one which is adapted to be powered from a 240 volt, 50 Hertz alternating current supply, an additional 6.8 kilohm resistor 40 is connected in series with the resistor 38.
When the circuit 10 is used with a 120 volt, 60 Hertz alternating current supply, the resistor 38 is connected directly to a 100 mfd. electrolytic capacitor 42 which filters the ripple out of the rectified supply voltage from the bridge 34. In the 240 volt embodiment the resistor 40 is connected to the electrolytic filter capacitor 42. A reverse-biased Zener diode 44, in this embodiment a 1N4742, having a reverse breakdown voltage of 12 volts, is connected across the electrolytic filter capacitor 42 between a twelve volt D.C. supply lead 46 and a ground D.C. supply lead 48. The twelve volt D.C. supply lead 46 is connected to the junction of the resistor 38 (or resistor 40) and the electrolytic filter capacitor 42. The ground D.C. supply lead 48 is connected to a second output terminal of full wave rectifier bridge 34. Rectifier bridge 34, resistor 38 (or resistors 38 and 40), the electrolytic filter capacitor 42 and the Zener diode 44 function in the well-known fashion to provide a smooth regulated twelve volt D.C. output between the D.C. supply leads 46 and 48. A plurality of resistors 49 is connected in a voltage divider circuit between D.C. supply leads 46 and 48 and includes a resistor 50 having a fixed resistance of 100 kilohms, a potentiometer 52 having a fixed resistance of 10 kilohms, a potentiometer 54 having a fixed resistance of 2.2 kilohms and a resistor 56 having a fixed resistance of 1 kilohm. A tap 52a of potentiometer 52 and a tap 54a of potentiometer 54 have a 100 kilohm potentiometer 58 connected there across. A tap 60 of the potentiometer 58 is connected to other portions of the circuit to provide a selectable regulated reference voltage for purposes which will become clear hereinafter.
The output voltage of the pickup coil 24 in the instant embodiment is of the magnitude of 0.5 to 5.0 volts as measured directly across the pickup coil 24. After being clipped, the voltage of the coil signal is further attenuated by a voltage divider comprised of a 10 kilohm resistor 62 connected to the cathode of the diode 30 and a 1 kilohm resistor 64 connected to resistor 62 in parallel with diode 30. The attenuated voltage across the resistor 64 varies between 0.05 volts and 0.15 volts.
In order to convert the attenuated and clipped voltage to a digitized signal, a National Semiconductor LM358N dual operational amplifier 65 is provided. Digitizing of the clipped, attenuated signal is particularly important as it yields a signal having a uniform amplitude and waveform. Without the digitizing the coil signal would vary in both amplitude and frequency as the speed of the motor 12 is changed and thereby introduce error in the speed control function.
One half of the dual operational amplifier 65 is configured as a comparator 66 having a noninverting terminal 68 connected to the junction of the resistor 62 and the resistor 64. An inverting terminal 70 of the comparator 66 is connected to the opposite end of the resistor 64. The comparator 66 also has an output terminal 72 and a positive power supply terminal 73 (identified as pin 8 by National Semiconductor, the manufacturer of the amplifier). The positive power supply terminal 73 is connected by a positive power supply lead 75 to the positive lead 46 to receive regulated 12 volt D.C. current.
The comparator 66 generates a digitized signal, in that a rectangular wave having a frequency substantially proportional to the frequency of the coil signal is provided at the comparator output terminal 72. Since the signal has been digitized and has a uniform amplitude of approximately 12 volts, the comparator 66 minimizes circuit error due to amplitude fluctuations of the coil signal at varying fan speeds.
The digitized signal is fed from the comparator output pin 72 to a 0.015 mfd. differentiating capacitor 74 connected thereto. A 1N4148 diode 76 connected between the capacitor 74 and the lead 28 clips the signal provided by the differentiating capacitor 74. The differentiating capacitor 74 and a 2.2 kilohm resistor 78 connected in parallel with the diode 76 provide a spiking or differential signal the negative portions of which are clipped by the diode 76.
The positive pulse portions of the differential signal have a substantially uniform amplitude and duration and are fed to an integrator 80 comprised of a resistor 82 having a resistance of 22 kilohms and an electrolytic capacitor 84 connected to the resistor 82 and in parallel with the resistor 78 to provide an integrated signal having an amplitude substantially proportional to the frequency of the coil signal, and thus the speed of rotation of the motor 12. The integrated signal is supplied to an operational amplifier 86, comprised of the second half of the LM358N dual operational amplifier 65, through a resistor 88 having a resistance of 100 kilohms which is connected to an inverting terminal 90 of the operational amplifier 86. A noninverting terminal 92 of the operational amplifier 86 is connected to the tap 60 of the potentiometer 58 for receipt of the reference voltage provided by the voltage divider network 49. A negative supply terminal 94 of the operational amplifier 86, identified by National Semiconductor as pin 4, is connected to the lead 28 and the lead 48 and held at circuit ground.
For reasons which will become apparent hereinafter, the output signal from the operational amplifier 86 is converted to a light signal by an optical coupler 100 having a light emitting diode 102 which is connected to an output terminal 104 of the operational amplifier 86. In order to obtain a substantially linear response, in other words, a light flux from the light emitting diode 102 which is substantially proportional to the voltage supplied to terminal 92 minus the voltage on terminal 90, a feedback resistor 103, in this instance having a resistance of 2 megohms, is connected to the cathode of the light emitting diode 102. The light emitting diode 102 is included within the amplifier feedback loop so that the amount of current provided to the diode is proportional to the difference between the input voltages. Thus, when the input voltage proportional to the motor speed is less than the reference voltage from the tap 60, the light emitting diode 102 is illuminated and the amount of light produced by the light emitting diode 102 is substantially proportional to the difference between the reference voltage and the motor speed voltage. In other words, the light flux of the light emitting diode 102 is proportional to the error voltage of the operational amplifier 86. The light emitted by the diode 102 is provided to a phototransistor 105 at its base 106 for control of other portions of the circuit, as will become clear hereinafter. The feedback loop of the operational amplifier 86 has connected thereto a resistor 110 which is also connected to ground lead 48.
Thus, in summary, the portion of the circuit already, described, which might be termed the low voltage portion 111, receives a varying pulse-like ill-conditioned signal from coil 24, clips the signal, attenuates it, digitizes it at the comparator 66, differentiates the signal and selects only the positive spikes representative of the positive going portions of the digitized signal, one of which occurs for each pulse from the pickup coil 24. The differentiated signal has a uniform amplitude so that when the pulses are integrated by the integrator 80, a substantially D.C. signal proportional to the motor speed is provided to the error amplifier 86 which produces an error signal in the form of a light flux. Since the optical coupler 100 couples the low voltage and high voltage sides of the circuit 10, power supply fluctuations and the like are prevented from affecting the sensing and measuring portions of the circuit.
A high voltage portion 115 of the circuit 10 includes a resistor 120, in this embodiment a 10 kilohm resistor, which is connected between a lead 122, which is connected to the field coil 16, and a full wave rectifier bridge 124. The full wave rectifier bridge 124 provides a full wave rectified signal to the phototransistor 105 which controls the amount of alternating current flowing through the bridge and thus through resistor 120 and a lead 126. It is clear, however, that although the phototransistor 105 controls a uni-directional flow of current through itself, the current provided to the lead 126 is alternating current.
In the event that the circuit is to be used with an alternating current power supply of 240 volts, rather than 120 volts, the value of resistor 120 must be changed to 47 kilohms and a resistor 128, also having a value of 47 kilohms must be connected as shown by the dotted lines to the full wave rectifier bridge 124 and to ground lead 36.
The current from the full wave rectifier bridge 124 as controlled by the phototransistor 105 is fed to a first timing capacitor 130, which is connected to the lead 126 and to the ground lead 36. A 10 kilohm resistor 132 is connected to the first timing capacitor 130 and has a second timing capacitor 134 connected thereto in parallel with the first timing capacitor 130. Both first and second timing capacitors 130 and 134 are 0.047 mfd. capacitors. The timing capacitor 134 is charged by current flowing through the lead 126 and when it reaches a preselected level, causes a GT-32 diac 136, which is connected at the junction of the resistor 132 and the capacitor 134, to become conducting. When the diac 136 switches conducting, it supplies a gating signal to a gate terminal 137 of triac 138 to switch the triac 138 into conduction.
A 150 ohm resistor 142 is connected between the triac gate 137 and the ground lead 36 to prevent false triggering of the triac and to limit the current flow to the triac gate. The triac 138 also has a pair of main terminals, respectively numbered 144 and 146, which are respectively connected to the leads 122 and 36. Thus, when the triac 138 is switched on, A.C. power is supplied from plug 18 through field coils 14 and 16 and motor armature 13, thereby energizing the motor. When the motor 12 reaches a preselected speed the light flux from the light emitting diode 102 decreases, thereby modifying the current from the phototransistor 105 and modifying the current flow through the lead 126 to the first timing capacitor 130 and the second timing capacitor 134, thereby controlling the triggering of the diac 136 and controlling the conduction through triac 138.
The speed control circuit 10, however, functions as a proportional controller because the error signal indicative of the difference between the actual motor speed and the preselected speed proportionately controls the amount of current flowing through the phototransistor 105 and thus affects the charging time of the capacitors 130 and 134. Since the triac 138 is configured to function as a conduction angle control the conduction angle of the triac 138 is proportional to the error signal from the operational amplifier 86.
Motor speed control circuit 10 is easy to calibrate and inexpensive to construct. Calibration can be achieved prior to connection of the circuit with an electric motor 12 by supplying a sine wave signal to resistor 26 and lead 28. The sine wave signal has a frequency equal to that generated by the coil 24 at the minimum desired speed of rotation of the electric motor. Wiper 60 of potentiometer 58 is then rotated to its lowest potential and tap 54a of trimpot 54 is adjusted until light emitting diode 102 is extinguished. Similarly, the high speed setting of the motor control circuit 10 is calibrated by supplying to resistor 26 and lead 28 a sine wave having a frequency equal to the coil signal frequency at maximum motor speed. The tap 60 of the potentiometer 58 is rotated to its highest potential position and the tap 52a of the trimpot 52 is adjusted until light emitting diode 102 is barely illuminated. It may be appreciated that at no time in the calibration procedure is it necessary to connect a motor 12 and sensing coil 24 in the circuit. This considerably reduces the cost of manufacture of the unit.
As may be appreciated from the above, it is unnecessary to provide additional mechanical elements as signal producing means when the ill conditioned signal supplied by the ferromagnetic fan blades rotating in proximity with coil 24 is conditioned by digitizing differentiating and integrating the signal in the electronic components of the motor speed control circuit 10. This also produces a considerably cost saving as mechanical variances in the tolerances in the fan blades or their displacement from the magnetic pickup coil 24 are easily compensated for in the electronic circuitry at relatively low cost. Furthermore, it may be appreciated that the sensing and conditioning portion of the circuitry is isolated from the control portion of the circuitry through the use of an optical coupler which prevents damage to the operational amplifiers and associated semiconductors due to switching transients caused by triac 138.
While there has been illustrated and described a particular embodiment of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true spirit and scope of the present invention. | A motor speed control circuit for closed loop control of an electric motor of a household electric appliance is disclosed herein. The motor speed control circuit includes a coil adapted to be placed in proximity with a fan connected to an electric motor and producing a time varying signal in response to rotation thereof. A comparator connected to the coil generates a rectangular wave having a frequency proportional to the frequency of the coil signal. Additional means are provided for converting the rectangular wave signal, a D.C. signal having an amplitude which corresponds to the frequency of the rectangular wave. The D.C. signal is compared to a reference signal at an amplifier to produce an error signal which is fed through an opto-isolator to a conduction angle controlled thyrister. The thyrister is connected to the electric motor and a source of electric power to control the speed of the electric motor. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Present Invention
[0002] The field of the present invention relates to a method of playing a poker game wherein a 52-card deck entertainment value is maximized without increasing the probabilities against a gaming house or casino.
[0003] 2. Description of the Prior Art
[0004] Ways or methods to play a poker game are many. However, there is no description of playing multiple five-card hands from just one previously shuffled 52-card poker deck, wherein the probabilities against a casino do not increase, while maintaining maximum entertainment value.
[0005] By way of example, U.S. Pat. No. 6,638,163 to Moody describes a poker game that start with a poker deck, and an incentive component derived from a complete newly shuffled poker deck, thus, renewing or duplicating the gambler probabilities against a casino. Other examples are U.S. Patent Application No. 20060267283A1 by Jackson, U.S. Pat. No. 5,908,353 to Andrews, U.S. Pat. No. 5,845,907 to Wells, U.S. Patent Application No. 20060157936A1 by Moody, U.S. Pat. No. 6,131,907 to Nucifora, etc.
[0006] The present invention provides a poker game playing method that overcomes the mentioned limitations of the prior art.
SUMMARY OF THE INVENTION
[0007] The present invention provides a poker game playing method wherein multiple five-card hands from once previously shuffled 52-card poker deck can be played without increasing probabilities against a casino, while maintaining maximum entertainment value, and with immediate certainty of winning or losing. The method of the present invention maximizes entertainment value derived from said poker deck by rewarding a gambler with free five-card hands when there had been five-card hand winning combinations, wherein the rewarding free five-card hands are from the remaining un-played cards of said same poker deck, thus, without increasing chances against a casino or gaming house, and wherein a gambler may have a false impression of increased probabilities in his favor because of the rewarding free five-card hands, therefore increasing his gambling desire to start anew waging against newly shuffled 52-card poker decks.
[0008] More specifically, the present invention provides a method of playing a poker game on a table, wherein the method comprises:
A) A player starting a game by making wagers to play a facedown five-card hand from a once previously shuffled 52-card poker deck, wherein the player can play between one and ten facedown five-card hands from said same 52-card poker deck, wherein the player makes a wager for each facedown five-card hand, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards; B) A dealer Dealing to the player between one and ten facedown five-card hands from said same 52-card poker deck; C) Opening the five-card hands from said same 52-card poker deck; D) Determining the poker hand ranking of each one of the five-card hands; E) If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand;
[0014] wherein, if any of the five-card hands is a winning combination and if there are remaining cards from said same poker deck, rewarding to the player another five card hand for each winning combination, wherein the remaining cards from said same deck could be 47 if one initial five-card hand was played, 42 if two initial five-card hands were played, 37 if three initial five-card hands were played, 32 if four initial five-card hands were played, 27 if five initial five-card hands were played, 22 if six initial five-card hands were played; 17 if seven initial five-card hands were played; 12 if eight initial five-card hands were played; 7 if nine initial five-card hands were played, wherein if there are less number of remaining cards than the cards needed to reward several concomitant winning combination the player is rewarded with just the maximum possible five-card hands from the remaining cards based on which winning combinations have the highest ranking, wherein if there is a rewarding five-card hand winning combination, the player is rewarded according to a a pre-established winning amount based on the amount of the original wager for the original five-card hand, wherein the game is over when there are no winning combinations; and wherein the game is also over when there are just two remaining cards from said same card deck.
[0015] In one aspect of the method of the present invention, more than one player participate in the game, wherein the game starts when there is wagers for at least two facedown five-card hands from the same 52-card poker deck, wherein more than one player make wagers to play between two and ten concurrent facedown five-card hands from the same 52-card poker deck, wherein there is a wager for each facedown five-card hand from the same 52-card poker game, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards.
[0016] In another aspect of the method of the present invention, the rewarding five card-hands are taken from the remaining cards of said same poker deck, wherein the remaining cards of said same poker deck are not shuffled anymore.
[0017] In one embodiment of the method of the present invention, the five-card hands from the same 52-card poker deck are opened.
[0018] In another embodiment of the method of the present invention, the poker game can be played on a gaming machine with a video screen, wherein the gaming machine is programmed to assume the role of the dealer.
[0019] In one more embodiment, the present invention is a method of playing a poker game on a gaming machine with a video screen, wherein the method comprises:
A. A player activating a game in the gaming machine by making wagers for five-card hands from a previously shuffled 52-card poker deck, wherein the player can play between one and five five-card hands from the same 52-card poker deck, and wherein the player makes a wager for each five-card hand, and wherein the wager for a five-card hand can be different from the wagers for the other five-hand cards; B. The gaming machine dealing on the video-screen between one and five five-card hands from the same 52-card poker deck; C. Determining the poker hand ranking of each one of the five-card hands; D. If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand; E. The machine dealing, as incentive, only for each five-card winning combination, another five-card hand from the remaining cards of said same original poker deck; F. If any of the latest dealt-as-incentive five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the original wager for the corresponding original five-card hand; G. If there is available a five-card hand from the same original poker deck, and if there is a five-card winning combination, steps E. and F. are repeated successively until the game ends;
[0027] wherein, the game ends when there are no more available five-card hands from the remaining cards of said same original poker deck. In another version of this embodiment of the present invention, the poker game is played on a table and the five-card hands are dealt by a dealer.
[0028] In a further embodiment of the present invention is a method of playing a poker game on a table, wherein the method comprises:
A) A player starting a game by making wagers to play at least two facedown five-card hands from the same 52-card poker deck, wherein the player can play between two and ten facedown five-card hands from the same 52-card poker deck, wherein the player makes a wager for each facedown five-card hand, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards; B) A dealer Dealing to the player between two and ten facedown five-card hands from the same 52-card poker deck; C) Opening the five-card hands from the same 52-card poker deck; D) Determining the poker hand ranking of each one of the five-card hands; and, E) If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand.
[0034] wherein, if any of the five-card hands is a winning combination and if there are remaining cards from said same poker deck, rewarding to the player another five card hand for each winning combination, wherein the remaining cards from said same deck could be 47 if one initial five-card hand was played, 42 if two initial five-card hands were played, 37 if three initial five-card hands were played, 32 if four initial five-card hands were played, 27 if five initial five-card hands were played, 22 if six initial five-card hands were played; 17 if seven initial five-card hands were played; 12 if eight initial five-card hands were played; 7 if nine initial five-card hands were played, wherein if there are less number of remaining cards than the cards needed to reward several concomitant winning combination the player is rewarded with just the maximum possible five-card hands from the remaining cards based on which winning combinations have the highest ranking, wherein if there is a rewarding five-card hand winning combination, the player is rewarded according to a a pre-established winning amount based on the amount of the original wager for the original five-card hand, wherein the game is over when there are no winning combinations; and wherein the game is also over when there are just two remaining cards from said same card deck. In another version of this embodiment of the present invention, more than one player may participate in the game, and the game starts when there is wagers for at least two facedown five-card hands from the same 52-card poker deck, wherein more than one player make wagers to play between two and ten concurrent facedown five-card hands from the same 52-card poker deck, wherein there is a wager for each facedown five-card hand from the same 52-card poker game, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards. Yet, in one more version of this embodiment of the method of the present invention, the five-card hands from the same 52-card poker deck are opened. Even more, in a further version of this embodiment of the method present invention, the poker game can be played on a gaming machine with a video screen.
[0035] In one more embodiment, the present invention is a method of playing a game on a gaming machine with a video screen, wherein the method comprises:
A. A player activating a game in the gaming machine by making wagers for at least two five-card hands from the same 52-card poker deck, wherein the player can play between two and five five-card hands from the same 52-card poker deck, and wherein the player makes a wager for each five-card hand, and wherein the wager for a five-card hand can be different from the wagers for the other five-hand cards; B. The gaming machine dealing on the video-screen between two and five five-card hands from the same 52-card poker deck; C. Determining the poker hand ranking of each one of the five-card hands; D. If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand; E. The machine dealing, as incentive, only for each five-card winning combination, another five-card hand from the same original 52-card poker deck; F. If any of the latest dealt five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the original wager for the corresponding original five-card hand; G. If there is available a five-card hand from the same original 52-card poker deck, and if there is a five-card winning combination, steps E. and F. are repeated successively until the game ends;
[0043] wherein, the game ends when there are no more available five-card hands from the same original 52-card poker deck. Yet, in another version of this embodiment of the present invention, the game is played on a table and the five-card hands are dealt by a dealer.
[0044] Objectives and additional advantages of the present invention will become more evident in the description of the figures, the detailed description of the invention and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] FIG. 1 shows a gaming table where the poker game can be played applying the method of the present invention, wherein the table is configured for up to seven five-card hands from a previously shuffled 52-card poker deck.
[0046] FIG. 2 shows the ranking table for five-card hand winning combinations.
DETAILED DESCRIPTION OF THE INVENTION
[0047] FIG. 1 shows a gaming table where the poker game can be played applying the method of the present invention. Although in FIG. 1 , the gaming table is configured for 7 five-card winning combinations out of one previously shuffled 52-card poker deck, in other embodiments of the present invention, the table can be configured for up to 5, for up to 10, etc. five-card hands from a previously shuffled 52-card poker deck.
[0048] FIG. 2 shows the preferred ranking table for five-card hand winning combinations. However, other ranking tables can be used for five-card hand winning combinations.
[0049] In no case, a pair is a defined under this application as a winning combination. A pair is a tie, which entitles the player reimbursement of the wage, but a pair DO NOT mean that the player receives as incentive an additional rewarding free five-card hand from the remaining cards of the same poker deck from which the original five-card hand wage was made. In contrast, as explained below, a five-card winning combination results in a free rewarding five-card hand if there are available cards from the same poker deck from which the original five-card hand wage was made. By defining a pair as a tie, a gambler stays motivated to keep playing by making new wages against new previously shuffled 52-card poker decks; and by not defining a pair as a winning combination, probabilities against the casino do not increase. In other words, the method of the present invention maintains the motivation of the gambler without increasing odds against a gaming house or casino.
[0000]
TABLE 1
Hand
Frequency
Probability
Cumulative
Odds
Straight
40
0.00154%
0.00154%
64,973:1
flush
Four of a
624
0.0240%
0.0256%
4,164:1
kind
Full house
3,744
0.144%
0.170%
693:1
Flush
5,108
0.197%
0.367%
508:1
Straight
10,200
0.392%
0.76%
254:1
Three of a
54,912
2.11%
2.87%
46.3:1
kind
Two pair
123,552
4.75%
7.62%
20.0:1
One pair
1,098,240
42.3%
49.9%
1.37:1
No pair
1,302,540
50.1%
100%
0.995:1
Total
2,598,960
100%
100%
0:1
[0050] Table 1 enumerates the frequency of each hand, given all combinations of five-card hands randomly drawn from a full deck of 52 without replacement. Wild cards are not considered. The probability of drawing a given hand is calculated by dividing the number of ways of drawing the hand by the total number of 5-card hands (the sample space, ( 5 52 )=2,598,960 five-card hands). The odds are defined as the ratio (1/p)-1:1, where p is the probability. (The frequencies given are exact; the probabilities and odds are approximate.) Once cards are drawn from a 52-card poker deck, the probabilities of a five-card hand winning combination diminish for the un-drawn remaining cards of the same deck due to the effect of retiring drawn cards from the deck, wherein said retired cards are no more available to be part of a possible winning combination.
[0051] The method of the present invention specifically provides a method of playing a poker game on a table, wherein the method comprises:
A) A player starting a game by making wagers to play a facedown five-card hand from a once previously shuffled 52-card poker deck, wherein the player can play between one and ten facedown five-card hands from said same 52-card poker deck, wherein the player makes a wager for each facedown five-card hand, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards; B) A dealer Dealing to the player between one and ten facedown five-card hands from said same 52-card poker deck; C) Opening the five-card hands from said same 52-card poker deck; D) Determining the poker hand ranking of each one of the five-card hands; E) If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand;
[0057] wherein, if any of the five-card hands is a winning combination and if there are remaining cards from said same poker deck, rewarding to the player another five card hand for each winning combination, wherein the remaining cards from said same deck could be 47 if one initial five-card hand was played, 42 if two initial five-card hands were played, 37 if three initial five-card hands were played, 32 if four initial five-card hands were played, 27 if five initial five-card hands were played, 22 if six initial five-card hands were played; 17 if seven initial five-card hands were played; 12 if eight initial five-card hands were played; 7 if nine initial five-card hands were played, wherein if there are less number of remaining cards than the cards needed to reward several concomitant winning combination the player is rewarded with just the maximum possible five-card hands from the remaining cards based on which winning combinations have the highest ranking, wherein if there is a rewarding five-card hand winning combination, the player is rewarded according to a a pre-established winning amount based on the amount of the original wager for the original five-card hand, wherein the game is over when there are no winning combinations; and wherein the game is also over when there are just two remaining cards from said same card deck.
[0058] In one aspect of the method of the present invention, more than one player participate in the game, wherein the game starts when there is wagers for at least two facedown five-card hands from the same 52-card poker deck, wherein more than one player make wagers to play between two and ten concurrent facedown five-card hands from the same 52-card poker deck, wherein there is a wager for each facedown five-card hand from the same 52-card poker game, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards.
[0059] In another aspect of the method of the present invention, the rewarding five card-hands are taken from the remaining cards of said same poker deck, wherein the remaining cards of said same poker deck are not shuffled anymore.
[0060] In one embodiment of the method of the present invention, the five-card hands from the same 52-card poker deck are opened.
[0061] In another embodiment of the method of the present invention, the poker game can be played on a gaming machine with a video screen, wherein the gaming machine is programmed to assume the role of the dealer.
[0062] In one more embodiment, the present invention is a method of playing a poker game on a gaming machine with a video screen, wherein the method comprises:
A. A player activating a game in the gaming machine by making wagers for five-card hands from a previously shuffled 52-card poker deck, wherein the player can play between one and five five-card hands from the same 52-card poker deck, and wherein the player makes a wager for each five-card hand, and wherein the wager for a five-card hand can be different from the wagers for the other five-hand cards; B. The gaming machine dealing on the video-screen between one and five five-card hands from the same 52-card poker deck; C. Determining the poker hand ranking of each one of the five-card hands; D. If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand; E. The machine dealing, as incentive, only for each five-card winning combination, another five-card hand from the remaining cards of said same original poker deck; F. If any of the latest dealt-as-incentive five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the original wager for the corresponding original five-card hand; G. If there is available a five-card hand from the same original poker deck, and if there is a five-card winning combination, steps E. and F. are repeated successively until the game ends;
[0070] wherein, the game ends when there are no more available five-card hands from the remaining cards of said same original poker deck. In another version of this embodiment of the present invention, the poker game is played on a table and the five-card hands are dealt by a dealer.
[0071] In a further embodiment of the present invention is a method of playing a poker game on a table, wherein the method comprises:
A) A player starting a game by making wagers to play at least two facedown five-card hands from the same 52-card poker deck, wherein the player can play between two and ten facedown five-card hands from the same 52-card poker deck, wherein the player makes a wager for each facedown five-card hand, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards; B) A dealer Dealing to the player between two and ten facedown five-card hands from the same 52-card poker deck; C) Opening the five-card hands from the same 52-card poker deck; D) Determining the poker hand ranking of each one of the five-card hands; and, E) If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand.
[0077] wherein, if any of the five-card hands is a winning combination and if there are remaining cards from said same poker deck, rewarding to the player another five card hand for each winning combination, wherein the remaining cards from said same deck could be 47 if one initial five-card hand was played, 42 if two initial five-card hands were played, 37 if three initial five-card hands were played, 32 if four initial five-card hands were played, 27 if five initial five-card hands were played, 22 if six initial five-card hands were played; 17 if seven initial five-card hands were played; 12 if eight initial five-card hands were played; 7 if nine initial five-card hands were played, wherein if there are less number of remaining cards than the cards needed to reward several concomitant winning combination the player is rewarded with just the maximum possible five-card hands from the remaining cards based on which winning combinations have the highest ranking, wherein if there is a rewarding five-card hand winning combination, the player is rewarded according to a a pre-established winning amount based on the amount of the original wager for the original five-card hand, wherein the game is over when there are no winning combinations; and wherein the game is also over when there are just two remaining cards from said same card deck. In another version of this embodiment of the present invention, more than one player may participate in the game, and the game starts when there is wagers for at least two facedown five-card hands from the same 52-card poker deck, wherein more than one player make wagers to play between two and ten concurrent facedown five-card hands from the same 52-card poker deck, wherein there is a wager for each facedown five-card hand from the same 52-card poker game, and wherein the wager for a facedown five-card hand can be different from the wagers for the other facedown five-hand cards. Yet, in one more version of this embodiment of the method of the present invention, the five-card hands from the same 52-card poker deck are opened. Even more, in a further version of this embodiment of the method present invention, the poker game can be played on a gaming machine with a video screen.
[0078] In one more embodiment, the present invention is a method of playing a game on a gaming machine with a video screen, wherein the method comprises:
A. A player activating a game in the gaming machine by making wagers for at least two five-card hands from the same 52-card poker deck, wherein the player can play between two and five five-card hands from the same 52-card poker deck, and wherein the player makes a wager for each five-card hand, and wherein the wager for a five-card hand can be different from the wagers for the other five-hand cards; B. The gaming machine dealing on the video-screen between two and five five-card hands from the same 52-card poker deck; C. Determining the poker hand ranking of each one of the five-card hands; D. If any of the five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the wager for each five-card hand; E. The machine dealing, as incentive, only for each five-card winning combination, another five-card hand from the same original 52-card poker deck; F. If any of the latest dealt five-card hands is a winning combination, awarding the player a pre-established winning amount based on the amount of the original wager for the corresponding original five-card hand; G. If there is available a five-card hand from the same original 52-card poker deck, and if there is a five-card winning combination, steps E. and F. are repeated successively until the game ends;
[0086] wherein, the game ends when there are no more available five-card hands from the same original 52-card poker deck. Yet, in another version of this embodiment of the present invention, the game is played on a table and the five-card hands are dealt by a dealer.
[0087] In all possible embodiments of the present invention, it is possible that after multiple initial five-card hand wages from one previously shuffled 52-card poker deck, there is more five-card hands showing winning combinations, than remaining cards from the same deck to reward the five card winning combinations. For example, there may be 6 five card hands showing winning combinations, and in just 22 cards remaining from the same deck that will produce only 4 free rewarding five-card hands. In the example, the method of the present invention rule is to reward the 4 five-card hand winning combinations with the highest ranking, and the game is over. In other words, when there is more five-card hands showing winning combinations than rewarding free five-card hands possible out of the remaining cards left on the poker deck, only the highest five-card hand winning combinations will be rewarded with the possible free five-card hands left on the remaining cards of the same poker deck, and the game will be over. In this way, there is no possibility that the probabilities against a casino or gaming house are renewed by rewarding a gambler with new hands from another 52-card poker deck.
[0088] While the description presents the preferred embodiments of the present invention, additional changes can be made in the form and disposition of the parts without distancing from the basic ideas and principles comprised in the claims. | The present invention provides a poker game playing method wherein multiple five-card hands from once previously shuffled 52-card poker deck can be played without increasing probabilities against a casino, while maintaining maximum entertainment value, and with immediate certainty of winning or losing. The method of the present invention maximizes entertainment value derived from said poker deck by rewarding a gambler with free five-card hands when there had been five-card hand winning combinations, wherein the rewarding free five-card hands are from the remaining un-played cards of said same poker deck, thus, without increasing chances against a casino or gaming house, and wherein a gambler may have a false impression of increased probabilities in his favor because of the rewarding free five-card hands, therefore increasing his gambling desire to start anew waging against newly shuffled 52-card poker decks. | 6 |
FIELD OF THE INVENTION
The field of the invention is lock mandrels that engage a mating profile in a tubular with dogs and more particularly design features that distribute shear loads on the dogs when stacked or that transfer loads on the housing between dog windows to the dogs from the adjacent body portion to reduce stress otherwise passing to the housing portions between dog windows.
BACKGROUND OF THE INVENTION
FIGS. 1-3 show an existing design for a lock mandrel tool 10 that has an outer housing 14 with openings 16 for extendable dogs 18 shown retracted in FIG. 1 . One or more seals 20 engage a seal bore in a surrounding tubular that is not shown when the tool 10 hits a no-go also not shown in the surrounding tubular. A setting sleeve 22 has a thin lower end 24 that is under the dogs 18 for run in so that dogs 18 will be retracted inside windows 16 . A ramp 26 leads to a larger diameter portion 28 . As seen in FIG. 2 when the ramp 26 is pushed against the dogs 18 the dogs 18 get pushed out through the windows 16 to the point where portion 28 underlies the dogs 18 and the dogs 18 are extended into a surrounding profile that is not shown. The extension of the dogs 10 raises the tool 10 off the no-go that is not shown.
Housing 14 has elongated segments 30 that define the windows 16 between them. There needs to be sufficient wall in segments 30 so that when there is a pressure differential from uphole and the dogs 18 are extended into a surrounding profile and the tool 10 as a result of dog extension is no longer supported on the no-go, that the tensile stress in the segments 30 is not exceeded. There is normally a tradeoff between making the dogs 18 wider and the need for sufficient wall thickness to tolerate the stresses administered from pressure differential. Wider dogs 18 can hold more shear load but the strength of the body is reduced when the width of segments 30 is reduced to make the dogs 18 wider.
The present invention addresses this issue in at least two ways that can be used separately or together. In one aspect the load is transferred to the dogs from the housing while avoiding or minimizing loading the window periphery and the sections of the housing that are among the windows. In another approach multiple rows of dogs are presented to share the shear loading and flexibility in the housing between rows of dogs allows the sharing of shear loading. This addresses an issue of manufacturing tolerances being high enough so that engagement of a first row of dogs can move another row of dogs into a position where they do not take the shear loading at all because they are displaced from the profile end. These and other aspects of the present invention will be more readily apparent to those skilled in the art from a review of the description of the preferred embodiment and the associated drawings while recognizing that the full scope of the invention is to be determined from the appended claims.
SUMMARY OF THE INVENTION
A plurality of rows of locking dogs are provided with housing flexibility between rows to allow them to share a shear loading while leaving enough structural integrity in the housing to define the windows through which the dogs emerge. The dogs can also have extensions with a surface that grippingly engages the housing adjacent the window on extension of the dogs such that loads can transfer from the housing into the extension and into the profile in which the dog is disposed rather than passing the shear stress through the window edge into the dog that is in the profile. The dog configuration can also share the load on multiple contact surfaces of the housing to reduce stress at each contact location.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a run in configuration of a prior art lock mandrel tool;
FIG. 2 is the view of FIG. 1 during the extension of the dogs;
FIG. 3 is the view of FIG. 2 with the dogs fully extended;
FIG. 4 shows the multi-row version of the lock mandrel tool in the dogs extended position.
FIG. 5 is a view along lines 5 - 5 of FIG. 4
FIG. 6 shows the dogs having extensions that engage the housing on radial extension of the dogs to transfer stress from the housing to the extension and into a surrounding profile;
FIG. 7 is a view along lines 7 - 7 of FIG. 6 ;
FIG. 8 is a view of an alternative embodiment of a load distributing dog design;
FIG. 9 is a section view showing the dog of FIG. 8 in a nipple profile;
FIG. 10 is a top view of the dog of FIG. 8 extending through a matching pattern in the dog housing; and
FIG. 11 is an alternative view of the dog of FIG. 8 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 4 shows the tool 40 with a nose 42 and a flow port 44 to allow fluid movement through the tool 40 during run in. A housing 46 has an upper row of openings or windows 48 disposed circumferentially in a predetermined pattern and in a quantity that space will allow. FIG. 5 shows four dogs circumferentially spaced at 90 degrees but other even or uneven spacing or number of windows 48 and dogs 50 can be used. A second row of windows 52 each having a radially extendable dog 54 is illustrated below windows 48 and dogs 50 . More than two rows can be used and the windows 48 and 52 can be aligned or misaligned in the axial direction. The windows 48 and 52 and their corresponding dogs 50 and 54 can be identical in shape or volume or they can be different. A surrounding tubular 56 has profiles 58 and 60 to match the shape and size of the dogs 50 and 54 . The spacing of the rows of dogs or the shape of the dogs and their mating profiles can be unique so that of more than one tool is to be located in a given tubular 56 at different locations each location can have a unique profile location using profiles such as 58 or 60 .
The housing 46 also has seals 62 and 64 to align with a seal bore 66 that is just above the no-go 68 on the tubular 56 . When the housing 46 hits the no go 68 the seals 62 and 64 line up with the seal bore 66 while the dogs 50 and 54 line up with the profiles 58 and 60 . For initial run in the actuation sleeve 70 is supported by a running string that is not shown in FIG. 4 . FIG. 4 shows a plug 72 that is later delivered in a separate trip as will be later explained. With the housing 46 landed on the no-go 68 , setting down weight will first ramp out dogs 50 as they are engaged by taper 74 on the actuation sleeve 70 as a result of setting down weight on the running string that is not shown. The dogs 50 cam against the profile as they are extended picking the tool up off the no-go profile. Further setting down weight advances the taper 74 into contact with dogs 54 to radially extend them into their profile 60 . A snap ring 76 jumps into groove 78 in the housing 46 after all the dogs 50 and 54 are forced radially out to hold the position of sleeve 70 with respect to the housing 46 . Drill hole 80 allows attachment of the running tool, not shown, to the housing 46 via a shear wire, not shown. A port 44 allows for by-pass fluid to flow through the tool during run-in.
The objective of multiple rows is to reduce the stress on a given dog by having more dogs share the same loading. The issue when doing this in axially offset rows is that the machining tolerances of the windows 48 and 52 and the associated dogs 50 and 54 is such that advancing of the dogs 54 into profiles 60 can lift the dogs 50 in their profiles 58 because of the way the clearances play out to the point that dogs 50 carry no load or minimal load. This would defeat the purpose of the rows of dogs sharing the load. Accordingly, the present invention addresses this issue by providing axial flexibility between the rows of dogs. One way this is done is to take a section 83 between the rows of windows 48 and 52 and make it axially elastically flexible or/and elastically flexible in other planes or in torsion. What is illustrated is a series of circumferentially oriented elongated narrow openings that have opposed ends that are offset circumferentially from slots in an adjacent row. The rows can be equally or unequally spaced or the pattern can a spiral slot pattern as opposed to slots in a plane perpendicular to the longitudinal axis of the housing 46 . Rather than slots, scores can be used in conjunction with slots or by themselves. A series of identical or differing openings can be used.
Section 83 in whole or in part can be made from a shape memory alloy (SMA) such as Nitinol®. SMAs will tolerate stretch for a predetermined distance at low modulus so that the load can be shared by the rows of dogs 50 and 54 without a failure of the part and with the ability to revert to the original dimension when the dogs are retracted. The section 83 can be a solid annular shape and its inherent properties will give it a spring-like quality within the anticipated amount of stretch envisioned when the dogs are extended so that they can share the load between or among rows.
Another concern is that the no-go 68 can receive a large load and fail if differential pressure loading puts the taper on the tool 40 against the no-go 68 . One way to minimize or eliminate this risk is to use an SMA on the body in the region between the taper that is designed to initially land on the no-go 68 for extending the dogs 50 and 54 . The run in dimension will properly position the dogs 50 and 54 to enter recesses 58 and 60 . However after setting the tool 40 well fluids or another heat source can make that lower end of the tool 40 get shorter as it reverts to that length when the transition temperature for the SMA is crossed. This feature can be used regardless of whether there is a single row or multiple rows in the tool of FIG. 4 or FIG. 6 .
Regardless of the approach the goal is to increase flexibility of the housing 46 between the rows of windows such as 48 and 52 so that radially extending one row of dogs will not cause the other row or rows of dogs to not take their share of the load. As previously explained this can happen when the spacing of the dogs 50 and 54 is axially off the spacing of the profiles 58 and 60 due to the various tolerances in the assembled tool 40 . By providing the flexibility in the alignment process the result of sharing the load among multiple rows of dogs is achieved and each dog can then be designed for a smaller loading without reduction of the overall ability of the tool 40 to resist the targeted load.
The plug 72 with its seals 82 and 84 lands in the nose 42 on a separate trip. It has passages 85 to allow fluid flow during run in. Its upper end 86 is secured to the sleeve 70 by rotation or another way.
FIGS. 6 and 7 show a single row of openings 100 through which a dog assembly 102 extends. Rather than having an internal flange to prevent overextension from housing 46 as is the case with the dogs 50 and 54 , the dog assembly 102 in each window or at least some windows has an extension 104 that has a surface gripping profile 106 that matches a similar profile 108 on the housing 110 . When the dog assemblies are pushed out radially in the same manner as in FIG. 5 , the radial movement brings profiles 106 and 108 into an interlocking relationship when a shear load is applied due to differential pressure acting on seals when the housing 110 is no longer supported on a no-go of a surrounding tubular that is not shown for clarity in FIG. 6 but is the same as illustrated in FIG. 4 . For example when there is a net pressure differential from above the dog assemblies 102 the result is a tensile force on the housing between the dogs 102 and the seals 112 and 114 . Was it not for the engagement of the gripping profiles 106 and 108 , which could be a series of ridges parallel to each other or a spiral thread form to name a few options, the stress can be communicated to the portions of the housing between the windows 100 . This phenomenon was discussed earlier with regard to the FIGS. 1-3 embodiment with regard to segments 30 that have to be designed to take stress from differential pressure stresses. As previously explained this limited the size of the dogs 18 as there had to be enough body material left to take the stress communicated through it with the dogs 18 extending into their respective profiles.
However, in the FIG. 6 design the extensions 104 transfer the stress from a location on the housing 110 where there are no windows and through the dogs 102 and into the surrounding profile that is not shown in FIG. 6 . Thus, the portion of the housing 110 that is between the windows 100 , best seen as 116 in FIG. 7 , is minimally stressed. This allows for windows 100 and their respective dogs 102 to be made larger for a greater capacity for stress while still reducing the extent of the wall areas at 116 as compared to the design of FIGS. 1-3 where the portions 30 are more severely stressed.
While FIG. 7 shows a single row, multiple rows as shown in FIG. 4 can be used with the feature of the extensions 104 also shown in FIG. 7 . The flexible segment 82 would be located between rows as shown in FIG. 4 . Combining the features allows the use of larger dogs and smaller spaces between windows in a given row with the feature of load sharing that is achieved from using multiple rows without the concern that one row will not adequately share the loading with dogs in another row.
In another embodiment, shown in FIGS. 8-10 the dogs 220 extend into a nipple profile 290 . Dogs 220 extend through a dog housing 200 and are driven out radially into the profile 290 by a ramped sleeve 210 . The dogs 220 extend through a similarly shaped opening 230 in the dog housing 200 as seen in FIG. 10 . As shown in FIG. 8 there are multiple generally parallel rows 204 , 206 and 208 that are spaced apart using connecting segments 212 connecting 204 and 206 and 214 connecting 206 and 208 . The end contact surfaces 310 and 300 are tapered to the angle of end surfaces 216 and 218 in the profile 290 . Row 206 does not contact the profile 290 and has opposed parallel sides 222 and 224 . Segments 204 and 208 have interior surfaces 226 and 228 respectively. Surface 226 is substantially parallel to surface 222 and surface 228 is substantially parallel to surface 224 . Surface 232 on dogs 220 faces surface 240 on the opening 230 in housing 200 . On the other end of the dogs 220 , surface 234 faces surface 236 of opening 230 in housing 200 .
The shape of the opening 230 is shown in more detail in FIG. 10 . In the position shown there is differential loading on the housing 200 with the dogs 220 extended into the profile 290 . As a result there are three loading surfaces on the housing 200 that are loaded by each dog 220 and those surfaces are 240 , 250 and 252 . Those surfaces are stressed by the following surfaces, respectively on each dog 220 , when there is differential loading in the downhole direction on the housing 200 as represented by arrow 243 : 232 , 222 and 228 . The dogs 220 are loaded in compression. Tension loading can result in necking that can lead to dog failure and possible loss of well control if the dogs 220 were retaining a well plug for example.
Note that the segments 204 , 206 and 208 progressively reduce in length from 204 to 208 . The sections 286 , 284 and 282 of the housing 200 between the openings 230 correspondingly increase in width. Load 243 is applied to the housing below the dogs 220 at seal 292 so the full load is transmitted in tension through section 282 and all other sections between 282 and the seals 292 . A portion of the load is transmitted through surface 252 into the dog 220 , thus the amount of load that goes through housing section 284 is the remainder of the portion transmitted through surface 252 and total load 243 . Likewise a portion of the load is transmitted to the dog 220 through surfaces 240 and 250 and thus housing section 286 carries the least load out of sections 282 , 284 and 286 . This apportions the load so the strongest of housing sections 282 , 284 and 286 takes the most load. It should be noted that surface 232 has two disparate segments 235 and 237 separated by the recess 239 with the purpose being to bring the stressed areas on the dog closer to equivalence so as to more equally distribute stress among the three loaded surfaces 240 , 250 and 252 .
Load 243 transmitted to the dog 220 from the housing 200 occurs at surfaces 232 , 222 , and 228 and each portion is transmitted through the length of the dog between said surfaces and surface 300 where the load is transmitted to profile 290 . Thus the portions of the dog 220 closer to surface 300 carry more load.
When the differential loading is in the uphole direction opposite arrow 202 , surfaces 260 , 270 and 280 are loaded by surfaces 233 , 241 and 236 . Section 282 and all other sections between section 282 and the seal 292 again transmit the load but in this case it is a compressive load.
The spacing of the loading surfaces 240 , 250 and 252 can be even or uneven and the same is true for the load surfaces 232 , 222 and 228 on the dogs 220 . While three locations of load distribution are shown for each dog extending through a respective opening, other numbers of load distributing surface pairs can be employed within the scope of the invention.
Those skilled in the art will appreciate that multiple rows or other orientations of dogs can be provided and the issue of cumulative tolerances causing the insertion of one dog into its profile to move another dog out of a load carrying placement in its profile will be addressed with a flexibility feature in the housing among axially spaced dogs. The housing flexibility can be provided by selective weakening of the housing with slots or scores of a variety of shapes and regular or random patterns. Alternatively the material itself can change properties to provide the flexibility when extending the dogs in response to a stimulus such as well fluids, heat, pressure or various applied fields, to mention a few flexibility providing features. The housing material itself between the rows of dogs can be flexible as long as it can tolerate the stress imposed on dog extension and subsequent pressure differential loading when latched.
The above description is illustrative of the preferred embodiment and many modifications may be made by those skilled in the art without departing from the invention whose scope is to be determined from the literal and equivalent scope of the claims below: | A plurality of rows of locking dogs are provided with housing flexibility between rows to allow them to share a shear loading while leaving enough structural integrity in the housing to define the windows through which the dogs emerge. The dogs can also have extensions with a surface that grippingly engages the housing adjacent the window on extension of the dogs such that loads can transfer from the housing into the extension and into the profile in which the dog is disposed rather than passing the shear stress through the window edge into the dog that is in the profile. The dog configuration can also share the load on multiple contact surfaces of the housing to reduce stress at each contact location. | 4 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation in part of U.S. patent application Ser. No. 07/741,257 filed Aug. 5, 1991 now U.S. Pat. No. 5,213,573 and entitled "IV Administration Set Infiltration Monitor".
FIELD OF THE INVENTION
The present invention relates generally to intravenous (IV) infusion of medical solutions. More particularly, the present invention relates to methods and apparatus for monitoring the proper operation of an IV infusion procedure. The present invention is particularly, though not exclusively, useful for determining if a medical solution is being infiltrated into the tissue surrounding a venous access site rather than being infused into a patient's blood vessel.
BACKGROUND OF THE INVENTION
Intravenous (IV) infusion therapy is a widespread medical technique in which fluid nutrients or fluid medicaments are infused into the bloodstream of a patient through an IV tube as part of a medical procedure for treatment of the patient. More specifically, an IV administration system for IV infusion includes a fluid source, an IV tube and a venipuncture device inserted through the skin into one of the patient's blood vessels at a venous access site. This establishes a flow path from the fluid source to the blood vessel. The fluid nutrients or medicaments may be pumped from the fluid source through the IV tube or drained by gravity through the IV tube into the patient's bloodstream.
While infusion therapy has proven effective in treating a wide range of maladies, it is not without potential complications. One complication, which is of particular concern, is infiltration of the fluid from the IV set into the patient's tissue. More particularly, it sometimes happens that the medical technician who inserts the needle of the IV tube into the patient may fail to properly insert the needle into a blood vessel and instead the needle is inserted into the tissue which surrounds the blood vessel. This results in the infiltration of the IV fluid into the patient's tissue, rather than passage into the blood vessel.
Infiltration of IV fluid into a patient's tissue can also occur during the course of fluid infusion to a patient even though the IV set was originally established for proper operation. For example, patient motion may cause a needle which was originally properly inserted into a blood vessel to become separated from the vessel or lodge against the wall of the vessel or another obstruction. Moreover, the infusion needle may become clotted or an occlusion may occur in the IV tube upstream of the needle. The following disclosure and claims will be generally couched in terms of an infiltration condition, but the term "infiltration" will be understood to include such conditions as clogging of the needle or occlusion of the tube.
It is unfortunately the case that in many circumstances, infiltration of IV liquids into a patient's tissue can go unnoticed by hospital personnel for relatively lengthy periods. This is because it is not feasible for medical establishments to routinely provide personnel who can continuously monitor each and every IV infusion procedure that the medical establishment undertakes. Such infiltration monitoring procedures are relatively labor intensive and generally require a manual test wherein a venous access device such as a hypodermic syringe needle is placed in fluid communication with the venous access site and a return flow of blood from the vein to the IV tube is initiated.
Such manual techniques are difficult to perform and consequently may be unreliable. As an example, for conducting an infiltration test using a hypodermic syringe, the syringe must first be placed in fluid communication with the IV tube. The tube is then manually pinched while the plunger of the syringe is simultaneously retracted to initiate the return flow of fluid. The absence of blood in the return flow is an indication of infiltration.
This procedure requires a good deal of manual dexterity and experience on the part of the clinician. In addition, due to different syringe sizes and different techniques used for performing an infiltration test, results of the tests may vary. Moreover, relatively high pressures can be generated by the syringe, and these pressures may subject the weakened blood vessel walls to damage and the patient to trauma.
Further, it may often be necessary to infuse a supplemental medicament into the patient during infusion therapy. As an example, the primary infusion may be for maintenance of nutrients, while the supplemental fluid may be an antibiotic, sedative, or a medicament administered in conjunction with chemotherapy. Typically, such a supplemental medicament is administered using the same IV administration set but with a separate hypodermic needle which is connected in flow communication with the IV tube. Using the syringe, the physician or other clinician can infuse a supplemental medicant from the syringe into the patient.
With such a supplemental infusion, as with any other IV administration, it is necessary to monitor for infiltration to ascertain whether the venous access site is patent both before and during the IV infusion of the supplemental medicament. In the past, infiltration has been detected manually by the clinician during the supplemental infusion. Typically this is accomplished by manually pinching or occluding an upstream end of the IV tube and then manipulating the syringe to initiate a return flow of blood from the patient into the IV tube. Often times this procedure must be performed several times during the infusion of the supplemental medicament. Such a procedure, in addition to being difficult to perform, may subject the venous access site to excessive pressures and fluid flow rates. Such high pressures and fluid flow rates may damage the walls of the blood vessel which may be weakened by the venipuncture device.
It is thus desirable to be able to automatically monitor IV infusion procedures to ensure the liquid is being infused into the patient's bloodstream and not into the patient's tissue. Automatic systems for monitoring an infusion procedure for infiltration are known in the art. One such prior art system for automatically detecting infiltration during intravenous infusion is disclosed in U.S. Pat. No. 4,816,019 to Kamen. With this system, a valve is used to close off the IV tube. A piston in fluid communication with the contents of the IV tube is then moved to cause a negative pressure step in the IV tube. If the infusion needle is properly situated in the vein, a quantity of fluid will be drawn into the IV tube and the pressure in the IV tube will return to the pressure prior to the negative pressure step. In an infiltration condition however, the pressure in the IV tube will not return to the pre-step pressure in the same time period. By monitoring the pressure in the IV tube during this procedure an infiltration condition can be detected.
Other infiltration detection systems are also known in the art. Although such automatic infiltration systems may function effectively, there is still some room for improvement in the art. In particular, most of these systems are relatively complicated to operate and may not be portable or easily transported. Others may induce relatively high pressures and flow rates of the medical solution being infused. As previously stated, such high pressures and flow rates may damage the blood vessel and cause patient discomfort. Moreover, the medical solution being infused may be subjected to direct contact and contamination or subjected to excessive agitation by the infiltration detection apparatus. In addition, none of the prior art systems permits an infiltration detection apparatus to be controlled in conjunction with the infusion of a supplemental medical solution into the patient from a secondary source of fluids, such as a syringe.
The present invention is directed to an infiltration detection system which uses relatively low pressures and fluid volumes and in which there is no direct contact with the infusion solution. Additionally, the infiltration detection system of the invention is relatively simple to operate and is reliable and portable. Further, the infiltration detection system of the present invention can be selectively controlled while a hypodermic syringe is used to administer a supplemental medicament. This is accomplished using an infiltration detection apparatus connected to the IV tube of the administration set and a novel pressure sensitive thumb switch which is worn by the clinician to control the infiltration detection apparatus.
Accordingly, it is an object of the present invention to provide a method and apparatus for automatically detecting infiltration during an infusion therapy procedure. Another object of the present invention is to provide a method and apparatus for infiltration detection which requires low fluid pressures and low volumes, and which operates without contacting or substantially agitating the medical solution being infused. It is another object of the present invention to provide a method and apparatus for automatically detecting infiltration during an IV infusion therapy procedure in conjunction with infusion of a supplemental medicament from a hypodermic syringe. It is a further object of the present invention to provide an infiltration detection apparatus having a novel pressure sensitive thumb switch that can be operated in conjunction with a hypodermic syringe coupled to an IV administration set to control the infiltration detection procedure during the infusion of a supplemental medicament. It is yet another object of the present invention to provide an apparatus for infiltration detection that is portable and reliable. Finally it is an object of the present invention to provide a method for infiltration detection that is easy to use and an apparatus that is cost effective to manufacture.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method and apparatus for determining whether a medical solution being intravenously administered has infiltrated into the tissue of a patient are provided. The method includes the steps of occluding the IV tube upstream from a venous access site and initiating a pressure drop within the IV tube, by modifying external contact with the IV tube. In order to ascertain if there is infiltration, the pressure within the IV tube, and a time for the pressure to return to a base testing pressure after the pressure drop, are simultaneously monitored. A time interval between the pressure drop and the return of fluid pressure to the testing base pressure is termed herein as a recovery interval. A recovery interval greater than a predetermined time interval is an indication of an infiltration condition. In accordance with the present invention, a method and apparatus are also provided for administering a supplemental fluid to a patient during IV infusion of a primary fluid, while detecting for an infiltration condition.
The infiltration detecting apparatus is adapted to removably engage a length of IV tube. The IV tube is coupled at one end to a supply of a medical solution to be infused and at an opposite end to a venipuncture device at a venous access site. The venipuncture device may be an infusion needle or a sharpened cannula tip. The infiltration detection apparatus is portable and self contained and includes an internal power supply and a keypad for imputing operational instructions. The infiltration detection apparatus also includes visual displays for displaying equipment condition and site status information, an audible alarm to indicate site status and equipment condition, and a microprocessor and associated circuitry.
The infiltration detection apparatus includes an occluder finger coupled to a stepper motor for occluding the IV tube upstream from the venous access site. A fluid moving finger downstream from the occluder finger is coupled to another stepper motor. The fluid moving finger initially partially occludes the IV tube. For generating a pressure drop, the fluid moving finger is partially withdrawn from the IV tube. This movement allows the IV tube to expand, which drops the pressure in the tube and eventually withdraws a quantity of fluid from the patient. The infiltration detection apparatus also includes a pressure sensitive thumb switch for interrupting the infiltration detection procedure when the switch is pressed, followed by initiation of an infiltration detection check by the apparatus when the thumb switch is released. The thumb switch fits over the clinician's thumb and is sandwiched between the clinician's thumb and the plunger of the hypodermic syringe during the supplemental infusion procedure. The thumb switch is electrically coupled by a cable to the control circuit for the infiltration detection apparatus. Thumb pressure exerted by the clinician on the thumb switch during the supplemental infusion closes the thumb switch and temporarily deactivates the infiltration detection procedure. The thumb switch may then be used to reinitiate an infiltration test on demand by lifting the thumb switch off the syringe plunger.
With this arrangement the clinician may infuse a small quantity of the supplemental fluid into the patient and then immediately test for infiltration by lifting the thumb away from the syringe plunger to release pressure on the thumb switch. This initiates an infiltration detection test. The hypodermic syringe can then be manipulated to infuse another quantity of the supplemental fluid, followed by another infiltration test until the contents of the syringe are completely discharged as desired.
During a test sequence, the fluid pressure during a pressure drop and a subsequent pressure recovery interval are measured using a pressure transducer in contact with the exterior of the IV tube. Using the microprocessor, the fluid pressures and times during the pressure drop and the subsequent recovery interval are monitored during a selected number of test steps, for example, ten steps. This data is used to evaluate the patency of the IV tube at the venous access site and to ascertain the occurrence of an infiltration condition.
Initially, a positive pressure exists in the IV tube by virtue of the operating pressure of the IV administration set, and the fluid moving finger is set to partially occlude the IV tube. A test sequence begins by moving the occluder finger to completely occlude the IV tube. The fluid pressure in the IV tube downstream of the occluder finger is then allowed to stabilize. A pressure of 0.5 psig below the stabilized pressure is then calculated. The fluid moving finger is then partially withdrawn to achieve a testing base pressure within the IV tube that is about 0.5 psig below the stabilized pressure.
Once the testing base pressure is reached, the fluid moving finger is additionally withdrawn incrementally, allowing the IV tube to expand, creating a pressure drop from the testing base pressure, for withdrawing fluid. Fluid is then withdrawn from the patient because of this pressure drop, and the pressure in the IV tube returns to the testing base pressure during this recovery interval. The pressure drop is generated by the natural resiliency of the IV tube, which causes it to expand. Pressure recovery is caused by flow of fluid into the tube from the patient. Following this pressure drop and recovery to testing base pressure, this test cycle is repeated through a selected number of test steps, for example, ten steps. Each step of the test sequence, as well as the stabilizing and testing base pressure steps of the test, are timed. Test sequences can be automatically repeated at selected frequencies, for example, one sequence every 5 minutes.
The microprocessor determines whether infiltration has occurred by evaluating the pressure in the IV tube as a function of time during the pressure drop and subsequent recovery interval, as well as the time elapsed over a complete test sequence. For instance, if there is no infiltration, the time for a pressure drop interval and the time for a subsequent recovery interval during a single test step will both be comparatively short, and the time for completion of a test sequence of a given number of steps will be within a predetermined limit. If there is infiltration, on the other hand, the time for a recovery interval will be substantially greater than the time for a pressure drop interval. In general, this is because a fluid can not be as easily withdrawn from infiltrated tissue as from a blood vessel. An obstruction in the needle at the venous access site or a downstream occlusion in the IV tube will provide the same result and may prevent the pressure in the IV tube from returning to the testing base pressure after a pressure drop. Additionally, if the pressure in the IV tube does not stabilize within a predetermined time period after initial occlusion of the IV tube, or if a predetermined testing base pressure is not reached within a predetermined number of motor steps or before a predetermined volume of fluid is withdrawn, then a system malfunction may exist.
The method of the invention may also be used during the infusion of fluids by using an IV administration set for infusion of a primary fluid, and using a hypodermic syringe connected to the IV administration set for infusion of supplemental fluid.
This method, generally stated, includes the steps of connecting a hypodermic syringe in fluid communication with an IV tube of an existing IV administration set, interrupting the infiltration detection procedure while infusing a quantity of a supplemental fluid from the hypodermic syringe into the IV tube, immediately thereafter testing for infiltration, and then infusing another quantity of the supplemental fluid from the syringe until the syringe is emptied as desired, followed by returning to the automatic repetition of infiltration detection test sequences.
Under normal operation, the apparatus will be programmed to automatically repeat the test sequence after a selected time lapse, for example, 5 minutes. This will continue until stopped, either by the operator, equipment malfunction, or the occurrence of an alarm condition where appropriate. If a given automatically initiated test sequence senses an alarm condition, the test frequency can be programmed to automatically increase, for example, to one sequence every minute. The first occurrence of an alarm condition during automatic testing might give one type of alarm indication, while repeated alarm conditions sensed at the increased testing frequency might give a second, more urgent type of alarm indication. Further, it is optional to provide for the performance of a test sequence on demand at the device or by use of the syringe thumb switch. If such a test on demand results in an alarm condition, it might be desirable to program the apparatus to give the more urgent type of alarm indication.
The results of the test can be displayed visually or audibly. As an example, a green light may be used to indicate patency at the venous access site, a yellow light may be used to indicate the first occurrence of an infiltration or obstruction condition which may be transitory, and a red light may be used to indicate that a selected number of consecutive test sequences have resulted in alarm conditions, indicating a sustained infiltration or obstruction condition. A red light may also be used to indicate an alarm result given by a test on demand. Audible signals may also be used to notify the operator of different levels of urgency in the alarm conditions.
The novel features of this invention, as well as the invention itself, both as to its structure and its 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:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an IV infiltration detection apparatus constructed in accordance with the invention and seen in its intended environment;
FIG. 2 is an exploded perspective view showing the assembly of the IV infiltration detection apparatus shown in FIG. 1;
FIG. 3 is a flow diagram of the steps involved in performing an infiltration test in accordance with the method of the invention;
FIG. 4 is a continuation of the flow diagram shown in FIG. 3;
FIG. 5 is a schematic diagram showing pressure as a function of time during an infiltration test conducted in accordance with the invention and in which a venous access site of the IV tube is patent;
FIG. 6 is a schematic diagram showing pressure as a function of time during an infiltration test conducted in accordance with the invention and in which an IV line is in a condition of infiltration; and
FIG. 7 is a perspective view of an infiltration detection device constructed in accordance with the invention shown in use during the infusion of a supplemental medicament.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to FIG. 1 an infiltration detection apparatus constructed in accordance with the invention is shown and generally designated as 10. The infiltration detection apparatus 10 is shown in use in an infusion system 14 for infusing a medical solution into a patient 16. The infusion system 14 includes an IV stand 18 on which is mounted a supply reservoir 20 of the primary medical solution. Also shown is optional pressure sensitive thumb switch 12.
An IV line in the form of a resilient IV tube 22 is connected at a distal end in fluid communication with the supply reservoir 20. The IV tube 22 is connected at a proximal end to a venipuncture device 24, such as a hollow needle or sharpened cannula, that is inserted into a vein of the patient 16 at a venous access site 25 in fluid communication with the vein. A pumping device 27, such as a peristaltic pump, is also mounted to the IV stand 18 for positively moving the medical solution through the infusion system 14. By way of example, such a pump may be a peristaltic pump of the type marketed by IMED Corporation under the trade names "PC-1" and "PC-2". Alternately any other suitable mechanism may be used for generating pressure in the IV tube 22 or the medical solution may flow by gravity from the supply reservoir 20 and through the IV tube 22 to the patient.
As shown in FIGS. 1 and 7, if infusion of a supplemental fluid is desired, a syringe 104 can be inserted into injection site 102 of y-section 100. Thumb switch 12 is placed between the operator's thumb and plunger 164. Switch 12 is electrically connected to infiltration detection apparatus 10 by cable 162.
The infiltration detection apparatus 10 is portable and self contained and is adapted to be placed on a support surface such as a work table (not shown) that is located in close proximity to the patient 16. The infiltration detection apparatus 10 includes a housing 26 formed as a generally rectangular shaped hollow enclosed structure. Most of the individual components of the infiltration detection apparatus 10 including a battery pack 46 (FIG. 2) and a microprocessor 36 (FIG. 2) are mounted within the housing 26.
Externally, the housing 26 includes an IV tube receiving portion 28, with a hinged door 30 formed on a side portion thereof, for receiving a test section 29 of the IV tube 22. In addition, externally, the housing 26 includes a keypad portion 34 having a plurality of keys 32 for imputing instructions into the microprocessor 36 (FIG. 2) of the infiltration detection apparatus 10.
Additionally, the external surface of the housing 26 includes a site status display portion 38 on which a plurality of visual displays are mounted. In an illustrative embodiment the visual displays include a green light 40, a yellow light 42 and a red light 44. The green light 40 indicates an unobstructed venous access site 25. The yellow light 42 indicates an obstruction or infiltration result from a single test sequence during automatic testing. The red light 44 indicates an obstruction or infiltration result from a test sequence performed on demand or from a selected number of consecutive automated sequences. Equipment condition display portion 39 includes a plurality of visual display lights 45, which can indicate equipment conditions such as test in progress, thumb switch activated, pause in test procedure, low battery, or help needed.
Referring now to FIG. 2, the assembly of the infiltration detection apparatus 10 is shown in an exploded view. The housing 26 includes an upper portion 48 and a mating nestable lower portion 50. The housing 26 may be constructed of a sturdy cleanable material such as molded plastic. The upper portion 48 of the housing 26 is removably attached to the lower portion 50 of the housing 26 using suitable fasteners (not shown). This construction allows access to and assembly of the individual components of the infiltration detection apparatus 10 within the housing 26.
A main plate member 60 is mounted within the housing 26 for mounting various components of the infiltration detection apparatus 10 located within the housing 26. The main plate member 60 is shaped substantially as shown in FIG. 2 and contains various openings for the different components of the infiltration detection apparatus 10.
The infiltration detection apparatus includes an occluder finger 52 and a fluid moving finger 54 mounted within the housing 26, extending through the main plate member 60. The occluder finger 52 is mounted for reciprocal movement by a stepper motor 58 which is controlled by the microprocessor 36. The occluder finger 52 is adapted to contact the outside of the test section 29 of the IV tube 22 held within the IV tube receiving portion 28 of the housing 26 to pinch close or occlude the IV tube 22.
The occluder finger 52 has a relatively narrow tip portion 56 for contacting the IV tube 22. The occluder stepper motor 58 moves the occluder finger 52 in a forward or reverse direction as required with respect to the IV tube 22. The main plate member 60 of the housing 26 includes an elongated opening 64 for the tip portion 56 of the occluder finger 52.
For occluding the IV tube 22, the occluder finger 52 is moved forward by the occluder stepper motor 58 such that a portion of the test section 29 (FIG. 1) of the IV tube 22 is pinched closed. As shown in FIG. 1 the housing door 30 is formed with a flat platen portion 66 for supporting the test section 29 of IV tubing 22 for pinching by the occluder finger 52.
The fluid moving finger 54 is mounted for reciprocal movement by a stepper motor 70 controlled by the microprocessor 36. The fluid moving finger 54 is adapted to extend through opening 72 in main plate 60 to contact the outside of the test section 29 of the IV tube 22 to vary the fluid pressure within the IV tube 22. Specifically, face 68 of the fluid moving finger 54 is initially positioned to partially occlude the test section 29 of the IV tube 22 at the time the IV tube is loaded into the infiltration detection apparatus 10. Incrementally withdrawing the fluid moving finger 54 away from the IV tube 22 will allow the IV tube 22 to expand as a result of its natural resiliency, creating a pressure drop within the IV tube 22. A pressure transducer 62 is mounted to extend through opening 73 of the main plate member 60 of the housing 26 for contacting the outside wall of the IV tube 22 to measure the pressure within the IV tube 22.
The components involved can be structured and operated to move quantities of fluid on the order of one (1) microliter or less. The pressure transducer 62 is adapted to detect the pressure within the IV tube 22. The pressure transducer 62 is of a type that does not require an entry site into the IV tube 22 in order to measure the fluid pressure inside the IV tube 22. In a preferred embodiment, the pressure transducer 62 may incorporate a pressure sensing strain beam (not shown). Such a transducer 62 also incorporates a strain gauge (not shown) which may be piezoelectric, that is mounted on the strain beam. The strain beam is connected to a pressure sensing arm that contacts the outside wall of the IV tube 22. Force exerted on the pressure sensing arm, caused by changes of fluid pressure within the IV tube 22 can be detected by the strain gauge to generate an electrical signal representative of the fluid pressure. This signal is sent to the microprocessor 36. Such an arrangement is more fully described in the parent application, Ser. No. 07/741,257, filed Aug. 5, 1991, which is incorporated herein by reference.
Still referring to FIG. 2, further details of the construction of the infiltration detection apparatus 10 will be described. The door 30 for the IV tube receiving portion 28 is hingedly mounted to the lower portion 50 of the housing 26. A latch mechanism 74 is attached to the door 30 for latching the door 30 in a closed position. The latch mechanism is biased by a spring member 75.
Referring now to. FIG. 1, the door 30 includes the platen portion 66 and molded cavities 76, 78 on either end for retaining fitments 82, 86 that are attached to either side of the test section 29 of the IV tube 22. The IV tube retaining portion 28 also includes clips 84 removably attached to the main plate member 60 for initially loading and holding the test section 29 of the IV tube 22. The test section 29 can thus be loaded into the IV tube retaining portion 28 of the housing 26 and retained by the clips 84. The IV tube retaining portion 28 is sized such that with the door 30 closed the test section 29 is initially partially occluded by contact with the contact face 68 of the fluid moving finger 54. In addition, the test section 29 of the IV tube 22 is in contact with the pressure transducer 62.
Referring again to FIG. 2, the infiltration detection apparatus 10 can also include a seal member 88, not shown in FIG. 1 for the sake of clarity, sized and shaped to cover main plate member 60 of the housing 26. The seal member 88 may be formed of a thin flexible material such as polyurethane that seals the openings 64, 72, 73 in the main plate member 60 yet allows the occluder finger 52, the pressure transducer 62, and the fluid moving finger 54 to interact with the test section 29 of the IV tube 22. A bezel 90 attaches the seal 88 to the main plate member 60 of the housing 26.
The infiltration detection apparatus 10 also includes an electrical control circuit for controlling the operation of the infiltration detection apparatus under direction of the microprocessor 36. A circuit board 92 is mounted within the housing 26 for mounting various electrical components of the electrical control circuit including the microprocessor 36. Specifically, the control circuit operatively connects the microprocessor 36 with the stepper motors 58, 70 for operating the occluder finger 52 and fluid moving finger 54, respectively. In addition, the control circuit operatively connects the microprocessor 36 with the pressure transducer 62, the keypads 32 (FIG. 1), and the visual display lights 40, 42, 44, 45 (FIG. 1). The control circuit also includes the electrical components for electrically connecting the battery pack 46. Moreover, the control circuit includes an audible alarm 94. The electrical control circuit also includes a thumb switch jack 96 that can be used to attach the thumb switch 12 to the infiltration detection apparatus 10 via cable 162. The thumb switch 12 functions to deactivate the testing procedure upon application of thumb pressure to the syringe plunger during infusion of a supplemental fluid medicament into the IV tube 22 using a hypodermic syringe, and to immediately initiate a test sequence upon release of thumb pressure.
OPERATION
With reference to FIGS. 3 and 4, the infiltration detection apparatus 10 is adapted to perform an infiltration test that includes the following sequence of steps.
1. To start the test sequence the occluder finger 52 is moved forward to occlude the IV tube 22, step 110.
2. During the test, the pressure in the IV tube 22 is monitored, by the pressure transducer 62 and microprocessor 36, step 112. While IV tube 22 is occluded, the pressure in the IV tube 22 is allowed to stabilize. This sequence is timed. If the pressure does not stabilize, decision step 118, within a predetermined time period, decision step 114, this is indicative of a system malfunction. Accordingly, the test is stopped and an alarm is initiated, step 116.
3. If the pressure stabilizes, decision step 118, the microprocessor 36 calculates a testing base pressure that is 0.5 psi below the stabilized pressure, step 120.
4. The fluid moving finger 54 is then partially withdrawn to drop the pressure in the IV tube 22 to the testing base pressure, step 122. If this testing base pressure cannot be reached, decision step 128, within a predetermined number of motor steps or volume of fluid withdrawn, decision step 124, this is indicative of a system malfunction. Accordingly the test is stopped and an alarm is initiated, step 126.
5. If the testing base pressure is reached, step 128, an incremental test sequence is initiated. This test sequence is shown in FIG. 4. Simply stated, this incremental test sequence comprises additional incremental withdrawals of the fluid moving finger 54 to expand the IV tube 22 to initiate a series of pressure drops and withdraw fluid. The time it takes the pressure to return to the testing base pressure, or the recovery interval, is monitored by the pressure transducer 62, and the sequence includes a selected number of steps, such as 10. If the pressure does not return to the testing base pressure within a predetermined time period for a given interval, or if a given test sequence of 10 steps takes longer than a predetermined time period, then an infiltration condition may exist. Some applications, such as neonatal care, will require a modification in the analysis of the test sequence, in order to determine whether an alarm condition truly exists. This is because in such applications, the time for pressure recovery will be extended because of the small size of the cannula, even if patency exists at the venous access site. Therefore, if a given test sequence time limit is exceeded, the microprocessor can be programmed to determine whether at least a selected reduced number of intervals, such as 4, were completed during the sequence, and whether all of the test intervals performed before expiration of the time limit were substantially equal. If both of these conditions are met, the microprocessor can be programmed to indicate patency at the venous access site.
6. During the incremental testing procedure, pressure and time are continuously monitored, step 130 as seen in FIG. 4. If the pressure does not rise during a recovery interval to a level at or above the testing base pressure, decision step 132, within a predetermined recovery interval time limit, decision step 134, then a red or yellow site status light is displayed, step 137, and if appropriate an audible alarm is sounded, step 138. If the pressure does rise during a recovery interval to the testing base pressure, decision step 132, but a predetermined test sequence time limit, for example, 2 seconds, has been exceeded, decision step 136, then appropriate visible and audible displays are initiated as described above. The predetermined recovery interval time limit and the predetermined test sequence time limit can be the same, or they can be different. If an infiltration condition is sensed during a test sequence initiated on demand by the operator, this will result in display of a red light 44 and sounding of a first type of audible alarm, such as 2 beeps. If an infiltration condition is sensed during an automatically initiated test sequence, this will result in display of a yellow light 42 and sounding of 2 beeps as above, accompanied by an automatic increase in the test sequence frequency, such as from one every 5 minutes to one every minute. If a selected number, such as 5, of these more frequent automatic sequences result in infiltration indications, this will result in display of a red light 44 and sounding of a second type of audible alarm, such as continuous beeping.
7. If the pressure does rise to the testing base pressure during a recovery interval, decision step 132, and the test sequence time limit has not been exceeded, decision step 136, and ten test steps have been taken, decision step 140, the infiltration apparatus is returned to a non test status. A green site status is displayed, step 142, and the next test is awaited, step 144. Prior to the next testing sequence the fluid moving finger 54 is advanced forward to its original position.
8. If ten test steps have not been taken as determined in decision step 140, then one additional incremental withdrawal of the fluid moving finger 54 is made, step 146, and step 130 is repeated.
Referring now to FIGS. 5 and 6, this testing sequence is shown schematically in a pressure vs. time format. FIG. 5 represents a test sequence in which no infiltration or occlusion condition is detected. FIG. 6 represents a test sequence in which infiltration or an occlusion is detected. With reference to FIG. 5, at time T1 the IV tube 22 is occluded by the occluder finger 52. The pressure in the IV tube 22 drops to a stable pressure 148 at time T2. The microprocessor 36 then calculates a testing pressure that is 0.5 psi below the stable pressure 148. At time T3, the fluid moving finger 54 is partially withdrawn from the IV tube to lower the pressure to the testing base pressure 150. Ten test steps, each comprising a pressure drop followed by a pressure rise or pressure recovery interval, are then taken (steps 1-10). Each pressure drop is initiated by partially withdrawing the fluid moving finger 54 and allowing the IV tube to expand. This drops the pressure in the IV tube 22 by a predetermined amount. The pressure is then allowed to rise back or return to the testing base pressure 150 by the flow of fluid out of the patient and into the IV tube. Once the testing base pressure 150 is reached or exceeded, the negative pressure step is repeated. This incremental pressure step is repeated a total of ten times, or until a predetermined time limit is reached.
During each test step, the pressure drops almost instantaneously once the fluid moving finger 54 is withdrawn. This is represented by the vertical portion 152 of the pressure curve during a test step (i.e step 1). The pressure then rises back to the testing pressure 150 in almost the same time increment as indicated by the sloping portion 154 of the test step. This is because with the IV tube 22 patent at the venous access site, the small quantity of fluid required to restore pressure in the IV tube will flow into the tube very quickly from the blood vessel, and the pressure will return to the testing base pressure 150.
Compare the normal situation shown in FIG. 5 to an abnormal or infiltration condition as noted in FIG. 6. With an infiltration or occlusion condition, the quantity of fluid necessary to restore pressure will not flow out of the patient in as short a period of time as with a patent venous access site. In other words, the infiltration, clot, occlusion, or other obstruction will prevent the subsequent return to the testing base pressure from occurring as quickly. The sloping pressure rise portion 154' of each test step will thus continue over a much larger time increment. If a test sequence time limit, such as 2 seconds, or a recovery interval time limit is reached, then an occlusion or infiltration condition has been demonstrated.
Thus the invention provides a method and apparatus for continuously and automatically testing for infiltration during an IV infusion procedure. While the particular Method and Apparatus for Infiltration Detection During IV Administration as herein shown and disclosed in detail are fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that they are 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. | A method for testing for patency at a venous access site during intravenous infusion of a medical solution includes the steps of occluding an intravenous injection tube upstream from the venous access site and monitoring the time and fluid pressure within the tube while the fluid pressure within the tube is varied by external contact with the tube. An apparatus for practicing the method of the invention includes a housing formed with a tube receiving portion for holding a portion of the tube in contact with an occluder finger, a fluid moving finger and a pressure transducer. The fluid moving finger is adapted to contact the tube so as to achieve a testing base pressure in the fluid, after occlusion by the occluder finger. A sequence of pressure drops are then effected by moving the fluid moving finger in stepped increments. An excessive time interval between a pressure drop and a recovery of fluid pressure back to the testing base pressure is an indication of an infiltration condition or some other obstruction. | 8 |
BACKGROUND OF INVENTION
[0001] The present invention relates generally to heating, ventilation and air conditioning (HVAC) systems for vehicles, and more particularly to HVAC systems employed with hybrid vehicles having belt driven refrigerant compressors.
[0002] On vehicles that employ internal combustion engines, some hybrid versions shut off the engine while stopped at a traffic light in order to improve fuel economy. For such vehicles that also employ a belt driven refrigerant compressor (i.e., the belt driven by the engine), the compressor cannot operate while the engine is off. So, while a vehicle is waiting at a stop light on a hot day, the requirement to keep passengers thermally comfortable is in direct conflict with increasing fuel economy.
[0003] Some have addressed this concern by using an electric driven compressor, which can operate with the engine off. However, the electric compressor operates at a higher cost in energy and materials due to the complexity and additional stages in power transfer. This higher cost may be unacceptable for certain vehicles.
SUMMARY OF INVENTION
[0004] An embodiment contemplates a method of controlling a HVAC system for a hybrid vehicle having a refrigerant compressor driven only by an engine, the method comprising the steps of: determining a requested air conditioning operating point for a passenger compartment; estimating a time to reach the requested air conditioning operating point; based on the previous two steps, estimating a maximum allowed compressor off time; determining if the maximum allowed compressor off time is greater than a minimum allowed engine off time; if the maximum allowed compressor off time is greater than the minimum allowed engine off time, determining if the vehicle is entering an allowable engine off mode; if the vehicle is in the allowable engine off mode, commencing engine shut-off mode; if engine shut-off mode is anticipated, prior to commencing the engine shut-off mode, adjusting at least one component of the HVAC system to maximize cooling of the passenger compartment with minimum energy usage; and if the engine shut-off mode is commenced, monitoring the HVAC system to determine when engine restart is needed to maintain thermal comfort in the passenger compartment.
[0005] An embodiment contemplates a method of controlling a HVAC system for a hybrid vehicle, the method comprising the steps of: determining an engine temperature requirement; determining an engine temperature parameter; comparing the engine temperature parameter to the engine temperature requirement; if the engine temperature parameter is greater than the engine temperature requirement, determining that a heating engine shut-off requirement is satisfied; if the heating shut-off requirement is satisfied and the vehicle is entering an allowable engine off mode, commencing an engine shut-off mode; if the heating engine shut-off requirement is satisfied, adjusting at least one component of the HVAC system to maximize heating of a passenger compartment with minimum energy usage prior to commencing the engine shut-off mode; and if the engine shut-off mode is commenced, monitoring the HVAC system to determine when engine restart is needed to maintain thermal comfort in the passenger compartment.
[0006] An advantage of an embodiment is that the HVAC control strategy will meet thermal comfort requirements while maximize fuel savings by reducing compressor operation of a belt driven compressor, which allows for maximum engine off time at vehicle idle in a hybrid vehicle. This is achieved while minimizing fogging, re-fogging, musty smell/humid air discharges, and excessive temperature swings in the passenger compartment. Also, maximum engine off time is achieved while providing heat to the passenger compartment.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 is a schematic diagram of a vehicle including a HVAC system.
[0008] FIGS. 2A-2B show a flow chart illustrating a portion of a method for operating the HVAC system of FIG. 1 .
[0009] FIGS. 3A-3B show a flow chart illustrating a portion of a method for operating the HVAC system of FIG. 1 .
DETAILED DESCRIPTION
[0010] Referring to FIG. 1 , a portion of an automotive vehicle, indicated generally at 10 , is shown. The vehicle 10 may have a hybrid powertrain including an internal combustion engine 22 . The vehicle 10 includes an engine compartment 12 and a passenger compartment 14 . Within the compartments 12 , 14 are an engine cooling system 16 and a heating, ventilation and air conditioning (HVAC) system 18 .
[0011] The engine cooling system 16 includes a water pump 20 that pushes water through the engine 22 and other portions of the engine cooling system 16 . This water pump 20 may be driven by the engine 22 . A radiator 24 and fan 26 are employed for removing heat from the engine coolant. A thermostat 28 may be employed in a conventional fashion for selectively blocking the flow of coolant through the radiator 24 when the coolant is below a desired operating temperature.
[0012] A powertrain controller 32 controls the engine operation, including switching the engine operation between a normal operating mode and a deactivation (engine shut-off) mode, such as, for example, when a vehicle is stopped at a traffic light.
[0013] A heater core outlet 30 from the engine 22 directs coolant to a heater core 38 , located in a HVAC module 40 . Optionally, an electrically driven auxiliary coolant pump 39 may selectively pump coolant from the engine 22 to the heater core 38 . A coolant line 42 directs coolant from the heater core 38 to an inlet to the water pump 20 . The dashed lines shown in FIG. 1 represent coolant lines through which engine coolant flows.
[0014] The HVAC system 18 includes the HVAC module 40 , within which is located a blower 44 for drawing in air through an air inlet 46 past a recirculation door 47 and directing it through an evaporator 48 . Downstream of the evaporator 48 is the heater core 38 , which has a blend door 50 located on its upstream side that selectively directs air around or through the heater core 38 . The HVAC module 40 may also include a defrost outlet and door 52 , a floor outlet and door 54 , and a chest height outlet and door 56 , which direct air into different portions of the passenger compartment 14 , depending upon the particular HVAC operating mode.
[0015] A cooling portion 58 of the HVAC system 18 may include the evaporator 48 , a thermal expansion valve 60 , a refrigerant compressor 62 , and a condenser 64 connected together via refrigerant lines 66 . The dash-dot lines shown in FIG. 1 represent refrigerant lines through which refrigerant flows. The compressor 62 is driven by the engine 22 , via a belt and pulley assembly 61 . A clutch 63 may be employed to selectively connect and disconnect the compressor 62 from the driving torque of the belt and pulley assembly 61 , or, alternatively, the compressor 62 may be a variable capacity compressor.
[0016] The HVAC system 18 also includes a HVAC controller 68 that communicates with the powertrain controller 32 and controls the compressor 62 (or the compressor clutch as the case may be), as well as the blower 44 , blend door 50 and the outlet doors 52 , 54 , 56 . The powertrain controller 32 may also control the speed of the fan 26 . Accordingly, various portions of the HVAC system 18 and engine 22 can be automatically controlled to optimize vehicle fuel economy while providing for adequate heating and air conditioning to the passenger compartment 14 . The flow charts of FIGS. 2A-3B illustrate a method for operating the HVAC system 18 of FIG. 1 to allow for adequate thermal comfort in the passenger compartment 14 while maximizing the vehicle fuel economy by maximizing the engine off time at idle.
[0017] The HVAC system 18 may also include various sensors for detecting a temperature or pressure at certain points in the system. For example, the HVAC system 18 may include an ambient air temperature sensor 72 for measuring ambient air temperature outside of the vehicle, a passenger compartment air temperature sensor 74 for measuring the air temperature in the passenger compartment 14 , and a solar load sensor 76 for measuring a solar load on the passenger compartment 14 . A humidity sensor 78 may be included to measure a humidity level in the passenger compartment 14 . An evaporator air temperature sensor 80 may be employed to measure the temperature of air flowing out of the evaporator 26 . Also, a coolant temperature sensor 82 may be employed to measure a temperature of coolant flowing to the heater core 38 , and another temperature sensor 84 may be employed to obtain an engine temperature, which may measure engine oil temperature.
[0018] FIGS. 2A-3B are flow charts illustrating a method for operating the HVAC system 18 (in coordination with the engine operation) of FIG. 1 to provide heat to the passenger compartment 14 . When operating a hybrid automotive vehicle, a compromise has to be made between maximizing the fuel economy and operating the HVAC system 18 to maintain thermal comfort for the passengers.
[0019] FIGS. 2A-2B show a flow chart illustrating a method for managing the heating operations of the HVAC system 18 of FIG. 1 . Ambient temperature and engine temperature are read, block 100 . The ambient temperature sensor 72 and the coolant temperature sensor 82 may be employed for determining these temperature readings. An engine temperature requirement is determined, block 102 . This engine temperature requirement is the temperature needed to allow for adequate heat to be supplied to the heater core 38 from the engine coolant. An engine oil temperature and a catalytic converter temperature are determined, block 102 . The oil temperature may be determined from the engine temperature sensor 84 , while the converter temperature may be estimated based on, for example, engine operating conditions and run time as well as the ambient temperature. The current thermal conditions of the engine 22 are the engine thermal parameters, which are indicative of the heat that can be removed from the engine 22 to provide heat to the passenger compartment 14 . The engine temperature parameters are compared to the engine temperature requirement, block 106 . If the engine temperature parameters are not greater than the engine temperature requirement, then the process starts again. If the engine temperature parameters are greater than the engine temperature requirement, then the heating engine shut-off requirement is satisfied, block 108 .
[0020] The heating engine shut-off requirement is just one requirement that needs to be met in order to allow engine shut-off at vehicle idle. Another condition will be discussed below relative to FIGS. 3A and 3B . And, of course, the general vehicle and battery pack conditions need to be met that allow for engine shut-off at idle. For example, there may be a minimum engine-on time before another shut-off is allowed and the battery may require a minimum charge to allow for engine shut-off.
[0021] A determination is made whether passenger compartment heating is requested, block 109 . If not, the process starts again. If passenger compartment heating is requested, then a determination is made if engine shut-off is anticipated, block 110 . If not, the process starts again. If engine shut-off is anticipated, then adjustments are made to the HVAC system 18 to account for the fact that passenger compartment heating is will be provided while the engine 22 is off. This may include, activating the auxiliary coolant pump 39 to pump warm coolant from the engine 22 through the heater core 38 , adjusting the blend door to direct all air flow through the heater core 38 , adjusting the blower speed, and/or adjusting the mode door 47 to recirculate air flow, block 112 . These changes are directed to maximizing the heat available for passenger compartment heating during the periods of engine off vehicle operation. Then, engine shut-off mode is commenced, block 113 .
[0022] While providing heat to the passenger compartment 14 during an engine off condition, the method assures that adequate heat can continue to be supplied to the passenger compartment 14 . The HVAC sensors are read, block 114 . The HVAC sensors to be read are those that are indicative of the ability to continue providing adequate heat to the passenger compartment 14 while the engine 22 remains off. A difference between a requested heating point and a current heating point is determined, block 116 , in order to determine how far the passenger compartment temperature is from a desired temperature range. An estimated time until the engine temperature parameters are less than the engine temperature requirements is calculated, block 118 . The estimated time is compared to a time limit, block 120 . The time limit is the amount of time that the engine 22 would need to operate after restarting to provide the heat needed for the heater core 38 . Thus, the estimation is monitored and if the thermal comfort limits will be exceeded, the request for an engine restart is sent in time to allow the engine 22 to be restarted and the system returned to normal operation before the threshold is reached.
[0023] If the estimated time is not less than the time limit, then the process returns to block 114 . If the estimated time is less than the time limit, then the heating engine shut-off requirement is no longer satisfied, block 122 . Once this engine shut-off requirement is not satisfied, an engine restart is requested, block 124 . With the engine 22 now operating, the auxiliary pump 39 may be deactivated, and the blend door 50 , blower speed and/or the mode door 47 may be adjusted, block 126 , to pre-engine shut-off conditions.
[0024] Simultaneously with the method shown in FIGS. 2A-2B , a method for controlling the air conditioning operations may be operated. FIGS. 3A-3B show a flow chart illustrating a method for managing the air conditioning (A/C) operations, which may include passenger compartment cooling, as well as defog/defrost operations, for the vehicle of FIG. 1 .
[0025] HVAC sensors are read, block 200 . A requested A/C performance and requested A/C operating point are read, block 202 . The requested A/C performance may include maximum A/C, high fuel economy A/C performance, defogging prevention and/or defrost operation. The requested A/C operating point is the thermal comfort range requested by the vehicle occupant. A time to reaching the requested A/C point is estimated, block 204 . Also, a maximum allowed refrigerant compressor off time is estimated, block 206 . This is the time the compressor may be off while still approaching or maintaining the thermal comfort in the passenger compartment 14 within an acceptable range around the requested A/C point. The compressor off time may be zero under some operating conditions.
[0026] The allowed compressor off time is then compared to the minimum allowed engine off time, block 208 . The minimum allowed engine off time is the minimum amount of time for which it is advantageous to turn the engine off. If the allowed compressor off time is not greater than the minimum allowed engine off time, then the process returns to block 200 . If the allowed compressor off time is greater than the minimum allowed engine off time, then a determination is made as to whether the vehicle is in an allowable engine off mode, block 210 . That is, the general vehicle and battery pack conditions need to be met that allow for engine shut-off at idle, as well as the conditions relating to the method of FIGS. 2A-2B . If not in allowable engine off mode, then the process returns to block 200 . If in allowable engine off mode, then the A/C engine shut-off requirement is satisfied, block 212 . If engine shut-off is not anticipated, block 214 , due to other operating conditions preventing an engine shut-off mode, then the process returns to block 200 . If engine shut-off is anticipated, then the blend door 50 , speed of the blower 44 , and/or mode door 47 are adjusted, block 216 . These adjustments may include moving the blend door 50 to divert all air flow to bypass the heater core 38 , and moving the mode door 47 to recirculate air rather than drawing in fresh air. Then, engine shut-off mode is commenced, block 217 .
[0027] While providing A/C (or defrost/defog) to the passenger compartment 14 during an engine off condition, the method assures that adequate A/C can continue to be supplied to the passenger compartment 14 . The HVAC sensors are read, block 218 . The HVAC sensors to be read are those that are indicative of the ability to continue providing adequate A/C to the passenger compartment 14 while the engine 22 remains off. These may include, for example, ambient temperature, relative humidity, and solar load and direction. A determination is made whether the user comfort request has changed, block 220 . A change may occur when an occupant changes the temperature or operating mode of the HVAC system 18 . Also, a comfort operating bandwidth based on the operating mode is determined, block 222 . The comfort operating bandwidth is the acceptable range of thermal comfort provided to the occupants in the passenger compartment 14 . A time to thermal comfort being outside of the comfort operating bandwidth is estimated, block 224 .
[0028] A comparison is then made between the estimated time and a time limit, block 226 . The time limit is an amount of time that the engine 22 would need to operate after restarting to provide the chilled refrigerant needed for the evaporator 48 . Thus, the estimation is monitored and if the comfort operating bandwidth will be exceeded, the request for an engine restart is sent in time to allow the engine 22 to be restarted and the system returned to normal operation before the threshold is reached. If the estimated time is not less than the time limit, then the process returns to block 218 . If the estimated time is less than the time limit, then the A/C engine shut-off requirement is not satisfied, block 228 . An engine restart is requested, block 230 . In addition, the blend door 50 , blower speed, recirculation door 47 and mode doors 52 , 54 , 56 are returned to the operating states before the engine shut-off condition.
[0029] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims. | A method of controlling a HVAC system for a hybrid vehicle having a refrigerant compressor driven by an engine is disclosed. The method may comprise: determining a requested air conditioning operating point for a passenger compartment; estimating a time to reach the requested operating point; based on the previous steps, estimating a maximum allowed compressor off time; determining if the allowed compressor off time is greater than a minimum engine off time; if the allowed compressor off time is greater than the engine off time, determining if the vehicle is entering an allowable engine off mode; if so, commencing engine shut-off mode; if engine shut-off is anticipated, prior to commencing the shut-off mode, adjusting the HVAC system to maximize cooling of the passenger compartment with minimum energy usage; and if the engine shut-off is commenced, monitoring the HVAC system to determine when engine restart is needed to maintain comfort. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to the production of a fire-resistant cellulose insulation product, and more particularly to fire-resistant cellulose insulation materials using alkali borates as liquid flame retardants.
2. Description of Related Art
Previously, the cellulose industry used powdered boric acid (H3BO3) and powdered borax (Na2B4O7.5H2O) sodium tetraborate pentahydrate, almost exclusively as flame retardants in the manufacture of cellulose insulation. These two chemicals, mixed in the ratio range of from 1:2 to 1:4 (boric acid:borax) is still generally accepted as the best flame retardant formula although today, because of its expense, it is not commercially used. Instead, ammonium sulfate is used as a substitute for borax in a ratio range of from 1:2 to 1:6 (boric acid:ammonium sulfate). The use of ammonium sulfate has introduced problems however, such as corrosion and unacceptable odor and therefore, research is ongoing in the industry to find an inexpensive substitute for the sulfate.
All cellulose insulation must pass a series of tests described in ASTM C-739, before the U.S. Government will permit its sale. The most important of these tests are: a corrosion test; a critical radiant flux test which measures the ability of the product to prevent the spread of fire by surface burning; and a smolder test which measures the ability of the product to extinguish burning beneath the surface. The boric acid and borax mixture described above, is able to easily pass all three of these tests. Boric acid alone is able to pass the critical radiant flux, and smolder tests, but being acidic it fails the corrosion test and, when used alone it is an expensive approach. Borax alone is able to pass the critical radiant flux and corrosion tests and is cheaper than boric acid, but it does not pass the smolder test because its alkalinity, due to the sodium, actually enhances smoldering.
When combined in the preferred ratio range as defined above, the two chemicals neutralize each other so as to easily pass the corrosion test. The boric acid overwhelms the effect of the sodium ensuring that the combination passes the smolder test as well.
U.S. Pat. No. 5,534,301 to Shutt, issued on Jul. 9, 1996 is hereby incorporated into the present application by reference. This prior art patent provides an up-to-date description of the field of the present invention so as to enable an understanding of the improvements provided by the present invention method. Further, this patent teaches a method for producing a fire-retardant composition including any one or more of ammonium sulfate, monoammonium phosphate, diammonium phosphate, boric acid, aluminum sulfate, sodium tetraborate, ferrous sulfate and zinc sulfate, which as will be described below is relevant to the present invention.
The prior art does not teach the use of alkali borates as liquid flame retardants in cellulose insulation. This has not been accomplished, most likely, because the solubility of boric acid and sodium tetraborate in water, is known to be quite low thereby producing a product with excessive water content.
SUMMARY OF THE INVENTION
The present invention teaches certain benefits in construction and use which give rise to the objectives described below.
The present invention provides a method for producing an improved fire retarding compound for use with cellulose insulation materials. The present inventive compound uses the same concept as the above described boric acid and borax, but substitutes liquid borates rather than powdered borates. Such liquid borates enable the amount of chemical to be reduced by approximately fifty percent, i.e., 9% liquid instead of 18% powder, for instance. This offsets the high cost of the use of borates. Additionally, the inexpensive borate, borax, is the only boron containing chemical used in the present invention method and it is converted to boric acid once impregnated into the cellulose insulation material. Because the present method impregnates the chemicals into the paper it is more effective than commercial powder applications. Because liquids are used only about one-half of the retardant is necessary as compared to dry processing. The method allows a manufacturer to effectively remove all dust from the product.
A primary objective of the present invention is to provide a method having advantages not taught by the prior art.
Another objective is to provide such a method capable of producing a low cost fire retarding compound for use with cellulose insulation materials.
A further objective is to provide such a method capable of producing such a low cost fire retarding compound for use with cellulose insulation materials that passes all of the tests prescribed in ASTM C-739 including corrosion, critical radiant flux and smolder.
Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
It is well known that both boric acid and borax have limited solubility in water. At 68° F., their solubilities are, respectively, 4.5% and 5.5%. At such a concentration their use as flame retardants in the cellulose industry is impractical. For instance, manufacturing equipment would be adversely affected and drying costs of production would be prohibitively high.
In the present invention a process is defined starting with borax as a raw material. It is then converted to metaborate by mixing it with an alkali hydroxide by the process:
Na2B4O7.5H2O+2Na(OH)+2H2O→2Na2O.B2O3.4H2O, or
Na2B4O7.5H2O+2K(OH)+2H2O→Na2O.B2O3.4H2O+K2O.B2O3.4H2O
Similarly, by adding a mixed alkali hydroxide the same end products would be produced albeit in varying proportions. The ideal solution concentration is 35% although a range of solution concentration from 20% to 45% may be acceptable. The use of sodium hydroxide or potassium hydroxide or a mixture is selected in accordance with operating temperature and the price of these raw materials. Potassium metaborate has much greater solubility in water than does sodium metaborate, however, potassium hydroxide is more than twice as expensive as sodium hydroxide. The alkali metaborate is prepared as an aqueous solution that is sprayed into newsprint. As an example, using a 35% concentration, one-hundred pounds of newsprint absorbs 9.9 pounds of metaborate and 18.4 pounds of water which is later driven off, yielding a dry product. It has been discovered that approximately 9% of the chemical in the newsprint is adequate for meeting ASTM requirements as the previously described (except the smolder test) and more than 9% would only tend to drive the cost of production upward.
A second liquid is added in order to convert the metaborate into boric acid plus a salt, and such is necessary to meet all of the ASTM requirements. The second liquid contains an acid radical which may be a true acid or an acid derivative capable of reacting with the alkali. Any acid will react with metaborate producing boric acid and a salt of the original acid, for example, citric acid and metaborate producing boric acid and sodium citrate. Hydrochloric acid would produce boric acid and sodium chloride; formic acid would produce boric acid and sodium formate., etc. In selecting an acid one must consider toxicity, volatility, end product and cost. For example formic acid because of its high volatility is too toxic to use in this industry; hydrochloric acid produces sodium chloride (common salt) which is corrosive in ASTM c-739; citric acid is too expensive for this industry. By far the cheapest acid to use in this application is sulfuric acid. However, although it performs well and is cheap it is dangerous to handle. Ferrous sulfate (which is acidic) is a reasonably safe material to handle and it is also cheap. Hence, it is the desired compound even though it is not as effective as pure acid.
An example of the use of an acid is:
Na2O.B2O3.4H2O+H2SO4→2H3BO3+Na2SO4.2H2O+H2
An example of an acid derivative is:
Na2O.B2O3.4H2O+FeSO4+2H2O→2H3BO3+Na2SO4.2H2O+Fe(OH)2
These reactions neutralize the metaborate bringing the pH into the range 6.5 to 8.0 and yielding boric acid to offset the effect of alkali in the smolder test. ASTM C-739 requires that cellulose insulation pass a corrosion test. In that test the flame-retardant in cellulose is caused to react with thin sheets of copper, aluminum and iron. If the pH of the insulation falls outside the range 6.5 to 8.0, one almost certainly gets corrosion of at least one of the metals. So, although pH alone doesn't lead to corrosion, it is almost inevitable that a pH outside of the range quoted indicates the presence of substances that will be corrosive.
It has been explained that high water solubility is the reason that metaborate is used. However, combinations of boric acid and borax, although more costly and less soluble can also be used in this process. Metaborate solution concentrations in excess of 60% can be used in the manufacture of cellulose insulation. However, the optimum concentration range is 25% to 45% because of viscosity, drying cost and liquid penetration rate considerations. As discussed, the optimum concentration has been discovered to be 35%.
Further, surfactants may also be inventively added into the metaborate solutions to assist in penetration rate. A typical surfactant is Rohm and Hass 9N9 which is added in the amount of 0.1% to the solution.
The solution may be sprayed into the paper at any step in the insulation manufacturing process in order to meet the requirements of ASTM C-739. However, an ideal location for spraying is directly after the grinding process so as to assure that the cutting edges of the equipment are not damaged or degraded by the chemicals. The ground but untreated cellulose is preferably introduced into the spray step in a continuous process with the metaborate solution first and then with the acid solution. The sprayed materials are then dried and bagged. The particle size of the sprayed liquid is preferably 40 to 100 microns. This is achieved by using spray nozzle pressures in the range of between 60 and 120 psi. The ideal droplet size is 40 to 100 microns. This range has been determined through experimentation in a manufacturing facility. It has been found that a particle size above 100 microns leads to poor coverage of the insulation thereby requiring more chemical. A particle size less than 40 micron also requires more chemical. This is because cellulose is transported by a high velocity air stream and in such an air stream a very small particle evaporates so quickly that some of the chemical in the droplet precipitates and turns to powder. Powder is only half as efficient as liquid hence the need for more chemical when using a particle size finer than 40 micron.
While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims. | A method for producing an improved fire retarding compound for use with cellulose insulation materials uses the same concept as boric acid and borax, but substitutes liquid borates rather than powdered borates. Such liquid borates enables the amount of chemical to be reduced by approximately fifty percent. This offsets the high cost of the use of borates. Additionally, the inexpensive borate, borax, is the only boron containing chemical used in the present invention method and it is converted to boric acid once impregnated inside the cellulose insulation material. | 3 |
CLAIM OF PRIORITY
[0001] This divisional application claims priority from U.S. patent application Ser. No. 11/480,097, filed on Jun. 29, 2006, which is incorporated herein by reference in its entirety.
BACKGROUND
[0002] Modifications or alterations to a vehicle or a facility may be made from time to time during the service life of a vehicle or facility. For example, additional equipment or systems may be added, either permanently or on a temporary basis.
[0003] Equipment or systems may be attached directly to attach points of the structure of the vehicle or facility. Alternately, a mounting structure, such as for example a false floor or the like, may be attached to the attach points, and the equipment or systems may be mounted on the mounting structure as desired. This latter approach permits the installation of equipment or systems without modifications to the structure of the vehicle or facility. Regardless of whether equipment, systems, or mounting structures (collectively, “mounted structure”) are attached to the attach points, the mounted structure is attached to the attach point via a fastener.
[0004] Mounting holes for receiving the attach point fasteners are planned and defined in the mounted structure based upon documented location of the attach point fasteners. In some applications the mounting hole may be counter-bored such that the attach point fastener will not extend past an upper surface of the mounted structure. The mounted structure is placed on the structure of the vehicle or facility such that the attach point fasteners are received in the mounting holes.
[0005] However, a variability may exist between documented location of an attach point fastener and actual location of the attach point fasteners. This variability may result from, without limitation, inaccurate documentation, assembly processes with large tolerances for inaccurate location, heavy use, damage, field repairs, or any combination thereof. In some instances, the variability may be on the order of around an inch or so. However, there is no limit to possible variability.
[0006] In the event of a large variability, a mounting hole that was defined based on a documented location of a fastener may not align properly with the actual location of the fastener. In the case of a counter-bored mounting hole, attachment may be precluded even if the attach point fastener fits within the counter-bored hole. This is because bushings or washers received within the counter-bored hole may not align with the fastener.
[0007] In such cases, the mounting hole may be re-drilled. Alternately, in some cases, a new mounted structure may have to be fabricated. Such rework introduces delays and cost increases into a modification or alteration.
[0008] The foregoing examples of related art and limitations associated therewith are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings.
SUMMARY
[0009] The following embodiments and aspects thereof are described and illustrated in conjunction with systems and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the problems described above in the Background have been reduced or eliminated, while other embodiments are directed to other improvements.
[0010] In an exemplary, non-limiting bushing assembly, a first bushing defines a first opening therethrough. The first opening has a first dimension along a first axis that is sized to receive a fastener therethrough. The first opening has a second dimension along a second axis, and the second dimension is larger than the first dimension. A second bushing defines a second opening therethrough that is sized to receive a fastener therein. Means are provided for engaging the first and second bushings.
[0011] According to an aspect, the engaging means may be provided by serrations defined on a surface of the first bushing and serrations defined on a surface of the second bushing. Alternately, the engaging means may be provided by, without limitation: an abrasive surface treatment defined on a surface of the first bushing and defined on a surface of the second bushing; an adhesive affixed to a surface of at least one of the first and second bushings; hook and loop fasteners affixed to the first and second bushings; or the like, as desired for a particular application.
[0012] According to another aspect, the first opening may be a slot. Further, the dimension along the second axis of the slot may be at least one-half an amount of variability of an actual location of a fastener from a documented location of the fastener.
[0013] In another exemplary, non-limiting bushing assembly, a first bushing defines a first slot therethrough that has a first dimension along a first axis that is sized to receive a fastener therethrough. The first bushing has a second dimension along a second axis that is larger than the dimension along the first axis. The first bushing defines a second slot therethrough that has a third dimension along the first axis that is bigger than the first dimension and that has a fourth dimension along the second axis that is larger than the second dimension. A second bushing defines a second opening therethrough that is sized to receive a fastener therein. Means are provided for engaging the first and second bushings.
[0014] Exemplary bushing assemblies may be used in attaching two structures to each other. In an exemplary method of attaching two structures to each other, a first structure and a second structure are disposed against each other such that a fastener that extends from the second structure is received in a counter-bored hole defined in the first structure. An actual location of the fastener may have a variability from a documented location of the fastener, and the counter-bored hole is defined to receive the fastener in the documented location of the fastener. A first bushing is placed into the counter-bored hole, and the first bushing defines a first opening therethrough that has a first dimension along a first axis that is sized to receive the fastener therethrough and that has a second dimension along a second axis that is larger than the dimension along the first axis. The first bushing is rotated until the first bushing receives the fastener therein. A second bushing is placed onto the first bushing, and the second bushing defines a second opening therethrough that is sized to receive the fastener therein. The first and second bushings engage with each other, and the first structure and the first and second bushings are secured onto the fastener.
[0015] In addition to the exemplary embodiments and aspects described above, further embodiments and aspects will become apparent by reference to the drawings and by study of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive.
[0017] FIG. 1 is an exploded perspective view of a buildup of two structures and an exemplary bushing assembly;
[0018] FIG. 2A is a perspective view of an exemplary compensator bushing;
[0019] FIGS. 2B-2F are plan views of the bushing of FIG. 2A ;
[0020] FIG. 3A is a perspective view of an exemplary lock bushing;
[0021] FIGS. 3B-3F are plan views of the bushing of FIG. 3A ;
[0022] FIG. 4A is a partial cutaway perspective view of the compensator bushing of FIG. 2A and the lock bushing of FIG. 3A engaged with each other;
[0023] FIG. 4B is a perspective view of the compensator bushing of FIG. 2A and the lock bushing of FIG. 3A engaged with each other;
[0024] FIGS. 4C-4H are top plan views illustrating exemplary engagement of an exemplary compensator bushing and an exemplary lock bushing;
[0025] FIGS. 5A-5C are top plan views illustrating placement of an exemplary compensator bushing in a counter-bored hole;
[0026] FIG. 6 is a perspective view of two structures attached to each other using an exemplary bushing assembly;
[0027] FIG. 7 is a partial cutaway perspective view of another exemplary bushing assembly held together with a retainer clip;
[0028] FIG. 8A is a perspective view of the exemplary compensator bushing of FIG. 7 ;
[0029] FIGS. 8B-8F are plan views of the bushing of FIG. 8A ;
[0030] FIG. 9A is a perspective view of the exemplary lock bushing of FIG. 7 ; and
[0031] FIGS. 9B-9F are plan views of the bushing of FIG. 9A
DETAILED DESCRIPTION
[0032] Given by way of overview and referring to FIG. 1 , an exemplary bushing assembly 10 may be used in attaching two structures 12 and 14 to each other. Given by way of non-limiting example, the structures 12 and 14 are disposed against each other such that a fastener 16 that extends from the structure 14 is received in a counter-bored hole 18 defined in the structure 12 . An actual location of the fastener 16 may have a variability, v, from a documented location (not shown for clarity) of the fastener 16 , and the hole 18 is defined to receive the fastener 16 in the documented location of the fastener 16 . A compensator bushing 20 is placed in the hole 18 , and the compensator bushing 20 defines an opening 22 therethrough that has a dimension 1 1 along an axis a 1 , that is sized to receive the fastener 16 therethrough and that has a dimension 1 2 along an axis a 2 that is larger than the dimension 1 1 . The compensator bushing 22 is rotated until the compensator bushing 20 is received in the counter-bored hole 18 . A lock bushing 24 is placed onto the compensator bushing 20 , and the lock bushing 24 defines an opening 26 therethrough that is sized to receive the fastener 16 therein. The bushings 20 and 24 engage with each other, and the structure 12 and the bushings 20 and 24 are secured onto the fastener 16 , thereby securing the structure 12 to the structure 14 . Details will now be set forth below.
[0033] Referring additionally to FIGS. 2A-2F , the compensator bushing 20 defines surfaces 28 and 30 and a side 32 . The compensator bushing 20 has an outer diameter that is equalized with a diameter of the counter-bore of the counter-bored hole 18 . The opening 22 extends completely through the compensator bushing 20 from the surface 28 to the surface 30 . In an exemplary embodiment, the opening 22 is a slot. The compensator bushing 20 may have any shape as desired for a particular application. While the compensator bushing 20 is shown herein as having a circular (that is, round) shape, the compensator bushing 20 may have any shape, such as without limitation oval, or square, or rectangular, or the like, as desired for a particular application.
[0034] The dimension 1 1 is sized to receive therein the fastener 16 . The dimension 1 2 is bigger than the dimension 1 1 and is sized to accommodate the variability v of the actual location of the fastener 16 from the documented location of the fastener 16 . Because the compensator bushing 20 can be rotated 360 degrees in the counter-bored hole 18 , the opening 22 can accommodate the variability v that is up to two times the dimension 1 2 . That is, the dimension 1 2 can be as little as one-half the length of the variability v. Thus, the dimension 1 2 is at least one-half the length of the variability v. The full variability v can be accommodated by rotating the compensator bushing 20 in the counter-bored hole 18 until the opening 22 is aligned to receive the fastener 16 therein. Given by way of non-limiting example, when the variability v is around ½ inch, the dimension 1 2 can be at least ¼ inch.
[0035] The compensator bushing 20 may have any thickness t 1 , as desired for a particular application. As a result, the thickness t 1 may be sufficiently thin that the compensator bushing 20 may be considered and referred to as washer. Thus, the term “bushing” as used herein is intended to include “washer” within its meaning. Further, the compensator bushing 20 may be made from any material whatsoever, such as without limitation plastic or metals such as stainless steel or titanium, as desired for a particular application. Factors that may be taken into consideration for selection of materials may include: whether the compensator bushing 20 will be used to transfer load; electro-corrosive compatibility with materials used for the fastener 16 and the structures 12 and 14 (such as avoiding use of dissimilar metals); environmental factors; or the like.
[0036] Referring additionally to FIGS. 3A-3F , the lock bushing 24 defines surfaces 34 and 36 and a side 38 . The lock bushing 24 has an outer diameter that is smaller than a diameter of the counter-bore of the counter-bored hole 18 . The opening 26 extends completely through the lock bushing 24 from the surface 34 to the surface 36 . The opening 26 has a diameter that is sized to receive the fastener 16 therein. The lock bushing 24 may have any shape as desired for a particular application. While the lock bushing 24 is shown herein as having a circular (that is, round) shape, the lock bushing 24 may have any shape, such as without limitation oval, or square, or rectangular, or the like, as desired for a particular application.
[0037] The lock bushing 24 may have any thickness t 2 as desired for a particular application. As a result, the thickness t 2 may be sufficiently thin that the lock bushing 24 may be considered and referred to as washer. Thus, the term “bushing” as used herein is intended to include “washer” within its meaning. Like the compensator bushing 20 , the lock bushing 24 may be made from any material whatsoever, such as without limitation plastic or metals such as stainless steel or titanium, as desired for a particular application. Factors that may be taken into consideration for selection of materials for the lock bushing 24 are the same as those set forth above for the compensator bushing 20 .
[0038] The compensator bushing 20 and the lock bushing 24 each include features that cooperate together to provide means for engaging the compensator bushing 20 and the lock bushing 24 . In an exemplary embodiment, serrations 40 are defined on the surface 28 of the compensator bushing 20 and serrations 42 are defined on the surface 34 of the lock bushing 24 . The serrations 40 are parallel and the serrations 42 are parallel. In an exemplary embodiment, the serrations 40 and 42 extend across the entire surfaces 28 and 34 , respectively.
[0039] The serrations 40 and 42 are made as small as desired for a particular application. Use of small serrations allows for finer control of variability of tolerances and a tighter tolerance with the shaft of the fastener 16 . In an exemplary, non-limiting embodiment, the serrations 40 and 42 are made according to industry machining standards.
[0040] As best seen in FIGS. 2A and 2B , in an exemplary embodiment the serrations 40 are aligned on the surface 28 of the compensator bushing 20 such that their axes form a non-zero angle with the axis a 2 (that is, the serrations 40 are not parallel with the axis a 2 ). The non-zero angle suitably is no more than ninety degrees. The amount of load that can be transferred is maximized when the non-zero angle is ninety degrees. The amount of load that can be transferred is reduced as the non-zero angle approaches zero. This reduction results because, after the lock bushing 24 is placed onto the compensator bushing 20 , the lock bushing 24 could slide on the serrations 40 and 42 along the axis a 2 .
[0041] Referring additionally to FIGS. 4A and 4B , after the compensator bushing 20 is placed into the counter-bored hole 18 (not shown in FIGS. 4A and 4B ), the surface 34 of the lock bushing 24 is placed against the surface 28 of the compensator bushing 20 such that “teeth” of the serrations 40 and 42 are received within (that is, engaged with) “valleys” of the serrations 42 and 40 , respectively.
[0042] The means for engaging may be implemented in several ways in other exemplary embodiments, as desired. For example, referring now to FIG. 4C , in another exemplary embodiment the surface 34 of a lock bushing 24 C and the surface 28 of a compensator bushing 20 C may be treated with a surface treatment 54 to provide a non-skid type surface with an increased coefficient of static friction. The surface treatment 54 may be effected by any suitable, abrasive mechanical processing or by a suitable chemical processing, such as an acid bath or the like. After the compensator bushing 20 C is placed into the counter-bored hole 18 (not shown in FIG. 4C ), the surface 34 of the lock bushing 24 C is placed against the surface 28 of the compensator bushing 20 C such that the increased coefficient of static friction of the surface treatment 54 engages the lock bushing 24 C and the compensator bushing 20 C. This engagement is similar to a knurled or cross-hatched washer that is used to prevent a nut from loosening after installation.
[0043] Referring now to FIGS. 4D , 4 E, and 4 F, in another exemplary embodiment an adhesive 56 may be affixed only to the surface 34 of a lock bushing 24 D ( FIG. 4D ) or only to the surface 28 of a compensator bushing 20 D ( FIG. 4E ) or to the surface 34 of the lock bushing 24 D and to the surface 28 of the compensator bushing 20 D ( FIG. 4F ), as desired. After the compensator bushing 20 D is placed into the counter-bored hole 18 (not shown in FIGS. 4D , 4 E, and 4 F), the surface 34 of the lock bushing 24 D is placed against the surface 28 of the compensator bushing 20 D. The adhesive 56 is allowed to cure, thereby engaging the lock bushing 24 D and the compensator bushing 20 D.
[0044] Referring now to FIGS. 4G and 4H , in another exemplary embodiment hook and loop fasteners may be used to engage a lock bushing 24 E and a compensator bushing 20 E in applications subject to light loading. Hooks 58 may be affixed to the surface 34 of the lock bushing 24 E and loops 60 may be affixed to the surface 28 of the compensator bushing 20 E ( FIG. 4G ). Alternately, the loops 60 may be affixed to the surface 34 of the lock bushing 24 E and the hooks 58 may be affixed to the surface 28 of the compensator bushing 20 E ( FIG. 4H ). After the compensator bushing 20 E is placed into the counter-bored hole 18 (not shown in FIGS. 4G and 4H ), the surface 34 of the lock bushing 24 E is placed against the surface 28 of the compensator bushing 20 E. The hooks 58 engage the loops 60 , thereby engaging the lock bushing 24 E and the compensator bushing 20 E.
[0045] Referring now to FIGS. 5A , 5 B, and 5 C, the structure 12 is placed onto the fastener 16 that may or may not be mislocated. The compensator bushing 20 is rotated as desired (if at all) to compensate for any mislocation of the fastener. In FIG. 5A , the fastener 16 is centered. The compensator bushing 20 is placed onto the fastener 16 and fits into the counter-bored hole 18 without being rotated. The lock bushing 24 is placed onto and engages the compensator bushing 24 .
[0046] In FIG. 5B , the fastener 16 is mislocated by an intermediate amount of variability. The compensator bushing 20 is placed onto the fastener 16 and is rotated until the compensator bushing 20 fits into the counter-bored hole 18 . The lock bushing 24 is placed onto and engages the compensator bushing 24 .
[0047] In FIG. 5C , the fastener 16 is mislocated by an amount of variability that is greater than that shown in FIG. 5B . The compensator bushing 20 is placed onto the fastener 16 and is rotated (more than the amount of rotation shown in FIG. 5B ) until the compensator bushing 20 fits into the counter-bored hole 18 . The lock bushing 24 is placed onto and engages the compensator bushing 24 .
[0048] Referring now to FIGS. 1 AND 6 , after the compensator bushing 20 is placed about the fastener 16 in the counter-bored hole 18 and the lock bushing 24 engages the compensator bushing 20 , a washer 62 is placed onto the lock bushing 24 . A nut 64 is placed onto threads of the fastener 16 and is tightened, thereby securing the structure 12 (and the compensator bushing 20 and the lock bushing 24 ) onto the fastener 16 .
[0049] Referring now to FIGS. 7 , 8 A, and 9 A, in some applications such as modifications or alterations or retrofits or repairs made in the field, it may be desirable to provide a bushing assembly as a one-piece unit. To that end, and given by way overview of another non-limiting example, in an exemplary bushing assembly 110 a compensator bushing 120 defines a slot 122 therethrough that has the dimension 1 1 along the axis a 1 , that is sized to receive the fastener 16 (not shown) therethrough. The compensator bushing 120 has a dimension 1 2 along an axis a 2 that is larger than the dimension 1 1 . The compensator bushing 120 defines a slot 123 therethrough that has a dimension 1 3 along the axis a 1 , that is bigger than the dimension 1 1 and that has a dimension 1 4 along the axis a 2 that is larger than the dimension 1 2 . A lock bushing 124 defines an opening 126 therethrough that is sized to receive the fastener 16 (not shown) therein. Means are provided for engaging the bushings 120 and 124 . Details will now be set forth below.
[0050] Referring additionally to FIGS. 8B-8F , the compensator bushing 120 is similar to the compensator bushing 20 ( FIGS. 2A-2F ) except that the compensator bushing 120 additionally defines the slot 123 . The slot 123 accommodates a retainer clip 102 and washer 104 . Moreover, a side 132 of the compensator bushing 120 optionally may be chamfered over a thickness t 3 , if desired, for radius relief. If provided, the chamfer may have any degree measurement as desired. The compensator bushing 120 includes the features that contribute to the means for engaging the lock bushing that are described above for the compensator bushing 20 .
[0051] Referring now to FIGS. 9A-9F , the lock bushing 124 is similar to the lock bushing 24 ( FIGS. 3A-3F ) except an opening 126 optionally may be chamfered toward a surface 136 , if desired. If provided, the chamfer may have any degree measurement as desired. The chamfer may accommodate receiving a one-piece nut 106 ( FIG. 7 ) thereagainst without a washer.
[0052] Because the bushing assembly 110 is a one-piece assembly, the compensator bushing 120 is rotated until it fits into the counter-bored hole 18 (not shown) and the nut 106 is rotated to secure the structure 12 (not shown) onto the fastener 16 (not shown).
[0053] While a number of exemplary embodiments and aspects have been illustrated and discussed above, those of skill in the art will recognize certain modifications, permutations, additions, and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions, and sub-combinations as are within their scope. | A particular method includes disposing a first structure and a second structure adjacent to each other. A fastener is extended from the second structure through a hole and a counterbore defined in the first structure. A first bushing is placed over the fastener by receiving the fastener through an elongated opening defined in the first bushing. When the fastener is not centered relative to the hole, the first bushing is rotated around the fastener and a position of the fastener is adjusted in the elongated opening until the first bushing is received into the counterbore defined in the first structure. The fastener is received through an opening defined in a second bushing. The first structure and the first and second bushings are secured onto the fastener. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 11/612,716 filed Dec. 19, 2006, which is hereby incorporated herein in its entirety by reference.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to a wire rack for mounting an iron on a wall and method of use thereof, and more specifically, to a wire rack for mounting an iron on a wall, the wire rack having a retractable rail for adjusting to different sizes of irons to be mounted on a wall and equipped with an ironing board holder and a product holder.
BACKGROUND
[0003] Articles of clothing, upholstery, and other fabrics used in households are typically made of fibers that wrinkle during washing, pressing, and handling. Clothing can also wrinkle when worn or manipulated. Shirts are tucked into pants and worn in contact with the skin, and seat covers of a couch are constantly compressed in a certain direction. Winter clothing is also sometimes stored in boxes or depressurized bags that create unwanted wrinkles. Wrinkle-free clothing and fabrics are generally preferred for aesthetical reasons.
[0004] Metal pans filled with charcoal were used in the first century BCE in China to flatten fabrics. In the early 20th century, iron boxes filled with coal were sold in the United States, but this technology was never widely accepted. In the 17th century, delta-shaped tools of cast iron began to be used. These tools had a front nose and a back heel and were placed on a fire with a removable wooden handle. While irons have slowly become almost exclusively stainless steel models, the name “iron” survived changes in materials technology. Ironing boards used in conjunction with irons were also developed during the 20th century. U.S. Pat. No. 19,390 to Vandenburg et al. teaches a primitive version of an ironing board for shirts. The most successful and widely used iron design today is the electric iron, which is heated by a resistive heating element and was invented in 1882 by Henry W. Seeley.
[0005] Wrinkle-free surfaces are desirable for a variety of functional reasons, such as enabling the pearling of water over surfaces; for aesthetical reasons, such as providing the illusion that a piece of clothing is new; and for comfort reasons, as in the case with freshly ironed bed sheets or table linens. Wrinkles are removed by ironing or smoothing a tissue or clothing. Fabrics are heated or pressurized during the ironing process to straighten fibers using the weight of the iron and the additional pressure of the arm of a user. Pressure, heat, and humidity are used jointly to smooth clothing and other fabrics. Some fabrics, such as silk, are heat sensitive and can be damaged if ironed improperly. Light wool also requires extra care, since the fibers are delicately interwoven and weak. Some fabrics, such as cotton, require the addition of water to loosen intermolecular bonds and facilitate ironing.
[0006] Most households place so much importance on ironing that it has become a routine step in the weekly laundry cycle. Ironing can be time consuming and requires equipment such as an iron, an ironing board, and surface treatment products. This troublesome task, much like folding clothes, has remained virtually unchanged over the past decades, and for this reason, improvements hold great commercial value.
[0007] Lighter irons are easier to handle but require more hand pressure to operate. Light irons are also quicker to heat but do not have lengthy internal thermal inertia that allows the surface temperature to remain unchanged when placed over a humid article of clothing. Heavier irons are often difficult to manipulate and must be stored in locations away from where they might potentially cause harm. Virtually all types of iron must be stored between uses, since households rarely have dedicated floor space or laundry rooms dedicated to ironing and handling clothing. U.S. Pat. No. 4,909,158 to Sorensen and Chinese Patent No. 1,202,339 teach the use of a combined wall cabinet equipped with a retractable ironing board fixed within the cabinet and folded up for storage. These devices do not permit users to purchase readily available ironing boards. Further, these devices are bulky and require affixing a heavy cabinet to a wall at a dedicated location. Users of these devices are also limited in their range of operation of the ironing boards. For instance, an operator is unable to access the back of the board. These devices also force users to remain in a stationary location. Other devices described in International Patent Application PCT/NL01/00129 to Okkerse and U.K. Patent Application GB 2,411,906 describe iron holders placed horizontally or attached to the ironing board to allow a hot iron to be held safely between uses or while the fabric is being repositioned. Neither of these devices is directed to short- or long-term storage of ironing boards and irons. U.S. Pat. No. 7,004,433 to Clausen et al. teaches the installation on a wall of two different superimposed components: a board holder and a iron holder. A board holder is attached to the wall in a first step and a iron holder made of one single large tab is then locked into place over the board holder. By holding the iron by the handle at a single point, irons may be damaged by their own weight and the iron may wobble in place since it is not fixed to the holder. Clausen et al. teaches a device unable to hold or adapt to different types of irons. The device as shown is bulky, heavy, and expensive to produce. The device is also incapable of holding extra ironing products or an ironing board constructed without a T-shaped foot.
[0008] What is needed is a light, adjustable device able to hold different types and geometries of irons without causing damage to the iron and able to be installed on a wall in a single operation. What is also needed is a device able to hold extra ironing products and equipped to hold ironing boards of different geometries in a limited space. What is also needed is a cost-effective, heat-resistant device able to provide the above-mentioned improvements.
SUMMARY
[0009] The present disclosure relates to a wire rack for mounting an iron on a wall and method of use thereof, and more specifically, to a wire rack for mounting an iron on a wall, the wire rack having a retractable rail for adjusting to different sizes of irons and equipped with an ironing board holder and a product holder. The iron holder holds the iron by the iron's base and can be adjusted to accommodate different sizes of irons. The frame is also made of heat-resistant, coated, welded wire that allows for the manufacture of a light, cost-effective device. The device is also equipped with large hooks to hold most types of ironing boards and arms designed to hold extra products used during ironing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a wire rack for mounting an iron on a wall according to a first embodiment of the disclosure and equipped with a movable heel segment according to a possible embodiment.
[0011] FIG. 2 is a perspective view of the wire rack of FIG. 1 showing in phantom lines the iron, ironing board, and extra products to be held by the wire rack according to a possible embodiment.
[0012] FIG. 3 is an exploded view of the wire rack of FIG. 1 according to a possible embodiment.
[0013] FIG. 4 is a perspective view of the wire rack equipped with a movable nose segment according to a second possible embodiment.
[0014] FIG. 5 is an exploded view of the wire rack of FIG. 4 according to a possible embodiment.
[0015] FIG. 6 is a block diagram of a method for storing ironing equipment according to a possible embodiment.
DETAILED DESCRIPTION
[0016] FIG. 1 shows a perspective view of the wire rack 100 according to a first embodiment of the disclosure equipped with a movable heel segment 12 according to a possible embodiment. FIG. 2 shows the wire rack 100 for mounting an iron 4 with phantom lines showing possible extra products, water storage, containers, and ironing boards placed upon the wire rack 100 . The body 10 comprises a wall mount 22 as shown in FIG. 1 adapted to secure the wire rack to a wall (not shown). The wire rack 100 has a movable torso 11 adapted to secure the iron 4 to the wire rack 100 with a retractable rail 35 having an upper holder 23 adapted for engaging a nose portion of the iron 4 (shown as the pointed end), and a lower holder 24 adapted for engaging the heel portion of the iron (shown as the flat end). The wire rack also includes an arm 19 disposed on the body 10 adapted to hold extra equipment 2 and a leg 15 disposed on the body 10 adapted to hold an ironing board 1 . The retractable rail 35 comprises intermediate positions located on horizontal segments 17 a , 17 b , etc. for moving the upper holder 23 and the lower holder 24 in relation to each other.
[0017] What is shown in FIG. 1 is a wire rack 100 with an essentially rectangular body 10 with different vertical and horizontal elements attached thereto. For example, a horizontal support brace 18 serves together with the arms 19 to hold extra equipment 2 and is fixed across the body 10 to increase the rigidity of the body 10 . In one preferred embodiment, a wall mount 22 is located on the top center portion of the wire rack 100 . Other wall mounts 34 are also shown and may be used if more support is needed. What is contemplated is the use of a wire rack of any type of geometry capable of giving the wire rack 100 sufficient rigidity to maintain its functions of holding an iron 4 , an ironing board 1 , and extra equipment 2 . What is also contemplated is the use of any type of wall mount 22 or 34 located at any position on the body 10 to affix the wire rack 100 to a vertical surface. What is also contemplated is the use of any type of mounting technology, such as but not limited to bolts, nails, screws, legs, magnets, tabs, and the like. In the disclosed embodiment and as shown in FIG. 2 , two legs 15 hold a board 1 using the legs tubes 40 of the ironing board 1 . It is understood that ironing boards 1 can have legs of different geometries based on consumer preferences and market production. What is contemplated in one disclosed embodiment is the use of legs 15 with a protector 16 curved upward to hold the leg tubes 40 of the ironing board 1 . It is understood by one of ordinary skill in the art that the size and orientation of the legs 15 may be modified to hold other types of ironing boards 1 . What is also contemplated is the use of a single leg 15 or a plurality of legs 15 to achieve the same result. While the legs 15 are shown attached to the lower outside corners of the body 10 , what is contemplated is the placement of legs 15 at any reasonable location to hold an ironing board 1 located below the wire rack 100 .
[0018] FIG. 1 also discloses the use of two arms 19 located on each side of the wire rack 100 and attached to vertical wires. While one possible embodiment is shown, what is contemplated is the use of arms 19 located at any reasonable orientation on the wire rack 100 to hold extra equipment 2 . FIG. 2 shows a configuration where two circular arms 19 hold spray cans 2 and a top arm 32 holds a small box 3 . The arm 19 is shown with a bottom wire 20 serving to hold vertically the spray can while the top arm 32 is shown without a bottom wire. What is contemplated is the use of wire technology or other flat surface technology to produce and place on the body 10 any reasonable amounts and types of holders designed to hold the different extra equipment 2 , 3 used during ironing. In the preferred embodiment, the wire rack 100 weighs approximately 13 oz, or less than one pound, and is about 14 inches wide by 14 inches high with a thickness of about 4 inches. The wire rack 100 in a preferred embodiment is made of formed steel wires of 1/16th inch in diameter or of other smaller diameters and is coated with a white, polymer-based thermoplastic. While one preferred embodiment is shown and disclosed in FIGS. 1-3 , and a second preferred embodiment is shown and disclosed in FIGS. 4-5 , what is contemplated is any type of wire rack 100 of any color, with any type of coating or even made of bare stainless steel, capable of holding the different elements disclosed within the same volume and of approximately the same weight. What is also disclosed is the use of thicker wires to form the body 10 and smaller wires to serve as the secondary features placed upon the body 10 in order to reduce the overall weight and manufacturing cost of the wire rack 100 .
[0019] The wire rack 100 has a movable torso 11 adapted to secure the iron 4 to the wire rack 100 with a retractable rail 35 having an upper holder 23 adapted for engaging a nose portion of the iron 4 (shown as the pointed end) and a lower holder 24 adapted for engaging the heel portion of the iron (shown as the flat end). FIG. 3 shows an exploded view of one possible embodiment of the lower holder 24 located on a movable segment 12 of the torso 11 adapted to attach to a horizontal spacing bar 17 a , 17 b on a fixed segment of the torso. The movable segment 12 has a fixation device 13 , shown in FIG. 3 as two hooks, capable of interlocking with one of the horizontal spacing bars 17 a , 17 b , etc. In the preferred embodiment as shown in FIG. 3 , a handful of horizontal spacing bars 17 a , 17 b allow the lower holder 24 to be placed at different distances from the upper holder 23 based on the spacing of the horizontal spacing bars 17 a , 17 b . The movable segment 12 also has lateral tabs 14 used to hold the iron 4 in place laterally as shown in FIG. 2 . The movable segment 12 includes a structural member 25 to increase the overall strength and rigidity of the movable segment 12 and acts as part of the structure placed between the bottom of the iron 4 and the wall (not shown). The lateral legs 14 as shown in FIGS. 1-3 may also be placed on the body 10 as shown in another embodiment in FIGS. 4-5 .
[0020] In the embodiments shown in FIGS. 1-5 , the lower holder 24 is made of a flat wire of rectangular shape and the upper holder 23 is made of a curved 33 wire adapted to receive a pointed nose section of an iron 4 . In these embodiments, a user inserts the nose portion of the iron 4 inside the upper holder 23 and locks the nose behind the curved wire 33 . Once the nose is locked, the heel portion of the base is then slid into the lower holder 24 without risk of falling since the top portion of the iron 4 is already locked in place. While one possible configuration of the upper holder 23 and the lower holder 24 is shown, what is contemplated is any type of upper holder 23 and lower holder 24 based on the existing and preferred geometries of commercial irons in the marketplace. For example, if an iron with two noses is commercialized, the upper holder 23 would be made of two different curves 33 . What is also contemplated is the use of any other fixation device to hold the iron 4 in place on the body 10 , including but not limited to magnets, rotating tabs, clipped on parts, sliding parts, and the use of external fixation means.
[0021] In another embodiment shown in FIGS. 4-5 , the wire rack 100 includes an upper holder 23 located on a movable segment 12 of the torso 11 adapted to repose on a segment of a vertical spacing bar 26 on a fixed segment of the torso 11 . FIGS. 4-5 show a series of fixed steps 17 a , 17 b , 17 c , corresponding to the horizontal spacing bars 17 a , 17 b , 17 c in FIGS. 1-3 , which serve the same function of allowing the movable segment 12 to be placed at regular intervals along the torso 11 on the rail 35 . In the embodiment shown in FIGS. 4-5 , the movable segment 12 is not hooked in place but bent into place into the sliding position shown in FIG. 5 . The upper holder 23 is then pushed down as shown by the arrows in FIG. 5 to secure the iron in place. The use of a bent segment with spaced steps 17 a , 17 b , 17 c instead of the horizontal spacing bars is one of many possible embodiments associated with spacing adjustable structures associated with wire frame technology. It is understood that the following disclosure contemplates any possible adjustable technology.
[0022] Finally, FIG. 6 teaches a method for storing ironing equipment, the method comprising the steps of placing a wire rack on a wall 140 , selecting an intermediate position on the retractable rail at a distance sufficient to hold the iron between the upper and lower holders 141 , positioning the lower holder in relation to the upper holder at a distance sufficient to hold the iron 142 , inserting the iron between the upper and lower holders 143 , suspending an ironing board on the legs 144 , and finally, placing extra equipment in the arms 145 .
[0023] It is understood by one of ordinary skill in the art that these steps correspond to the general steps to be taken to practice this method of this disclosure. Other auxiliary steps may be taken to store ironing equipment, but they do not affect the validity and completeness of the disclosure of this general method. Persons of ordinary skill in the art appreciate that although the teachings of the disclosure have been illustrated in connection with certain embodiments and methods, there is no intent to limit the invention to such embodiments and method. On the contrary, the intention of this application is to cover all modifications and embodiments falling fairly within the scope of the teachings of the disclosure. | The present disclosure relates to a wire rack for mounting an iron on a wall and method of use thereof, and more specifically, to a wire rack for mounting an iron on a wall, the wire rack having a retractable rail for adjusting to different sizes of irons and equipped with an ironing board holder and a product holder. The iron holder holds the iron by the iron's base and can be adjusted to accommodate different sizes of irons. The frame is also made of heat-resistant, coated, welded wire that allows for the manufacture of a light, cost-effective device. The device is also equipped with large hooks to hold most types of ironing boards and arms designed to hold extra products used during ironing. | 3 |
BACKGROUND OF THE INVENTION
This invention relates to gas burner controls for furnaces and the like, and in particular to a new and improved pilot burner gas ignitor and main burner valve controller. This system utilizes a pilot burner flame sensor and a control circuit for switching the main burner solenoid valve and the pilot burner spark ignitor circuit.
A typical system of this type is energized when the electrical contacts of a thermostat close in response to a drop in temperature of the area being heated by the gas furnace. When the thermostat switch closes, the pilot burner valve is opened and the spark ignitor circuit provides sparking at the pilot ignitor electrodes and the gas at the pilot burner should ignite. The flame sensor and control circuit detects the existance of the flame and actuates a switching circuit to energize the main burner valve and turn off the spark ignitor circuit. If flame outage occurs, the flame sensing circuitry will detect the absence of flame and close the main burner valve, while at the same time turning on the spark ignitor for reigniting the pilot burner.
Systems of this general type are known, and one such system is shown in U.S. Pat. No. 3,986,813. Other known systems are discussed in said patent.
However, there is a problem with the prior art systems. There is a possibility that the pilot burner will not ignite eventhough the pilot burner valve is open and the ignitor circuit is producing sparks. Under these circumstances, gas continues to flow from the pilot burner. When the fuel is natural gas, there is little problem, since this gas is lighter than air and the unburned gas goes up the flue. However, fuels which are heavier than air such as propane and butane are also being utilized. Under the situation referred to above, the unburned gas being heavier than air will collect in the area around the burners and there is a possibility that this fuel would be ignited by the sparking of the ignitor circuit, producing an undesired explosion.
Therefore, it is an object of the present invention to provide a new and improved ignition control system which will limit the spark ignitor action to a predetermined time, regardless of other conditions of the control system. A further object is to provide such a new and improved control system having fail safe characteristics so that the protection against continuous ignitor operation is achieved eventhough there is failure in the control components.
SUMMARY OF THE INVENTION
The control system of the invention utilizes the now conventional components of a pilot ignition and valve control system including a main burner, a main valve operated by a main solenoid for providing gas to the main burner, a pilot burner, a pilot valve operated by a pilot solenoid for providing gas to the pilot burner, a flame sensor and a flame sensor circuit providing a flame signal, ignition electrodes and an ignition circuit for driving the electrodes, a first switching circuit for controlling the ignition circuit and the main burner, a main valve control circuit for the first switching circuit, and input terminals for connection to the AC power source through the thermostat switch.
The new components of the combination include a storage capacitor, a charging circuit for charging the storage capacitor when the thermostat switch is initially closed and thereafter automatically disconnecting the storage capacitor from the charging circuit so that the closed thermostat switch does not continue to provide a turn on activity, a second switching circuit for providing power to the first switching circuit and the pilot valve solenoid, and a pilot valve control circuit for the second switching circuit. The pilot valve control circuit is actuated by the discharge of the storage capacitor and by the flame signal from the flame sensor depending upon the state of the system. A time delay circuit provides for discharge of the storage capacitor during ignition operation so that ignition operation can proceed for only a predetermined length of time regardless of the conditions at the burners. Ignition operation is initiated by a two-step sequence of first charging and then discharging the storage capacitor thereby providing the desired safety operation.
BRIEF DESCRIPTION OF THE DRAWING
The single FIGURE of the drawing is an electrical schematic of a furnace control incorporating the presently preferred embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The gas flow to a main burner 10 is controlled by a valve 11 actuated by a valve solenoid 12. Gas flow to a pilot burner 13 is controlled by a valve 14 actuated by a valve solenoid 15. A rod type flame sensor 18 and a pair of ignition electrodes 19 are positioned adjacent the pilot burner 13. All of these components may be conventional.
A conventional thermostat switch 21 serves to connect a 24 volt AC power supply across terminals T1, T2 when the main burner is to be turned on. The circuitry of the system includes a turn on control 22, a pilot valve control 23, a main valve control 24, and a spark ignitor 25. The main valve control 24 energizes a relay K1 with a contact set 30 and another contact set 31. The pilot valve control 23 energizes a relay K2 with a contact set 32. Another relay K3 with contact set 33 is included in the turn on control 22. The relays are shown in the unenergized state in the drawing.
The pilot valve control 23 and the main valve control 24 may be conventional and as shown in the drawing correspond to the main valve control 22 of aforesaid U.S. Pat. No. 3,986,813. The spark ignitor 25 may be conventional and as shown corresponds to the spark ignitor of U.S. Pat. No. 3,813,581 and the spark ignitor 23 of the aforesaid U.S. Pat. No. 3,986,813.
In the turn on control 22, the coil of relay K3 is connected in series with capacitor C1 and diode D1 across terminals T1, T2. Capacitor C2 and resistor R1 provide a filtering function for the half wave AC produced by diode D1. When the thermostat switch 21 is closed, capacitor C1 is charged through the coil of relay K3, thereby energizing the relay and moving the arm of contact set 33 up to connect storage capacitor C3 to terminal T1 through resistor R1 and diode D1. When capacitor C1 is charged, current in the coil K3 ceases, the relay is deenergized, and the arm of contact set 33 moves to the low position connecting the storage capacitor C3 to terminal T2. Relay K3 remains in the unenergized position until the thermostat switch 21 is opened and again closed. Resistor R2 provides a discharge path for capacitors C1 and C2 when the system is deenergized. This ensures that C1 will be in a state to accept full charge when the system is energized thus allowing K3 to pull-in momentarily.
Diode D3 is a 15 volt Zener which limits the charge on the capacitor C3. The capacitor C3 is connected to the control electrode of field effect transistor Q1 through the contact set 31, and the resistor-capacitor network of resistors R3, R4, R5 and capicitor C4, C5.
When storage capacitor C3 is charged through diode D1, the left terminal of the capacitor is positive. When relay K3 is deenergized, the left terminal of capacitor C3 is connected to terminal T2 as a reference point, which makes the right terminal of capacitor C3 negative with respect to circuit ground. This negative voltage is connected at the control electrode of transistor Q1 switching it into conduction and this ultimately energizes the coil of relay K2 moving contact set 32 and connecting terminal T1 to point 36. For details of operation of the pilot valve control 23, reference may be had to the aforementioned U.S. Pat. No. 3,986,813. While positive and negative voltages are referred to, it will be realized that negative and positive voltages may be utilized by changing the type of components, and that it is the sequence of polarity change which is significant.
Applying power at point 36 provides power to the spark ignitor 25 through contact set 30, providing sparks at the electrodes 19. Applying power at point 36 also energizes the pilot gas valve solenoid 15 to open pilot valve 14 and provides gas at the pilot burner 13. Power at point 36 also provides power to the main valve control 24.
When a flame is sensed by the flame sensor 18, a flame signal is provided at point 37 providing a negative voltage to the control electrode of the field effect transistor Q2 in the main valve control 24. The main valve control 24 operates in the same manner as the pilot valve control 23 to energize relay K1 and switch power from the spark ignitor 25 to the main gas valve solenoid 12. This opens main valve 11 providing gas to the main burner 10 which is ignited by the flame of the pilot burner 13. The furnace is now in normal operation.
Actuation of relay K1 also actuates contact set 31 to disconnect the storage capacitor C3 and connect the flame signal from point 37 as the input to the pilot valve control 23. Thus, the flame signal from the flame sensor maintains both relay K1 and relay K2 energized thereby maintaining both valve solenoids energized and both valves open. When the thermostat switch 21 opens indicating that heat is no longer required, all power is removed, both solenoids are deenergized and relays K1 and K2 are deenergized.
In the prior art devices, the ignitor circuit was continuously energized until there was a pilot flame. However, the turn on control 22 of the present control system limits the time during which the spark ignitor is energized in the event there is no flame. As discussed previously, capacitor C3 is charged only at the time the thermostat switch 21 is closed and is not charged again until the switch 21 is opened and reclosed. If for any reason relay K3 remains energized or is reenergized, there will be no effective input to the pilot valve control 23, since the negative signal for transistor Q1 is obtained only by connecting the capacitor C3 to the reference point by the contact set 33. When the charged capacitor C3 is connected to the reference point by contact set 33 and to transistor Q1 by contact set 31, the capacitor is discharged through the resistance-capacitance network at a rate determined by the parameters of the network. In the preferred embodiment, the parameters are selected to discharge the capacitor in about 60 seconds. After the capacitor C3 is discharged, there will be no negative signal at transistor Q1 and relay K2 cannot be energized. Hence, if there is no flame sensed within this preset 60 second period, relay K2 cannot be energized until thermostat switch 21 is opened and reclosed. This prevents any continuous operation of the spark ignitor beyond the initial 60 second period.
If a flame out occurs, there will be no flame sensed and no flame signal at point 37. Relay K1 will be deenergized, closing the main burner valve and energizing the ignitor circuit. At the same time, capacitor C3 will again be connected to transistor Q1 through contact set 31 and if there is any charge remaining on capacitor C3, transistor Q1 will be maintained in conduction, maintaining relay K2 energized and maintaining power to the spark ignitor circuit. Under normal conditions, this provides an adequate relight function since the pilot burner is ordinarily ignited in 5 to 10 seconds. Under normal conditions, capacitor C3 will be charged to provide the desired output for about 60 seconds, leaving a substantial charge after initial ignition. Of course a low leakage capacitor is desired. If the flame is not reignited within the time permitted by the further discharge of capacitor C3, the system will be off until the thermostat switch is opened and reclosed.
The turn on control 22 is also safe for failure of components. If the relay K3 fails in the unenergized position, the capacitor C3 cannot be charged. If the relay fails in the energized position, the capacitor C3 cannot be switched to the reference point to provide the proper polarity of voltage to the transistor Q1. Short circuiting or open circuiting or shorting to ground of the various components of the turn on control will prevent the sequence of operations required to achieve the negative voltage at Q1.
Hence, it is seen that the control system of the invention provides for flame ignition and at the same time prevention of continuous sparking when there is no ignition and a fail safe operation for component failure.
Typical values for certain of the components are set out in the following table. Reference may be made to the aforementioned U.S. Patents for typical values of the remaining components.
______________________________________Component Description______________________________________C1 50 mfd capacitorC2 50 mfd capacitorC3 2 mfd capacitorC4 .01 mfd capacitorC5 .01 mfd capacitorR1 1 kohm resistorR2 1.8 kohm resistorR3 1.3 megohm resistor______________________________________ | A system for controlling the pilot and main burner gas valves of a gas furnace or the like, including a pilot spark ignitor and a pilot flame sensor. A main burner valve control circuit for energizing the spark ignitor until a pilot flame is sensed and then energizing the main burner valve solenoid to provide gas to the main burner. A pilot solenoid valve control circuit for controlling application of power to the ignitor circuit and the pilot and main solenoids. A safety turn on control circuit which permits operation of the pilot valve and ignitor circuit for only a limited period of time to provide a fail safe operation of the ignition system. | 5 |
TECHNICAL FIELD
The present invention relates to a bill processing unit storing bills and a gaming machine including the same.
BACKGROUND ART
According to a known arrangement, a plurality of stackers storing stacked bills are provided as bill processing units for storing bills, the type of each bill is specified when it is taken into the machine, and the bills are sorted by type by transporting the bills to the stackers of the respective types (Patent Literatures 1-4). Furthermore, Patent Literature 5 discloses an authenticity determination method taking into account of bill specifications of respective countries, such as ink and paper quality.
CITATION LIST
Patent Literatures
[Patent Literature 1] Japanese Utility-Model Publication No. 6-51967
[Patent Literature 2] Japanese Unexamined Patent Publication No. 2002-352298
[Patent Literature 3] Japanese Unexamined Patent Publication No. 2003-2484
[Patent Literature 4] Japanese Unexamined Patent Publication No. 2003-296794
[Patent Literature 5] Pamphlet of International Publication No, 2009/093717
SUMMARY OF INVENTION
Technical Problem
The known bill processing unit aims at sorting and storing only bills distributed in a particular country or area. For this reason, the known bill processing unit must be adjusted, before used in each country or area, to conduct information processing and to have the mechanical specifications corresponding to the bills distributed in the country or area. It has therefore been desired to conceive of a way to easily change such settings.
An object of the present invention is therefore to provide a bill processing unit in which a change in the specifications of the unit required to correspond to bills distributed in a plurality of countries or areas is easily done, and a gaming machine provided with the bill processing unit.
Solution to Problem
According to the present invention, a bill processing unit includes: a bill slot allowing bills of a plurality of currency circulation zones to be dealt with from an outside; a bill transportation mechanism configured to transport the bills between the bill slot and parts of the bill processing unit; a plurality of bill cases connected to the bill transportation mechanism; a storage configured to store identification data of each of the bill cases and identification data of each of the currency circulation zones in association with one another; a bill reader configured to read information from the bills while the bills are being transported by the bill transportation mechanism; a bill identifying unit configured to identify the currency circulation zone of each of the bills based on bill information data read by the bill reader; and an import control unit configured to specify one of the bill cases associated with the currency circulation zone identified by the bill identifying unit based on the identification data stored in the storage and control the bill transportation mechanism to import the bills to the specified bill case.
According to the arrangement above, because the bills in the currency circulation zone identified by the bill identifying unit are imported to the bill case associated with that currency circulation zone, it is possible to sort the bills in accordance with the currency circulation zones in which the bills are issued and store the bills. With this, it is possible to adjust the device specifications in accordance with the currency circulation zone of the bills simply by, for example, selecting a bill case in consideration of the capacity thereof and the frequency of the use of the bills, in such a way that a bill case having a large capacity is selected for the bills of a frequently-used currency circulation zone, whereas a bill case having a small capacity is selected for the bills of a not-frequently-used currency circulation zone.
According tot present invention, in addition to the above, the bill processing unit may further include: a currency circulation zone classification unit configured to classify sets of information data of the respective currency circulation zones stored in the storage into information data of a particular currency circulation zone and information data of other currency circulation zones; a payout instruction unit configured to receive from the outside an instruction to pay out the bills; and an export control unit configured to specify, in response to an instruction from the payout instruction unit, one of the bill cases associated with the particular currency circulation zone based on the identification data stored in the storage, and control the bill transportation mechanism to export the bills from the specified bill case to the bill slot.
According to the arrangement above, when an instruction to pay out the bills is made to the payout instruction unit from the outside, the bills of the particular currency circulation zone are exported to the bill slot by the bill transportation mechanism. The bills of the particular currency circulation zone are therefore easily received.
According to the present invention, the bill processing unit may further include: a payout amount specifying unit configured to receive a payout amount of the bills from the outside, the export control unit controlling the bill transportation mechanism to export the bills, the number of which corresponds to the payout amount specified in the payout amount specifying unit, to the bill slot.
According to the arrangement above, as the bills the number of which has been specified from the outside, are exported to the bill slot by the bill transportation mechanism, with the result that the bills corresponding to a desired amount of money are received.
According to the present invention, the bill processing unit may be arranged so that the currency circulation zone classification unit sets a currency circulation zone in which the bill processing unit is installed as the particular currency circulation zone.
According to the arrangement above, when an instruction to pay out the bills is made to the payout instruction unit from the outside, the bills of the currency circulation zone in which the bill processing unit is installed, i.e., the bills of the player's country are exported to the bill slot. As such, the bills of the player's country are easily received.
According to the present invention, the bill processing unit may further include: a currency circulation zone selection unit that allows one of the currency circulation zones stored in the storage to be selectable from the outside, the export control unit setting, when one of the currency circulation zones is selected in the currency circulation zone selection unit, the selected one of the currency circulation zones as the particular currency circulation zone.
According to the arrangement above, as the bills of the currency circulation zone selected from the outside are exported to the bill slot, the bills of the desired currency circulation zone are received for a desired amount of money.
According to the present invention, the bill processing unit may further include: a total amount calculation unit configured to calculate the total monetary amount of the bills stored in the bill case; and an export determination unit configured to compare the payout amount specified by the payout amount specifying unit with the total monetary amount in the bill case from which payout is conducted, and prohibit the export control unit from controlling the bill transportation mechanism to conduct export when the payout amount is equal to or larger than the total monetary amount.
According to the arrangement above, it is possible to prevent in advance the occurrence of the case where the bills stored in the bill case run out while the bills are being paid out and the case is refilled with bills.
According to the present invention, the bill processing unit may further include: a countermeasure information output unit configured to, when the export determination unit prohibits the export, output at least one set of countermeasure information regarding the prohibition of the export to be recognizable by an operator who has instructed payout of the bills; a countermeasure information selection unit configured to allow the operator to select a set of the countermeasure information; and a countermeasure information execution unit configured to execute a process associated with the set of countermeasure information selected in the countermeasure information selection unit.
According to the arrangement above, because at least one set of countermeasure information in case of the prohibition of the payout of the bills is presented to the operator, the operator is able to take measures in line with his/her intention.
According to the present invention, the at least one countermeasure information may include: staff person calling information with which a staff person dealing with the bills in the bill cases is called; selection encouragement information with which the operator is encouraged to select another one of the currency circulation zones with which the payout is possible; and payout cancellation information with which the payout of the bills is canceled.
According to the arrangement above, because at least one set of countermeasure information in case of the prohibition of the payout of the bills is selectable by the operator, the operator is able to take measures in line with his/her intention.
According to the present invention, each of the bill cases may include: a storing frame configured to store the bills in a stacked form; a partition plate configured to contact an end of each of the bills stored in the storing frame; and a partition plate supporting mechanism configured to support the partition plate to be movable forward and backward with respect to the end of each of the bills.
Because this allows a bill case of a single type to store differently sized and/or differently shaped bills, the manufacturing cost of the bill case is reduced as compared to cases where bill cases are provided for respective types and sizes of bills.
According to the present invention, a gaming machine may include the bill processing unit arranged as described above.
According to the arrangement above, when installing a gaming machine in each country, only a simple initial setting is required to play games on the gaming machine with bills issued or circulated in each country.
Advantageous Effects of Invention
According to the present invention, a change in device specifications required to correspond to bills distributed in a plurality of countries or areas is easily done.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates an operation state of a bill processing unit mounted on a gaming machine.
FIG. 2 illustrates the internal arrangement of the components in the gaming machine.
FIG. 3 is a perspective view of the bill processing unit.
FIG. 4 is a perspective view of the bill processing unit.
FIG. 5 illustrates the internal structure of the bill processing unit.
FIG. 6 is a plan view of the bill case.
FIG. 7 is a cross section taken along the X-X line in FIG. 6 .
FIG. 8 illustrates how bills are imported into the case bill.
FIG. 9 is a block diagram of the bill processing controller.
FIG. 10 shows a bill management table.
FIG. 11 is an explanatory diagram of a functional flow of the gaming machine.
FIG. 12 is a block diagram of a game system.
FIG. 13 is a perspective view of an entire gaming machine.
FIG. 14 is a block diagram of a PTS system.
FIG. 15 is a block diagram of a PTS system.
FIG. 16 is a perspective view of a slot machine in the gaming machine.
FIG. 17 is an explanatory diagram of a button layout of a control panel.
FIG. 18 is a magnified perspective view of a PTS terminal.
FIG. 19 illustrates a display state of a PTS terminal.
FIG. 20 is an electrical block diagram of the slot machine.
FIG. 21 is an electrical block diagram of a PTS terminal.
FIG. 22 is an electrical block diagram of an IC card.
FIG. 23 is an explanatory diagram of a code No. determination table.
FIG. 24 is an explanatory drawing of a payout control table.
FIG. 25 is an explanatory drawing of a free game quantity table.
FIG. 26 is an explanatory diagram of a display state of a symbol display device.
FIG. 27 illustrates a bill payout screen.
FIG. 28 illustrates a bill payout screen.
FIG. 29 illustrates a payout selection screen and a bill selection screen.
FIG. 30 is a flowchart of a boot process routine.
FIG. 31 is a flowchart of a base game process routine.
FIG. 32 is a flowchart of a base game process routine.
FIG. 33 is a flowchart of a free game process routine.
FIG. 34 is a flowchart of a common game process routine.
FIG. 35 is a flowchart of a bill storing process routine.
FIG. 36 is a flowchart of a payout amount input process routine.
FIG. 37 is a flowchart of an area change process routine.
FIG. 38 is a flowchart of a payout process routine.
FIG. 39 is a flowchart of a bill payment process routine.
FIG. 40 is a flowchart of a bill switching process routine.
FIG. 41 is a flowchart of a bill discharging process routine.
DESCRIPTION OF EMBODIMENTS
(Outline of Bill Processing Unit)
As shown in FIG. 1 and FIG. 2 , a bill processing unit M 1 is arranged to be able to sort bills T that are a type of currency in accordance with each currency circulation zone in a country or area and individually store each type of sorted bills T, and is detachably provided in a cabinet 11 of a slot machine 10 . While the present embodiment assumes that the bill processing unit M 1 is used for the slot machine 10 , the unit may be used for gaming machines other than the slot machine 10 and devices other than gaming machines. Details of the gaming machine having the bill processing unit M 1 and the slot machine 10 will be given later.
To describe the bill processing unit M 1 more specifically, as shown in FIG. 5 , the bill processing unit M 1 includes: a bill slot M 5 that makes it possible to introduce bills T of a plurality of currency circulation zones into the device; a bill transportation mechanism (including components such as a bill transportation path M 3 and transportation rollers M 14 B, 15 B, 16 B, and 17 B) that transports bills T from the bill slot M 5 to various parts in the device; a plurality of bill cases M 300 connected to the bill transportation mechanism; a storage (a ROM M 222 and a RAM M 224 in FIG. 9 and a bill management table in FIG. 10 ) configured to store the identification data of each bill case M 300 and the identification data of a currency circulation zone in association with one another; a bill reader M 8 configured to read information from a bill T while the bill T is being transported by the bill transportation mechanism; a bill identifying unit M 230 shown in FIG. 9 configured to specify the currency circulation zone of a bill T based on bill information data read by the bill reader M 8 ; and an import control unit (a ROM M 222 , a RAM M 224 , and a CPU M 220 in FIG. 9 ) configured to specify which bill case M 300 is associated with the currency circulation zone specified by the bill identifying unit M 230 based on the identification data (storage stage, bill type, or the like) stored in the storage (a bill management table in FIG. 10 ) and control the bill transportation mechanism to import the bill T into the specified bill case M 300 .
It is noted that the term “bill T” is a type of currency. The term “currency” encompasses not only legal currencies issued by governments but also local currencies each used in a particular community and international currencies transacted internationally, such as Euro and United States Dollar. The term “currency circulation zone” indicates a geographical range in which the currency is used for transaction. For example, in case of a currency circulated in a country, the range within the border of the country is the currency circulation zone. In case of a common currency circulated in an area constituted by a plurality of countries, the area is the currency circulation zone. Furthermore, in case of a currency circulated in a region of a country, the region is the currency circulation zone.
The bill processing unit M 1 arranged as above is able to import the bills T associated with the currency circulation zone identified by the bill identifying unit M 230 to the bill case M 300 associated with that currency circulation zone. Bills T are therefore sorted by the currency circulation zone where each bill T was issued and stored. With this, it is possible to adjust the device specifications in accordance with the currency circulation zone of the bills T simply by, for example, selecting a bill case M 300 in consideration of the capacity thereof and the frequency of the use of the bills T, in such away that a bill case M 300 having a large capacity is selected for the bills T of a frequently-used currency circulation zone, whereas a bill case M 300 having a small capacity is selected for the bills T of a not-frequently-used currency circulation zone. In this way, in the bill processing unit M 1 the replacement of the bill case M 300 or the collection of the bills T when the bill case M 300 is fully filled with the bills T is less frequently required, and hence the availability of the device such as the gaming machine is improved.
Furthermore, while a conventional bill processing unit M 1 is designed solely in consideration of bills T in the currency circulation zone in which the unit is installed, the bill processing unit M 1 arranged as described above is designed in consideration of not only bills T in the currency circulation zone in which the unit is installed but also bills T circulated outside that currency circulation zone. This allows foreigners living outside the currency circulation zone to play games without doing troublesome currency exchange from the currencies circulated in their homes.
The bill processing unit M 1 further has an arrangement of paying out bills T of a particular currency circulation zone such as a player's country. More specifically, the bill processing unit M 1 includes: a currency circulation zone classification unit (bill processing controller M 200 shown in FIG. 9 ) configured to classify information data of currency circulation zones stored in a storage into information data of a particular currency circulation zone and information data of other currency circulation zones; a payout instruction unit (a touch panel 720 of a PTS terminal 700 in FIG. 1 ) which is able to receive an instruction from the outside to pay out a bill T; and an export control unit (a bill processing controller M 200 shown in FIG. 9 ) configured to specify a bill case M 300 (storage stage) associated with the particular currency circulation zone based on the identification data stored in the storage, in response to an instruction input to the payout instruction unit, and control the bill transportation mechanism to export a bill T from the specified bill case M 300 to the bill slot M 5 .
In connection with the above, while the payout instruction unit of the present embodiment utilizes the touch panel 720 of the PTS terminal 700 shown in FIG. 1 as an operation panel, an operation panel dedicated to the bill processing unit M 1 may be used as the payout instruction unit.
In the bill processing unit M 1 arranged as above, when, for example, in the bill payout screen F 1 shown in FIG. 27 an instruction to payout a bill T is made from the outside through the payout instruction unit, a bill T in a particular currency circulation zone indicated by the U.S. flag or the like on the currency displaying portion F 2 is exported to the bill slot M 5 by the bill transportation mechanism. As such, the bill T of the particular currency circulation zone is easily receivable.
In addition to the above, the bill processing unit M 1 has an arrangement of specifying a payout amount. More specifically, the bill processing unit M 1 is arranged to include a payout amount specifying unit (e.g., the touch panel 720 of the PTS terminal 700 ) that makes it possible to specify the payout amount of bills T from the outside and the export control unit is arranged to control the bill transportation mechanism such that the bills T, the monetary amount of which has been specified by the payout amount specifying unit, are exported to the bill slot M 5 .
In the bill processing unit M 1 arranged as above, when, for example, a payout amount displaying portion F 3 is pressed in the bill payout screen F 1 shown in FIG. 27 , the bills T the monetary amount of which has been specified from the outside are exported to the bill slot M 5 by the bill transportation mechanism. As such, a desired number of bills T is received.
In addition to the above, the bill processing unit M 1 is arranged to exchange bills T of a player's own currency circulation zone to bills T of a particular currency circulation zone and pay out the exchanged bills T. More specifically, the currency circulation zone classification unit of the bill processing unit M 1 is arranged so that the currency circulation zone where the bill processing unit M 1 is installed is set as the particular currency circulation zone. In the bill processing unit M 1 arranged as above, when an instruction to pay out bills T is made from the outside through the payout instruction unit, bills T of the currency circulation zone where the bill processing unit is installed, i.e., bills T of the player's country is exported to the bill slot M 5 . As such, bills T of the player's own country are easily receivable.
In addition to the above, the bill processing unit M 1 is arranged to be able to specify the currency circulation zone. More specifically, the bill processing unit M 1 includes a currency circulation zone selection unit (such as the touch panel 720 of the PTS terminal 700 ) which makes it possible to select one of currency circulation zones stored in the storage from the outside, and when one of the currency circulation zones is selected by using the currency circulation zone selection unit, the export control unit sets the selected currency circulation zone as the particular currency circulation zone.
In the bill processing unit M 1 arranged as above, when, for example, the currency selection portion F 5 is pressed in the bill payout screen F 1 shown in FIG. 28 , bills T of the externally-selected currency circulation zone are exported to the bill slot M 5 . As such, it is possible to receive a desired monetary amount of bills T of a desired currency circulation zone.
In addition to the above, the bill processing unit M 1 has an arrangement of prohibiting the export of bills T when it is impossible to payout the total amount. More specifically, the bill processing unit M 1 includes a total amount calculation unit (the bill processing controller M 200 in FIG. 9 ) configured to calculate the total monetary amount of bills T stored in the bill case M 300 and an export determination unit (bill processing controller M 200 in FIG. 9 ) configured to compare a payout amount specified by the payout amount specifying unit with the total amount in the bill case M 300 from which the payout is conducted, and prevent the export control unit from instructing the bill transportation mechanism to export when the payout amount is larger than the total amount.
In the bill processing unit M 1 arranged above, it is possible to prevent in advance the occurrence of the case where the bills T stored in the bill case M 300 run out while the bills T are being paid out and the case M 300 is refilled with bills T.
In addition to the above, the bill processing unit M 1 has an arrangement of notifying countermeasure information concerning the export prohibition by sound or image display. More specifically, the bill processing unit M 1 includes: when the export control is prohibited by the export determination unit, a countermeasure information output unit (such as the LCD 719 of the PTS terminal 700 ) configured to output at least one set of countermeasure information regarding the prohibition of the export control to be recognizable by the operator who has instructed the payout of bills T, a countermeasure information selection unit (such as the touch panel 720 of the PTS terminal 700 ) which allows the operator to select a set of countermeasure information, and a countermeasure information execution unit (the bill processing controller M 200 in FIG. 9 ) configured to execute a process associated with the set of countermeasure information selected by the countermeasure information selection unit.
In the bill processing unit M 1 arranged as above, for example, in the payout-impossible screen F 9 shown in FIG. 29 at least one set of countermeasure information when the payout of bills T is prohibited, such as a cancellation button F 72 , a staff person calling button F 71 , and a bill switching button F 73 , is presented to the operator, and hence the operator is able to take measures in line with his/her intention.
In addition to the above, the bill processing unit M 1 has an arrangement of notifying specific functions of sets of countermeasure information regarding the prohibition of export. More specifically, the bill processing unit M 1 is arranged to be able to notify one of the following sets of information as the countermeasure information: staff person calling information for calling a staff person dealing with bills T in the bill cases M 300 ; selection encouragement information encouraging the operator to select a currency circulation zone with which payout is possible; and payout cancellation information with which payout of bills T is canceled. The bill processing unit M 1 arranged as above allows the operator to select a set of specific information of at least one set of countermeasure information concerning the prohibition of the payout of bills T, and hence the operation is able to easily take measures in line with his/her intention.
(Bill Processing Unit: Device Main Body M 2 )
The bill processing unit M 1 arranged as above is installed so that the bill slot M 5 allowing bills T to pass through matches an insertion slot 22 a of the bill entry 22 as shown in FIG. 1 and FIG. 2 . The bill processing unit M 1 includes a device main body M 2 having the bill slot M 5 and a bill housing unit M 100 provided in the device main body M 2 to house bills T therein.
As shown in FIG. 3 , the device main body M 2 includes a main body frame M 2 A and a door member M 2 B arranged to be rationally opened or closed about one end portion of the main body frame M 2 A. The main body frame M 2 A and the door member M 2 B are arranged so that, when the door member M 2 B is closed with respect to the main body frame M 2 A, a gap (bill transportation path M 3 ) where bills T are transported is formed between these members, and the bill slot M 5 is formed to match the bill transportation path M 3 , on the side on which the members are exposed to the front surface. The bill slot M 5 is a slit allowing bills T to be inserted into the device main body M 2 with the short side of each bill T being the leading end.
Furthermore, as shown in FIG. 4 and FIG. 5 , in the device main body M 2 are provided: a bill transportation path M 3 ; a bill transportation mechanism configured to transport bills T along the bill transportation path M 3 ; an insertion detection sensor M 7 configured to detect bills T inserted into the bill slot M 5 ; a bill reader M 8 provided on the downstream of the insertion detection sensor M 7 to read information on each bill T being transported; a skew correction mechanism M 10 configured to precisely position each bill T with respect to the bill reader M 8 ; a movable piece passing detection sensor M 12 configured to detect that a bill T passes through a pair of movable pieces constituting the skew correction mechanism; and an ejection detection sensor M 18 configured to detect that a bill T has been ejected to the bill housing unit M 100 .
Now, the components of the device main body M 2 will be detailed. The bill transportation path M 3 extends toward the rear side from the bill slot M 5 , and includes a first transportation path M 3 A, a second transportation path M 3 B that extends to the downstream from the first transportation path M 3 A and is inclined downward from the first transportation path M 3 A at a predetermined angle, and a third transportation path M 3 C connected to the downstream end of the second transportation path M 3 B. The third transportation path M 3 C is vertically positioned along the rear end face of the bill housing unit M 100 . The third transportation path M 3 C is able to be connected with the leasing end of the bill case M 300 , to allow bills T to be imported to or exported from the bill case M 300 .
The bill transportation mechanism allows bills T having been inserted through the bill slot M 5 to be transported to each bill case M 300 along the insertion direction, and allows bills T being stored in the third transportation path M 3 C or being inserted to be sent back toward the bill slot M 5 . This bill transportation mechanism includes a motor provided in the device main body M 2 as a driving source and transportation roller pairs M 14 A and 14 B, M 15 A and 15 B, M 16 A and 16 B, and M 17 A and 17 B that are rotated by the motor and are provided at predetermined intervals in the bill transportation path M 3 along the bill transportation direction.
The transportation roller pairs are disposed so that a part of the pairs is exposed to the bill transportation path M 3 , and are each arranged so that a transportation roller below the bill transportation path M 3 is driven by the motor whereas a transportation roller M 14 A, 15 A, 16 A or M 17 A provided above the path is a pinch roller driven by the motor-driven roller. A single pair of transportation rollers M 14 A and M 14 B that sandwiches a bill T inserted through the bill slot M 5 first and transports the bill T toward the rear side is provided at a central portion of the bill transportation path M 3 , and pairs of transportation rollers M 15 A and M 15 B, M 16 A and M 16 B, and M 17 A and M 17 B that are serially provided on the downstream of the pair of rollers M 14 A and M 14 B are provided at two parts along the width direction of the bill transportation path M 3 .
In regard to the aforesaid pair of transportation rollers M 14 A and M 14 B in the vicinity of the bill slot M 5 , the pair is normally arranged so that the upper transportation roller M 14 A is detached from the lower transportation roller M 14 B, and the upper transportation roller M 14 A is moved toward the lower transportation roller M 14 B to sandwich an inserted bill T, when the insertion of the bill T is detected by the insertion detection sensor M 7 .
That is to say, the upper transportation roller M 14 A is driven by a roller elevation motor M 70 (see FIG. 9 ) which is a driving source to contact or move away from the lower transportation roller M 14 B. In this regard, when the skew correction mechanism M 10 executes a process (skew correction process) of correcting the tilting of an inserted bill T and aligning the bill T with the bill reader M 8 , the upper transportation roller M 14 A moves away from the lower transportation roller M 14 B to dismiss the load on the bill T, and when the skew correction process ends, the upper transportation roller M 14 A is driven again toward the lower transportation roller M 14 B to sandwich the bill T between the rollers. The driving source may be a solenoid or the like instead of the motor.
In addition to the above, the skew correction mechanism M 10 is provided with a pair of left and right movable pieces M 10 A for skew correction. As a motor M 40 for the skew correction mechanism is driven, the left and right movable pieces M 10 A move close to each other, so that a process of skew correction of the bill T is conducted.
The transportation roller provided below the above-described bill transportation path M 3 is rotationally driven by a motor and a pulley provided at an end of the driving shaft of each transportation roller. That is to say, a driving pulley is attached to the output shaft of the motor, and a driving belt wraps the pulley provided at an end of the driving shaft of each transportation roller and the driving pulley of the motor. The driving belt is engaged with tension pulleys at suitable parts so that the loosening of the belt is prevented.
As the motor rotates forward in the structure described above, the transportation rollers are rotated forward in sync with the motor and transport the bill T in the insertion direction. On the other hand, when the motor rotates backward, the transportation rollers are rotated backward in sync with the motor, and the bill T is transported toward the bill slot M 5 .
The insertion detection sensor M 7 generates a detection signal when detecting a bill T having been inserted into the bill slot M 5 . When the detection signal is output, the motor rotates forward and the bill T is transported in the insertion direction. The insertion detection sensor M 7 of the present embodiment is provided between the pair of transportation rollers M 14 A and M 14 B and the skew correction mechanism M 10 , and is constituted by an optical sensor, e.g., a retro-reflective photo sensor. Alternatively, the sensor M 7 may be constituted by a mechanical sensor.
In addition to the above, the movable piece passing detection sensor M 12 generates a detection signal when a detection result indicates that the leading end of the bill T has passed through the pair of left and right movable pieces M 10 A constituting the skew correction mechanism M 10 . When this detection signal is output, the motor is stopped and the skew correction process is conducted. The movable piece passing detection sensor M 12 of the present embodiment is provided upstream of the bill reader M 8 , and is constituted by an optical sensor or a mechanical sensor in the same manner as the insertion detection sensor.
In addition to the above, the ejection detection sensor M 18 detects the rear end of the passing bill T to find that the bill T is ejected to the bill housing unit M 100 . The sensor M 18 is provided immediately upstream of the bill housing unit M 100 , on the downstream side of the second transportation path M 3 B. Once the ejection detection sensor M 18 outputs the detection signal, the motor is stopped and the process of transporting the bill T is terminated. The ejection detection sensor M 18 is also constituted by an optical sensor or a mechanical sensor in the same manner as the insertion detection sensor.
The bill reader M 8 has a function of reading bill information data from a bill T which is transported after the skew thereof is corrected by the skew correction mechanism M 10 . The bill information data is used not only for the validity (authenticity) of the bill T but also to identify the currency circulation zone of the bill T. In the present embodiment, the bill reader M 8 is arranged to include a line sensor that reads information by applying light to the both sides of the transported bill T and receiving transmitted light and reflected light by light receiving elements. This bill reader M 8 is provided on the first transportation path M 3 A.
(Bill Processing Unit: Bill Housing Unit M 100 )
The device main body M 2 arranged as above is detachably provided with a bill housing unit M 10 . The bill housing unit M 100 is removed from the device main body M 2 in such a way that a handle M 101 on the front surface is pulled after an unillustrated locking mechanism is unlocked.
The bill housing unit M 100 includes a box-shaped cabinet M 100 A and bill cases M 300 provided in the cabinet M 100 A. The cabinet M 100 A has the handle M 101 on its front surface and detachably houses the bill case M 300 therein in a horizontal manner.
As shown in FIG. 6 and FIG. 7 , each bill case M 300 includes a storing frame M 301 storing stacked bills T, a first partition plate M 302 contacting the ends of the bills T stored in the storing frame M 301 , and a first partition plate supporting mechanism M 303 that supports the first partition plate M 302 to be movable with respect to the ends of the bills T. Because this allows a bill case M 300 of a single type to store differently sized and/or differently shaped bills T as the supporting position of the first partition plate M 302 is changed, the manufacturing cost of the bill case M 300 is reduced as compared to cases where bill cases M 300 are provided for respective types and sizes of bills T.
To more specifically describe the bill case M 300 , the storing frame M 301 of the bill case M 300 is rectangular parallelepiped in shape and is open-top to allow a staff person to supply or remove bills T. Alternatively, the storing frame M 301 may have an openable lid on the upper surface.
In addition to the above, a bill passing hole M 301 a is made through the downstream end face of the storing frame M 301 in an import direction A. The bill passing hole M 301 a is open to the third transportation path M 3 C to allow bills T to move between the storing frame M 301 and the third transportation path M 3 C. Furthermore, in the vicinity of the bill passing hole M 301 a , an import/export mechanism M 309 is provided to import and export bills T from and to the storing frame M 301 . This import/export mechanism M 309 may be provided in the bill case M 300 or in the third transportation path M 3 C. The import/export mechanism M 309 is preferably formed as a unit and detachable to the bill case M 300 or the third transportation path M 3 C.
Inside the storing frame M 301 is provided a horizontal supporting plate M 306 supporting the first partition plate M 302 , bills T, or the like. Above the bottom surface of the storing frame M 301 , the horizontal supporting plate M 306 is disposed to be in parallel to the bottom surface of the storing frame M 301 . As the horizontal supporting plate M 306 divides the internal space of the storing frame M 301 into upper and lower spaces, a first housing chamber M 301 A is formed above the supporting plate M 306 and a second housing chamber M 301 B is formed below the supporting plate M 306 .
On the upper surface of the horizontal supporting plate M 306 is provided a first partition plate M 302 that positions the bills T in the longitudinal direction. This first partition plate M 302 is provided upstream of bills T in the import direction A. The first partition plate M 302 includes a bill contacting portion M 302 a that positions the bills T in the import direction A and a partition plate supporter M 302 b supporting the bill contacting portion M 302 a . The bill contacting portion M 302 a is formed so that at least the surface contacting the bills T is flat to be able to contact the entirety of the upstream side of the bills T in the import direction A. The bill contacting portion M 302 a is disposed to be vertical with respect to the horizontal supporting plate M 306 , and is arranged so that the upper end thereof is higher than the height of the maximally-stacked bills T. On the other hand, the partition plate supporter M 302 b is provided at the lower end portion of the bill contacting portion M 302 a . The partition plate supporter M 302 b is formed so that the contacting surface contacting the horizontal supporting plate M 306 is a rectangular flat plate to surface-contact the horizontal supporting plate M 306 , so as to keep the bill contacting portion M 302 a to be vertically positioned.
The first partition plate M 302 described above is supported by the first partition plate supporting mechanism M 303 to be movable forward and backward. The first partition plate supporting mechanism M 303 includes a fitting member M 303 a provided on the lower surface of the partition plate supporter M 302 b and fitting holes M 303 b made through the horizontal supporting plate M 306 . The fitting member 303 a is rectangular parallelepiped in shape and is positioned to be long in the direction orthogonal to the import direction A of bills T. Each fitting hole M 303 b is shaped and sized to be fitted with the fitting member 303 a . The direction in which the fitting hole M 303 b are lined up is in parallel to the import direction A of bills T. With this, the first partition plate supporting mechanism M 303 is able to position the first partition plate M 302 in forward and backward directions with respect to the import direction A, as a fitting hole M 303 b to which the fitting member is fitted is selected.
The fitting holes M 303 b may be provided at regular intervals or provided at intervals corresponding to the sizes of the bills to be stored. When the fitting holes M 303 b are at regular intervals, it is possible to position the first partition plate M 302 to be optimal for many sizes of bills. On the other hand, when the fitting holes M 303 b are provided at intervals corresponding to the sizes of the bills to be stored, the first partition plate M 302 is easily disposed.
In addition to the above, on the upper surface of the horizontal supporting plate M 306 are provided two second partition plates M 307 configured to position the bills T in the width directions. These second partition plates M 307 are disposed to face each other and to be able to contact or get close to the respective ends of the bills T in the width directions.
The second partition plates M 307 are provided to be horizontal with respect to the import direction A, and in each of which at least the surface contacting the bills T has a planar shape. The second partition plates M 307 are disposed to be vertical with respect to the horizontal supporting plate M 306 and the height of the upper end of each plate is arranged to be higher than the height of the maximally-stacked bills T. The second partition plates M 307 are arranged to be symmetrical about the crosswise center line O of the horizontal supporting plates M 306 , and are movable forward and backward with respect to the center line. With this, by adjusting the distance between the second partition plates M 307 , it is possible to set the storage width to be optical for bills T of various sizes.
In addition to the above, as shown in FIG. 8 , the distance between the second partition plates M 307 is wide at the downstream ends in the import direction A. That is to say, each second partition plate M 307 has a guide portion M 307 a at the downstream end portion in the import direction A. The guide portion M 307 a is curved outward in the width direction from the upstream to the downstream in the import direction A. With this, the second partition plates M 307 make it possible to import bills T by guiding the bills T between the second partition plates M 307 without clogging the bills T, even if, at the initial stage of the import of the bills T, the transportation direction and the crosswise transportation position of the bills T are slightly deviated from the correct direction and position.
The second partition plates M 307 are supported by the second partition plate supporting mechanism M 308 . The second partition plate supporting mechanism M 308 includes guide mechanisms M 3081 and a symmetrical movement mechanism M 3082 . The guide mechanisms M 3081 are provided on the upstream side and on the downstream side in the import direction A, respectively. Each guide mechanisms M 3081 includes a guide groove hole M 3081 a formed to extend in the width direction of the horizontal supporting plate M 306 and a fitting member M 3081 b movably fitted to the guide groove hole M 3081 a . The guide groove holes M 3081 a are arranged to be in parallel to each other. The fitting members M 3081 b fitted to the guide groove holes M 3081 a are connected to the lower ends of the second partition plates M 307 . This allows the guide mechanisms M 3081 to move the second partition plates M 307 while keeping the plates to be in parallel to the import direction A.
Between the above-described guide mechanisms M 3081 is provided a symmetrical movement mechanism M 3082 . The important part of the symmetrical movement mechanism M 3082 is provided at the second housing chamber M 301 B below the horizontal supporting plate M 306 . The symmetrical movement mechanism M 3082 includes an insertion hole M 3081 b made through the horizontal supporting plate M 306 , gears M 3083 provided at the crosswise ends of the horizontal supporting plate M 306 to be symmetrical with each other, a chain M 3084 attached to the gears M 3083 , and connecting members M 3086 connecting the chain M 3084 with the second partition plates M 307 .
One connecting member M 3086 is attached to a predetermined part of the chain M 3084 on the upstream in the import direction A. The other connecting member M 3086 is attached to a predetermined part of the chain M 3084 on the downstream in the import direction A. With this, when one of the second partition plates M 307 is moved for a predetermined distance in the width direction, the second partition plate supporting mechanism M 308 moves the other second partition plate M 307 for a predetermined distance in the opposite direction.
(Electrical Structure of Bill Processing Unit)
A bill processing controller M 200 controlling the bill processing unit M 1 will be described with reference to the block diagram in FIG. 9 .
The bill processing controller M 200 illustrated by the block diagram in FIG. 9 includes a control board M 210 controlling the operations of the driving units described above. This control board M 210 controls the operations of the driving units, and on the control board M 210 are mounted a CPU (Central Processing Unit) M 220 , a ROM (Read Only Memory) M 222 , a RAM (Random Access Memory) M 224 , the bill identifying unit M 230 , and a communication unit M 91 constituting a bill identification unit.
The ROM M 222 stores operation programs of the driving units such as the motor M 13 for the bill transportation mechanism, the motor M 20 for driving the pressing plate, the motor M 40 for driving the skew correction mechanism, and the motor M 70 for the roller elevation, and permanent data such as various programs including an authenticity determination program for the a bill identifying unit M 230 and a currency circulation zone determination program.
The CPU M 220 operates in accordance with a program stored in the ROM M 222 to exchange signals with the above-described driving units via an I/O port M 240 so as to perform the overall control of the bill processing unit. That is to say, via the I/O port M 240 , the CPU M 220 is connected to the motor M 13 for the bill transportation mechanism, the motor M 20 for driving the pressing plate, the motor M 40 for driving the skew correction mechanism, and the motor M 70 for the roller elevation, and these driving units are controlled by control signals from the CPU M 220 based on an operation program stored in the ROM M 222 . Furthermore, via the I/O port M 240 , the CPU M 220 receives detection signals from the insertion detection sensor M 7 , the movable piece passing detection sensor M 12 , and the ejection detection sensor M 18 . Based on the detection signals, the above-described driving units are controlled.
Furthermore, via the I/O port M 240 , the CPU M 220 receives a detection signal generated based on transmitted or reflected light from an identification target, from the photo acceptance portion M 81 a of the light emitting/receiving unit M 81 of the bill reader M 8 described above.
The RAM M 224 temporarily stores data and programs used when the CPU M 220 operates, and obtains and temporarily stores light receiving data from a bill T which is the identification target (i.e., image data constituted by pixels).
The bill identifying unit M 230 conducts an authenticity determination process and a currency circulation zone determination process for a bill T to be transported, and determines the authenticity of the bill T and identifies the currency circulation zone and the face value. This bill identifying unit M 230 includes a converter M 231 configured to convert receiving light data of the identification target stored in the RAM M 224 into pixel information including color information (gray level) having brightness for each pixel and a data processing unit M 231 configured to process image data regarding the bill T obtained from the reflected light and the transmitted light based on the pixel information converted by the converter M 231 , such as specifying the print length of the transported bill T and conducting a correction process based on the print length.
In addition to the above, the bill identifying unit M 230 includes a reference data storage unit M 233 storing reference data regarding genuine bills T and a determination process unit M 235 configured to compare comparison data for which various types of data processes regarding the bills T of different face values and currency circulation zones, the authenticity of which is to be determined, have been conducted by the data processing unit M 231 , with reference data which is stored in the reference data storage unit M 233 , and determines the authenticity and specifies the currency circulation zone and the face value of the bill T. In this regard, the reference data storage unit M 233 stores data such as image data regarding genuine bills T used in the authenticity determination process and the currency circulation zone determination process, a reference value of the print length of each type of genuine bills T, and allowable range data indicating an allowable range determined based on the reference value.
While the reference data is stored in the dedicated reference data storage unit M 233 , the reference data may be stored in the ROM M 222 described above. Furthermore, while the reference value and the allowable range data referred to at the time of the comparison may be stored in the reference data storage unit M 233 in advance, receiving light data of a predetermined number of genuine bills may be obtained while transporting them by the bill transportation mechanism M 6 , and a reference value and an allowable range may be calculated form the obtained data and stored as reference data.
In addition to the above, the CPU M 220 is connected to the first light emitting portion M 80 a and the second light emitting portion M 81 b of the above-described bill reader M 8 via the I/O port M 240 . The lighting intervals and the turning-on/off of the first light emitting portion M 80 a and the second light emitting portion M 81 b are controlled by a control signal from the CPU M 220 based on an operation program stored in the above-described ROM M 222 , via the light emission control circuit M 260 .
(Bill Management Table)
FIG. 10 is a table referred to when the types of bills T and the number of stored bills are managed in the bill processing unit M 1 . The bill management table is stored in the RAM M 224 shown in FIG. 9 . The bill management table has a storage stage field, a transportation function field, a bill type field, a maximum number of stored bills field, a number of stored bills field, and an amount of money stored field, and the table associates stored sets of data with these fields.
The storage stage field is a data field used for specifying the bill cases M 300 attached to the bill processing unit M 1 . In the present embodiment, as bill cases M 300 of six stages are attached to be vertically lined up, the bill case M 300 of the uppermost stage is “1” whereas the bill case M 300 of the lowermost stage is “6”. In the meanwhile, when, for example, a single bill case M 300 is sized to be as large as the fourth to sixth stages, the total number of stages is four and hence the bill case M 300 of the uppermost stage is “1” whereas the bill case M 300 of the lowermost stage is “4”.
The transportation function field is a data field indicating the transportation mode of bills T in the bill case M 300 of each stage. When the field indicates “import”, the transportation mode in which bills T are imported to the bill case M 300 is set. When the field indicates “export”, the transportation mode in which bills T are exported from the bill case M 300 is set. When the field indicates “import and export”, the transportation mode in which bills T are imported to and exported from the bill case M 300 .
The bill type field is a data field that indicates a type of a bill T. The type of a bill T includes a bill amount and a currency unit. Based on this type of a bill T, the size of the bill T is specified. The bill amount indicates a face value in a legal currency, an international currency, or a local currency, whereas the currency unit is a unit such as U.S. dollar and yen. For example, the data of the bill type indicates 10 USD, the data indicates that the bill T is U.S. 10 dollar bill, and the bill case is dealt with as a for-one-type storage stage for 10 USD. That is to say, the bill case M 300 of the first stage functions as a for-one-type storage stage storing 10 dollar bills T. When the bill type field indicates “0”, the case is dealt with as a for-mixed-types storage stage for storing any types of bills T. In other words, the for-mixed-types storage stage stores bills T of types that are different from the types of bills T stored in for-one-type storage stages, among the types of bills T registered in advance.
The maximum number of stored bills field is a data field indicating the maximum number of bills stored in the bill case M 300 . For example, when the field indicates “1000”, the bill case M 300 of the corresponding stage can store up to 1000 bills. This data is utilized for determining, for example, a timing to collect the bills T.
The number of stored bills field is a data field indicating the number of currently-stored bills T. The amount of money stored field is a data field indicating the total monetary amount of the stored bills T, and is calculated by multiplying the data in the number of stored bills field by the data in the bill type field.
(Gaming Machine Overview)
The bill processing unit M 1 arranged as above is mounted in a gaming machine. The gaming machine 300 has a multi-player type structure, where a plurality of slot machines 10 each provided as a gaming terminal are connected to a center controller 200 so as to allow data communication therebetween, as shown in FIGS. 11 to 13 . The gaming machine 300 is configured in such a manner that a base game such as slot game is runnable individually at each slot machine 10 , and a common game is runnable in synchronization among each slot machine 10 . Note that the connection between the slot machines 10 and the center controller 200 may be wireless, wired, or a combination of these. Further, a unit of a bet amount may be a national or regional currency such as dollar, yen, and Euro, or a game point passable only at a hall where the gaming machine 300 is installed or an industry related to the gaming machine 300 .
More specifically, the gaming machine 300 includes the slot machines 10 and the center controller 200 . The slot machines 10 each have an input device which accepts an external input, and a terminal controller which runs the base game and which is programmed to execute various steps in order to run a common game executed at more than one of the slot machines 10 . The center controller 200 is connected in communication with the slot machines 10 and is programmed to execute various steps.
The terminal controller of the gaming machine 300 is arranged to be able to execute at least a first process in which a base game is run in response to a start command input to the input device, a second process in which a common game is run in response to a game start command from the center controller 200 , and a third process in which a game result of the common game is determined based on game result information from the center controller 200 .
It is noted that the “common game” is a sub game different from the main game of the gaming machine 300 , and is run along with the basic game or run while the basic game is stopped. Examples of the common game include craps, baseball, and soccer.
The center controller 200 of the gaming machine 300 is arranged to be able to execute at least a first process in which a game start command is output at a predetermined timing to a slot machine 10 which satisfies a game running condition, a second process in which the game result of the common game is determined, and a third process in which the game result determined in the second process is output, as game result information, serially to the slot machines 10 .
The “game running condition” is a condition for being qualified to participate in the common game. Examples of the game running condition include a cumulative value of a base game bet amount equal to or greater than a minimum bet amount, and the number of base game played being equal to or greater than a minimum number of bets. Note that the game running condition can be satisfied at the will of a player before the common game is begun. For example, when the cumulative value of bet amounts in the base game falls short of the minimum bet amount and the game running condition is not satisfied for this reason, the game running condition can be satisfied by paying a bet amount to compensate the differential between the minimum bet amount and the cumulative value of the bet amounts or making a payment for satisfying a predetermined condition, immediately before the common game is started. Further, in cases where the number of base games falls short, the game running condition can be satisfied by payment corresponding to the shortage, or by making a payment for satisfying a predetermined condition.
Further, the “predetermined timing” at which a game start command is outputted is a timing when a common game start condition has been satisfied at any one of the slot machines 10 . Here, examples of the common game start condition include: information of accumulated bet amounts, and an accumulated base game count. Note that the present embodiment is described using the gaming machine 300 having a center controller 200 aside from the slot machines 10 ; however, the present invention is not limited to this. In other words, the gaming machine 300 may be configured in such a manner that at least one slot machine 10 has a function of the center controller 200 , and the slot machines 10 may be connected with each other so as to allow data communication therebetween.
The “slot machines 10 ” each are a type of gaming terminal in the gaming machine 300 . Note that the present embodiment is described using slot machines 10 as an example of gaming terminals; however, the present invention is not limited to this: The present invention may adopt a model which has a terminal controller capable of independently running some base game.
The “base game” in the present embodiment is run by the slot machines 10 . The base game is a slot game where a plurality of symbols 501 are rearranged. Note that the base game is not limited to slot game: The base game may be any type as long as it is independently runnable at gaming terminals such as slot machines 10 .
The rearrangement of the symbols 501 in the slot game is conducted on the symbol display region 614 a of the display 614 . The slot game includes processes of: running a normal game on condition that a game value is bet, in which normal game the symbols 501 are rearranged, and awarding a normal payout according to the symbols 501 rearranged; when the symbols 501 are rearranged on a predetermined condition, running a bonus game where the symbols 501 are rearranged under such a condition that a payout rate thereof is greater than that of the normal game, and awarding a bonus payout according to the symbols 501 rearranged; and when a rescue start condition is met, running a rescue process.
The symbols 501 include “specific symbols 503 ” and “normal symbols 502 .” That is, the “symbols 501 ” is a superordinate conception of the specific symbols 503 and normal symbols 502 . The specific symbols 503 include wild symbols 503 a and trigger symbols 503 b , as shown in FIG. 26 . Each of the wild symbols 503 a is a symbol substitutable for any type of symbols 501 . Each of the trigger symbols 503 b is a symbol which triggers at least a bonus game. That is, a trigger symbol 503 b triggers transition from the normal game to the bonus game, and triggers stepwise increases in the number of specific symbols 503 at an interval from the start of the bonus game. Further, the trigger symbol 503 b triggers increases in the number of specific symbols 503 in the bonus game, that is, the trigger symbol 503 b triggers increases in the number of trigger symbols 503 b and/or wild symbols 503 a . Note that the trigger symbol 503 b may trigger an increase in the number of games in the bonus game.
The “game value” is a coin, a bill T, or electronic valuable information corresponding to these. Note that the game value in the present invention is not particularly limited. Examples of the game value include game media such as medals, tokens, cyber money, tickets, and the like. A ticket is not particularly limited, and a later-mentioned barcoded ticket may be adopted for example.
The “bonus game” has a same meaning as a “feature game.” In the present embodiment, the bonus game is a game in which free games are repeated. However, the bonus game is not particularly limited and may be any type of game, provided that the bonus game is more advantageous than the normal game for a player. Another bonus game may be adopted in combination, provided that a player is given more advantageous playing conditions than the normal game. For example, the bonus game may be a game that provides a player with a chance of winning more game values than the normal game or a game that provides a player with a higher chance of winning game values than the normal game. Alternatively, the bonus game may be a game that consumes fewer amounts of game values than the normal game. In the bonus game, these games may be provided alone or in combination.
The “free game” is a game runnable with a bet of fewer game values than the normal game. Note that “bet of fewer amounts of game values” encompasses a bet of zero game value. The “free game” therefore may be a game runnable without a bet of a game value, which free game awards an amount of game values based on symbols 501 rearranged. In other words, the “free game” may be a game which is started without consumption of a game value. To the contrary, the “regular game” is a game runnable on condition that a game value is bet, which regular game awards an amount of game value based on the symbols 501 rearranged. In other words, the “normal game” is a game which starts with consumption of a game value.
The expression “rearrange” in this specification means dismissing an arrangement of symbols 501 , and arranging symbols 501 once again. “Arrangement” means a state where the symbols 501 can be visibly confirmed by a player.
The phrase “base payout based on the rearranged symbols 501 ” means a normal payout corresponding to a rearranged winning combination. The phrase “bonus payout based on the rearranged symbols 501 ” means a bonus payout corresponding to a rearranged winning combination. Furthermore, the term “winning combination” indicates that a winning is established.
Examples of a “condition in which a payout rate is higher than in the normal game” includes the running of a free game and the running of a game in which the number of wild symbols or trigger symbols is increased or a replaced symbol table is used. In the base game, a rescue process may be executed when a rescue start condition is established.
The “rescue process” is a process for rescuing players. Examples of the rescue process include: running a free game, running a game in which the number of wild symbols or trigger symbols is increased or a replaced symbol table is used, and awarding an insurance payout.
Examples of the “rescue start condition” include a state in which the normal game is excessively repeated, i.e., the normal game is repeated a predetermined number or more times and a state in which the total amount of the obtained payout is excessively small, i.e., the normal payout and the bonus payout that a single player obtained as a result of playing a game a predetermined number or more times are not higher than a predetermined value. The “rescue process” is a process for rescuing players. Examples of the rescue process include the running of a free game, the running of a game in which the number of wild symbols or trigger symbols is increased or a replaced symbol table is used, and the awarding of an insurance payout.
In addition to the above, the gaming machine 300 includes a common display 700 which is installed to be visible from the operating positions of all slot machines 10 . The center controller 200 may cause the common display 700 to display states until the common game start condition is established. It is noted that the “operating position” is the eye-level position of the player at each slot machine 10 . The gaming machine 300 arranged in this way allows each player to estimate the waiting time until the common game starts, by displaying on the common display 700 the states until the common game start condition is established.
(Functional Flow of Gaming Machine 300 : Slot Machine)
The gaming machine 300 having the above structure has slot machines 10 and an external controller 621 (center controller 200 ) connected to the slot machines 10 so as to allow data communication therebetween. The external controller 621 are connected to the slot machines 10 installed in the hall so that data communication is possible therebetween.
The slot machines 10 each include a bet button 601 , a spin button 602 , a display 614 , and a game controller 100 which controls these units. Note that the bet button 601 and the spin button 602 each are a kind of an input device. Further, the slot machine 10 includes a transceiver unit 652 which enables data communication with the external controller 621 .
The bet button 601 has a function of accepting a bet amount through a player's operation. The spin button 602 has a function of accepting a start of a game such as normal game through a player's operation, that is, a start operation. The display 614 has a function of displaying still-image information and moving-image information. Examples of the still-image information are various types of symbols 501 , numeral values, and signs. Examples of the moving-image information include effect video. The display 614 has a symbol display region 614 a , an image display region 614 b , and a common game display region 614 c.
The symbol display region 614 a displays symbols 501 , as shown in FIG. 26 . The image display region 614 b displays various types of effect image information to be displayed during a game, in the form of a moving image or a still image. The common game display region 614 c is a region where a common game such as a jackpot game is displayed.
The game controller 100 includes: a coin insertion/start-check unit 603 ; a normal game running unit 605 ; a bonus game start determining unit 606 ; a bonus game running unit 607 ; a random number sampling unit 615 ; a symbol determining unit 612 ; an effect-use random number sampling unit 616 ; an effect determining unit 613 ; a speaker unit 617 ; a lamp unit 618 ; a winning determining unit 619 ; and a payout unit 620 .
The normal game running unit 605 has a function of running a normal game on condition that the bet button unit 601 has been operated. The bonus game start determining unit 606 determines whether to run a bonus game, based on a combination of rearranged symbols 501 resulted from the normal game. In other words, the bonus game start determining unit 606 has functions of: (i) determining that the player is entitled to a bonus game when one or more trigger symbols 503 b rearranged satisfy a predetermined condition; and (b) activating the bonus game running unit 607 so as to run a bonus game from the subsequent unit game.
Note that a unit game includes a series of operations executed within a period between a start of receiving a bet and a point where a winning may be resulted. For example, bet reception, rearrangement of symbols 501 having been stopped, and a payout process to award a payout are executed once each within a single unit game of the normal game. Note that a unit game in a normal game is referred to as a unit normal game.
The bonus game running unit 607 has a function of running the bonus game which repeats a free game for a plurality of times, merely in response to an operation on the spin button 602 .
The symbol determining unit 612 has functions of: determining symbols 501 to be rearranged based on a random number given from the random number sampling unit 615 ; rearranging the determined symbols 501 in the symbol display region 614 a of the display 614 ; outputting information on rearrangement of the rearranged symbols 501 to the winning determining unit 619 ; and outputting an effect specifying signal to the effect-use random number sampling unit 616 , based on the rearrangement of the symbols 501 .
The effect-use random number sampling unit 616 has functions of: when receiving the effect instruction signal from the symbol determining unit 612 , extracting an effect-use random number; and outputting the effect-use random number to the effect determining unit 613 . The effect determining unit 613 has functions of: determining an effect by using the effect-use random number; outputting image information on the determined effect in the image display region 614 b of the display 614 ; outputting audio and illumination information on the determined effect to the speaker unit 617 and the lamp unit 618 , respectively.
The winning determining unit 619 has functions of: determining whether a winning is achieved when information on symbols 501 rearranged and displayed on the display 614 is given; calculating an amount of payout based on a winning combination formed when it is determined that a winning has been achieved; outputting to the payout unit 620 a payout signal which is based on the payout amount. The payout unit 620 has a function of paying out a game value to a player in the form of a coin, a medal, a credit, or the like. Further, the payout unit 620 has a function of adding credit data to credit data stored on an IC card 500 inserted into a later-described PTS terminal 700 , the credit data to be added corresponding to the credit to be paid out.
In addition to the above, the game controller 100 includes an unillustrated storage unit which stores various types of bet amount data. The storage unit is a storage device which stores data in a rewritable manner, such as a hard disc and a memory.
Further, the game controller 100 has a common game running unit 653 . The common game running unit 653 has functions of: outputting bet amount information to the external controller 621 for each unit base game, the bet amount information being based on a bet amount placed as a bet on a normal game; running a common game in response to a game start command from the external controller 621 ; and accepting a bet input through the bet button unit 601 when the bet input corresponds to common game bet amount data indicating a bet amount bettable on the common game.
Further, the game controller 100 is connected to the PTS terminal 700 . The PTS terminal 700 is, as shown in FIG. 18 , a unit in which components such as a LCD 719 , microphones 704 and 705 , and human detection cameras 712 and 713 are integrated. By mutually communicating with the game controller 100 and the bill processing controller M 200 , the PTS terminal 700 performs, for example, effects in games and permission to the player to instruct the payout of bills T to the bill processing unit M 1 . Particularly, the PTS terminal 700 is provided with a card insertion slot 706 , where an IC card 500 can be inserted. Thus allows a player to use a credit stored on an IC card 500 at a slot machine 10 , by inserting the IC card 500 into the card insertion slot 706 . Note that a mechanical structure of the PTS terminal 700 is detailed later.
Further, when receiving credit data from the PTS terminal 700 , the game controller 100 updates a credit display on the display 614 . Further, when a cash out occurs, the game controller 100 outputs cash-out credit data to the PTS terminal 700 .
The PTS terminal 700 of each of the slot machines 10 constituting the gaming machine 300 is connected in communication with a management server 800 , which performs central management of image downloading, IC cards 500 , and credits.
(Functional Flow of Gaming Machine 300 : External Controller)
The gaming machine 300 arranged as above is connected to an external controller 621 . The external controller 621 has a function of remotely operating and remotely monitoring an operating status of each slot machine 10 and a process such as change in various game setting values. Furthermore, the external controller 621 has a function of determining the common game start condition for each gaming terminal, and running the common game at a plurality of slot machines 10 when a result satisfying the common game start condition is achieved in any one of the gaming terminals.
More specifically, as shown in FIG. 11 , the external controller 621 includes a common game start unit 6213 , a gaming terminal selection unit 6215 , and a transceiver unit 6217 . The common game start unit 6213 has functions of: determining whether the common game start condition is established, based on information of accumulated bet amounts transmitted from each slot machine 10 in each unit base game; outputting a game start command to the slot machines 10 ; and displaying on the common display 700 a screen showing states until the common game start condition is established.
Note that the determination of whether the common game start condition is established is made based on the information of accumulated bet amounts, as well as all the accumulated values which increase according to repetition of the unit base games. For example, the number of base games, the time spent in playing the base game, or the like may be used as the accumulated value.
In addition to the above, the common game start unit 6213 has a function of outputting a game start command to a slot machine 10 in which the accumulated value which increases as the base game is repeated satisfies the game running condition. Accordingly, the common game start unit 6213 does not qualify the one or more slot machines 10 whose accumulated value is less than the minimum setting value to participate in the common game. This motivates the player to proactively repeat base games.
Further, the common game start unit 6213 has functions of monitoring the no-input period during which no start operation is executed, and outputting a game start command to all the slot machines 10 except one or more slot machines 10 whose no-input period equals or exceeds the time-out period. Thus, the common game start unit 6213 is capable of determining that no player is present at a slot machine 10 where no base game is run for a period of time equal to or longer than the time-out period, thus preventing such a slot machine 10 from running the common game.
The gaming terminal selection unit 6215 has a function of selecting a specific slot machine 10 from among the slot machines 10 , and outputting a common game start command signal to the specific slot machine 10 . The transceiver unit 6217 has a function of enabling data communication with the slot machines 10 .
(Entire Structure of Game System)
The following describes a game system 350 having the gaming machine 300 with the above structure.
As shown in FIG. 13 , the game system 350 includes a plurality of slot machines 10 , and an external controller 621 which is connected to the slot machines 10 through communication lines 301 .
The external controller 621 is for controlling the slot machines 10 . In the present embodiment, the external controller 621 is a so-called hall server installed in a game arcade where the plurality of slot machines 10 are provided. Each slot machine 10 is allotted a unique identification number. The external controller 621 distinguishes an origin of data transmitted from each slot machine 10 . Further, the external controller 621 determines transmission destination of data with the identification number when transmitting data to a slot machine 10 .
Note that the game system 350 may be installed in one game arcade where various games take place such as a casino, or between a plurality of game arcades. In a case of the game system 350 being installed in one game arcade, gaming systems 350 may be provided for each floor or each section of the game arcade. The communication line 301 may have a wired or wireless structure. A dedicated line or exchange line may be employed as the communication line 301 .
As shown in FIG. 14 , the game system 350 is divided into three major blocks: a management server block, a customer terminal block, and a staff terminal block. The management server block has a casino hall server 850 , a currency exchange server 860 , a casino/hotel staff management server 870 , and a download server 880 .
The casino hall server 850 manages an entire casino hall where slot machines 10 are installed. The currency exchange server 860 creates currency exchange rate data, based on currency exchange information and the like. The casino/hotel staff management server 870 manages the casino hall, or staff persons of a hotel associated with the casino hall. The download server 880 downloads the newest information such as information or news related to a game, and informs a player to the newest information through the PTS terminal 700 of each slot machine 10 .
Further, the management server block has a member management server 810 , an IC card & money management server 820 , a megabucks server 830 , and an image server 840 .
The member management server 810 manages membership information of a player who plays at the slot machine 10 . The IC card & money management server 820 manages an IC card 500 utilized at the slot machine 10 . Specifically, the IC card & money management server 820 stores broken number cash data in association with an identification code, outputs the broken number cash data to the PTS terminal 700 , and the like. Note that the IC card & money management server 820 creates and manages denomination rate data and the like. The megabucks server 830 manages a megabucks which is a game where a total amount of wagers is utilized as a payout, the wagers being placed at slot machines 10 provided at a plurality of casino halls and the like, for example. The image server 840 downloads a newest image such as an image or news related to a game, and informs the player thereof, through the PTS terminal 700 of each slot machine 10 .
The customer terminal block includes a slot machine 10 , a PTS terminal 700 , and a settlement machine 750 . The PTS terminal 700 is attachable to a slot machine 10 , and is capable of communicating with the management server 800 . The settlement machine 750 performs settlement by converting cash data into cash, stores coins or bills T as cash data onto the IC card 500 , and the like, the cash data being stored on the IC card 500 carried by the player.
The staff terminal block has a staff person management terminal 900 and a member card issuance terminal 950 . The staff person management terminal 900 is provided for a staff person at the casino hall to manage various types of slot machines 10 . Particularly in the present embodiment, the staff person management terminal 900 allows a staff person at the casino hall to check for a possible excess number of IC cards 500 stocked in the PTS terminal 700 , or shortage of IC cards 500 in the PTS terminal 700 . The member card issuance terminal 950 is for a player who plays games at the casino hall to obtain a member card.
The PTS terminal 700 is incorporated in a PTS system, as shown in FIG. 15 . The PTS terminal 700 provided to a slot machine 10 is connected in communication with the game controller 100 , a bill validation controller 890 , and a bill processing controller M 200 of the slot machine 10 .
Through communication with the game controller 100 , the PTS terminal 700 executes an effect of a game with a sound or an image, updates credit data, and the like. Further, through communication with the bill validation controller 890 , the PTS terminal 700 transmits credit data necessary for settlement.
Further, the PTS terminal 700 is connected in communication with the management server 800 . The PTS terminal 700 communicates with the management server 800 through the two lines: a normal communication line and an additional function communication line.
Through the normal communication line, the PTS terminal 700 communicates data such as cash data, identification code data, player membership information, and the like. Meanwhile, through the additional function communication line, the PTS terminal 700 executes communication related to an additional function. In the present embodiment, through the additional function communication line, the PTS terminal 700 executes communication related to an exchange function, and IC card function, a biometric identification function, a camera function, a RFID (Radio Frequency Identification) function which is for executing a solid-matter identification function with radio wave.
(Mechanical Structure of Slot Machine)
The following describes an entire structure of a slot machine 10 with reference to FIG. 16 .
At a slot machine 10 , a coin, a bill T, or electronic valuable information corresponding to these are utilized as game medium. Specifically, credit-related data such as cash data stored on the IC card 500 is utilized in the present embodiment.
The slot machine 10 has a cabinet 11 , a top box 12 provided above the cabinet 11 , and a main door 13 provided on the front face of the cabinet 11 .
The main door 13 is provided with a lower image display panel 141 (display 614 ). The lower image display panel 141 is made of a transparent liquid crystal panel. A screen displayed on the lower image display panel 141 has display windows 150 at its center portion. The display window 150 includes twenty display blocks 28 which are arranged in five columns and four rows. The columns form simulated reels 151 to 155 , each having four display blocks 28 . The four display blocks 28 in each of the simulated reels 151 to 155 are displayed as if all the display blocks 28 are moving downward at various speeds. This enables rearrangement, in a manner that symbols 501 respectively displayed in the display blocks 28 are rotated in a longitudinal direction and stopped thereafter.
Here, as shown in FIG. 26 , payline occurrence columns are provided to the left and the right of the display windows 150 in a symmetrical manner. The payline occurrence column on the left side when viewed from the player includes 25 payline occurrence parts 65 L ( 65 La, 65 Lb, 65 Lc, 65 Ld, 65 Le, 65 Lf, 65 Lg, 65 Lh, 65 Li, 65 Lj, 65 Lk, 65 Ll, 65 Lm, 65 Ln, 65 Lo, 65 Lp, 65 Lq, 65 Lr, 65 LS, 65 Lt, 65 Lu, 65 Lv, 65 Lw, 65 Lx, and 65 Ly).
On the other hand, the payline occurrence column on the right includes 25 payline occurrence parts 65 R ( 65 Ra, 65 Rb, 65 Rc, 65 Rd, 65 Re, 65 Rf, 65 Rg, 65 Rh, 65 Ri, 65 Rj, 65 Rk, 65 Rl, 65 Rm, 65 Rn, 65 Ro, 65 Rp, 65 Rq, 65 Rr, 65 Rs, 65 Rt, 65 Ru, 65 Rv, 65 Rw, 65 Rx, and 65 Ry).
Each payline occurrence part 65 L is paired with one of the payline occurrence parts 65 R. Paylines L are prescribed, each extending from one of the payline occurrence parts 65 L to one of the payline occurrence parts 65 R which are paired with each other. Although there are 25 paylines L in the present embodiment, FIG. 26 only shows one payline L for the sake of easier understanding.
Each payline L is activated when the payline L connects a pair of payline occurrence parts 65 L and 65 R. The payline L otherwise is inactivated. The number of paylines L to be activated is determined based on a bet amount. In such a case where a MAXBET indicating the maximum amount of bet allowed, the maximum number of paylines L, that is, 25 paylines L are activated. An activated payline allows the symbols 501 to establish various types of winning combinations. Details of the winning combinations will be described later.
The present embodiment deals with a case where the slot machine 10 is a so-called video slot machine. However, the slot machine 10 of the present invention may partially adopt a so-called mechanical reel in place of the simulated reels 151 to 155 .
Further, as shown in FIG. 16 , a touch panel 69 is disposed on a front face of the lower image display panel 141 , and a player is able to input various instructions by operating the touch panel 69 . From the touch panel 69 , an input signal is transmitted to the main CPU 71 .
Provided below the lower image display panel 141 is a control panel 30 . In addition to various buttons, the control panel 30 has a coin entry 21 which accepts coins into the cabinet 11 , and a bill entry 22 . The bill entry 22 is connected to the bill processing unit M 1 housed in the device. Details of the bill processing unit M 1 will be given later.
Specifically, the control panel 30 has a reserve button 31 , a collect button 32 , and a game rule button 33 to an upper left region thereof. The control panel 30 further includes a 1-bet button 34 , a 2-bet button 35 , a 3-bet button 37 , a 5-bet button 38 , and a 10-bet button 39 to a middle left region thereof. Moreover, the control panel 30 further includes a play 2 line button 40 , a play 10 lines button 41 , a play 20 lines button 42 , and a play 40 lines button 43 , and a max lines button 44 provided to a lower left region thereof.
Further, the control panel 30 has the coin entry 21 and the bill entry 22 in an upper right region thereof, and a gamble button 45 and a start button 46 in a lower right region thereof.
The reserve button 31 is an operation button used when a player leaves the seat, or when requesting a staff person at the game arcade exchange of money. The collect button 32 is a so-called settlement button which adds credit data related to a credit obtained in various games to credit data stored on the IC card 500 inserted into the PTS terminal 700 . Furthermore, the collect button 32 outputs an image or sound on the PTS terminal 700 to ask whether the settlement is made by bills T for the player. The game rule button 33 is pushed when an operation method of a game or the like is unclear. Pushing the game rule button 33 causes a later-described upper image display panel 131 or the lower image display panel 141 to display various types of help information.
Each time a 1-bet button 34 is pushed, a credit is bet on each active payline L, the credit being currently owned by the player. The 2-bet button 35 is for starting a game with two bets placed on each active payline L. The 3-bet button 35 is for starting a game with three bets placed on each active payline L. The 5-bet button 35 is for starting a game with five bets placed on each active payline L. The 10-bet button 35 is for starting a game with ten bets placed on each active payline L. Thus, pushing which one of 1-bet button 34 , the 2-bet button 35 , the 3-bet button 37 , the 5-bet button 38 , and the 10-bet button 39 determines the amount of bet to be placed on each active payline L.
Pushing the play 2 line button 40 activates paylines L. Pushing the play 10 lines button 40 thus activates 2 paylines. Pushing the play 10 line button 41 activates paylines L. Pushing the play 10 lines button 41 thus activates ten paylines. Pushing the play 20 line button 42 activates paylines L. Pushing the play 20 lines button 42 thus activates twenty paylines. Pushing the play 2 line button 43 activates paylines L. Pushing the play 40 lines button 43 thus activates forty paylines. Pushing the max lines button 44 activates paylines L. Pushing the max lines button 44 thus activates the maximum number of paylines L: fifty paylines L.
The gamble button 45 is for causing transition from the bonus game to a gamble game or the like after the bonus game has ended. Here, the gamble game is run with an obtained credit.
The start button 46 is for starting scrolling of the symbols 501 . The start button 46 also serves as a button for starting a bonus game, adding a credit obtained in the bonus game, and the like. The coin entry 21 is for accepting a coin into the cabinet 11 . The bill entry 22 is structured to allow bills T dealt with in the bill processing unit M 1 in the cabinet 11 to be dealt with from the outside (e.g., by the player).
As shown in FIG. 16 , on a lower front face of the main door 13 , that is, below the control panel 30 is a coin receiving slot 18 for inserting coins, and a belly glass 132 with a character related to the slot machine 10 shown thereon.
Provided on a front face of the top box 12 is the upper image display panel 131 . The upper image display panel 131 is made of a liquid crystal panel, and it constitutes a display. The upper image display panel 131 displays an image related to an effect, or an image showing introduction or rules of the game. Further, the top box 12 is provided with a speaker 112 and a lamp 111 . At the slot machine 10 , an effect is executed with an image display and sound and light output.
Below the upper image display panel 131 is a data displayer 174 and the keypad 173 . The data displayer 174 is made of a fluorescent display, an LED, and the like. The data displayer 174 displays membership data read our from the IC card 500 inserted into the PTS terminal 700 , and data inputted by the player through the keypad 173 , for example. The keypad 173 is for inputting data.
(Mechanical Structure of the PTS Terminal)
Further, between the lower image display panel 141 and the control panel 30 is the PTS terminal 700 . The PTS terminal 700 has an LCD 719 , as shown in FIG. 18 . The LCD 719 is provided to a center portion of the PTS terminal 700 . The LCD 719 displays an effect image which brings an effect into the game, for example. Furthermore, as shown in FIG. 19 , the LCD 719 displays a bill payout screen F 1 .
The bill payout screen F 1 is displayed as an initial screen when the collect button 32 shown in FIG. 17 is pressed. The bill payout screen F 1 includes a specific currency displaying portion F 2 , a key input portion F 3 , a payout amount displaying portion F 3 , and a currency selection portion F 5 . The specific currency displaying portion F 2 is a region where the currency circulation zone of the currency set as the payout target is indicated by a symbol such as a national flag. The key input portion F 3 is a region that allows input of numerical data and various types of key data such as data for confirming an operation and data for instructing cancellation. The payout amount displaying portion F 3 includes a payout amount screen F 41 configured to display numerical data input through the key input portion F 3 and a currency unit screen F 42 configured to display a currency unit. The currency selection portion F 5 is a region where area display images such as national flags indicating the currency circulation zones of payable currencies are selectably displayed.
On the surface of the LCD 719 is provided a touch panel 720 . The touch panel 720 allows the bill payout screen F 1 of the LCD 719 to be recognizable from the outside, so as to allow the PTS terminal 700 to function as an externally-operable operation panel of the bill processing unit M 1 .
Provided to an upper portion of the PTS terminal 700 is human detection cameras 712 and 713 , microphones 704 and 705 , and bass reflex speakers 707 and 708 .
The human detection cameras 712 and 713 detects presence of a player with the camera function thereof, and outputs a signal to a later-described unit controller 730 . The microphones 704 and 705 is utilized for allowing a player to vocally participate in a game, authenticating a player through vocal authentication, and the like. The speakers 707 and 708 execute an effect through a sound, and output a notification sound when an IC card 500 is left. The speakers 707 and 708 also output a notification sound when authentication of an IC card 500 inserted fails. Note that the speakers 707 and 708 is disposed to allow a sound to reach beyond the LCD (to the player) 719 from the back of the LCD 719 through a duct. This saves space where the speakers 707 and 708 are provided.
Further, the PTS terminal 700 is provided with an LED 718 and a card insertion slot 706 . The LED 718 lights up in multiple colors to report the number of IC cards 500 stored in the later-described card stacker 714 . Specifically, the LED 718 lights in yellow when five or fewer IC cards 500 are left, blue when 6 to 24 IC cards 500 are left, and green when 25 or more IC cards 500 are left. Note that when no IC cards 500 is left, or 30 IC cards 500 are left, the LED 718 lights in gray and the ongoing game is halted. Thus, the LED 718 lighting in yellow enables a staff person at the casino hall to immediately determine that there are a few IC cards 500 left so that he/she can replenish IC cards 500 . Meanwhile, the LED 718 lighting in green enables a staff person at the casino hall to immediately determine that the card stacker 714 is full of IC cards 500 left, so that he/she can remove some IC cards 500 therefrom. A staff person inserts his/her exclusive IC card 500 into the card insertion slot 706 when replenishing IC cards 500 . On the other hand, a staff person inserts what is called a replenish card through the card insertion slot 706 to remove 10 IC cards 500 and the replenish card. Accordingly, staff persons are not required to confirm the number of IC cards 500 left in the slot machine 10 on the management server, or actually open the main door 13 of the slot machine 10 to confirm the number of IC cards 500 left. This improves the security of the casino hall.
The card insertion slot 706 has a mechanism which allows insertion and ejection of IC cards 500 . An IC card 500 is inserted with a display unit 510 on its upper side and in such a manner that the IC card 500 faces the direction opposite to the card insertion slot 706 . Further, the IC card 500 is completely inside the slot machine 10 while the player is playing a game. The IC card 500 is ejected in such a manner that the display unit 510 is exposed during settlement. This allows the player to confirm credit-related data such as updated cash data. Note that the IC card 500 is not required to completely stay inside the slot machine 10 while the player is playing a game. Instead, the IC card 500 may be kept in such a manner that the display unit 510 is exposed during the game. This allows the player to constantly confirm the credit being updated during the game. When the human detection cameras 712 and 713 detects absence of the player during credit settlement, the IC card 500 is drawn into the slot machine 10 and kept in the card stacker 714 . This prevents such an occurrence where the IC card stays inserted into the card insertion slot 706 for a long period of time, even when a player having confirmed few credits left on the IC card 500 displayed on the display unit 510 leaves the seat with the IC card 500 purposely left inserted therein. Note that in the present embodiment, that card stacker 714 is capable of holding 30 and fewer IC cards 500 .
As described above, the PTS terminal 700 of the present embodiment is configured as a unit where various devices having the microphone function, the camera function, the speaker function, the display function, and the like are put together integrally. This realizes a small space necessary for the PTS terminal 700 . Accordingly, this prevents such an inconvenience which is possible with each mechanism configured as a single device, where an LCD facing the player hinders the speakers to be provided facing the player.
(Electrical Structure of Slot Machine)
The following describes a circuitry structure of the slot machine 10 , with reference to FIG. 20 .
The gaming board 50 has a CPU 51 , a ROM 52 , a boot ROM 53 which are connected via an internal bus, a card slot 55 corresponding to the memory card 54 , and an IC socket 57 corresponding to a GAL (Generic Array Logic) 56 .
The memory card 54 is of a non-volatile memory, and stores therein a game program and a game system program. The game program includes a program related to progress of a game, and a program for executing an effect with an image and a sound. Further, the game program includes a symbol determination program. The symbol determination program is for determining symbols to be rearranged in the display blocks 28 .
Further, the game program includes: a normal game symbol table data showing a normal game symbol table showing each symbol of each symbol column of the display blocks in association with a code number and a random number; a bonus game symbol table data showing a bonus game symbol table showing each symbol of each symbol column of the display blocks in association with a code number and a random number; symbol number determination table data showing a symbol column determination table; a code number determination table data showing a code number determination table; wild symbol increase amount determination table data showing a wild symbol increase amount determination table; trigger symbol increase amount determination table data showing a trigger symbol increase amount determination table; odds data showing the number and types of symbols to be rearranged on a payline in association with a payout amount; and the like.
Further, the card slot 55 is structured to allow insertion and ejection of a memory card 54 . The card slot 55 is connected to the motherboard 70 through an IDE bus. Thus, it is possible to remove a memory card 54 from the card slot 53 S, write another game program onto the memory card 54 , and insert the memory card 54 back into the card slot 53 S to change the type or content of a game to be run at the slot machine 10 .
The GAL 56 is a type of a PLD (Programmable Logic Device) having an OR fixed array structure. The GAL 56 has input ports and output ports. When an input port receives a predetermined input, corresponding data is outputted through an output port.
Further, the IC socket 57 is structured to allow insertion/removal of the GAL 56 . The IC socket 57 is connected to the motherboard 70 through a PCI bus. The content of a game to be run at the slot machine 10 can be changed by replacing a memory card 54 with another one with another program written thereon, or replacing the program written onto the memory card 54 with another program.
The CPU 51 , the ROM 52 , and the boot ROM 53 connected to each other through internal buses are connected to the motherboard 70 through a PCI bus. The PCI bus transmits signals between the motherboard 70 and the gaming board 50 , and supplies power from the motherboard 70 to the gaming board 50 .
The ROM 52 stores an authentication program. The boot ROM 53 stores a pre-authentication program, a program (boot code) for the CPU 51 to boot the auxiliary authentication program, and the like.
The authentication program is for authenticating a game program and a game system program (falsification check program). The pre-authentication program is for authenticating the authentication program. The authentication program and the pre-authentication program is described along procedures for authenticating (authentication procedure) that program to be authenticated is not falsified.
The motherboard 70 is constituted with a motherboard for market use (printed circuit board with fundamental parts of a personal computer built thereon), and includes a main CPU 71 , a ROM (Read Only Memory) 72 , a RAM (Random Access Memory) 73 , and a communication interface 82 . Note that the motherboard 70 corresponds to the game controller 100 of the present embodiment.
The ROM 72 is made of a memory device such as a flash memory. The ROM 72 stores therein a program such as a BIOS (Basic Input Output System) run by the main CPU 71 , and permanent data. When the main CPU 71 runs the BIOS, predetermined peripheral devices are initialized. Further, the game program and the game system program stored in the memory card 54 are installed via the gaming board 50 . Note that, in the present invention, the ROM 72 may be rewritable or non-rewritable.
The RAM 73 stores data utilized when the main CPU 71 operates, program such as a symbol determination program, and the like. For example, the game program, game system program, and authentication program are stored in the RAM 73 after the programs are installed. Further, the RAM 73 is provided with an operation region for executing the above programs. Examples of the operation region is a region for storing a counter which manages a game count, a bet amount, a payout amount, and a credit amount, and a region for storing a symbol determined by a lottery (code number).
The communication interface 82 is for communicating with the external controller 621 such as a server and the bill processing unit M 1 , through the communication line 301 . Further, the motherboard 70 is connected to a later-described door PCB (Printed Circuit Board) 90 and the main body PCB 110 via USBs. The motherboard 70 is connected to a power supply unit 81 . Further, the motherboard 70 is connected to the PTS terminal 700 via a USB.
When power is supplied from the power supply unit 81 to the motherboard 70 , the main CPU 71 of the motherboard 70 is booted, and power is supplied to the gaming board 50 via the PCI bus and the CPU 51 is booted.
The door PCB 90 and the main body PCB 110 are connected to an input device such as a switch and a sensor, and peripheral devices whose operations are controlled by the main CPU 71 .
The door PCB 90 is connected to the control panel 30 , a reverter 91 , a coin counter 92 C and a cold cathode tube 93 .
The control panel 30 is provided with a reserve switch 31 S, a collect switch 32 S, a game rule switch 33 S, a 1-bet switch 34 S, a 2-bet switch 35 S, a 3-bet switch 37 S, a 5-bet switch 38 S, a 10-bet switch 39 S, a play 2 lines switch 40 S, a play 10 lines switch 41 S, a play 20 lines switch 42 S, a play 40 lines switch 43 S, a max lines switch 44 S, a gamble switch 45 S, and a start switch 46 S, respectively corresponding to the buttons described above. Each switch detects that the corresponding button is pushed by a player, and outputs a signal to the main CPU 71 .
Inside the coin entry 36 is provided with the reverter 91 and the coin counter 92 C. The reverter 91 detects validity of a coin inserted into the coin entry 21 , and discharges those other than genuine coins through a coin payout exit. Further, a coin counter 92 C detects genuine coins accepted, and counts the numbers thereof.
The reverter 91 operates based on a control signal outputted from the main CPU 71 , and distributes genuine coins determined by the coin counter 92 C into a hopper 113 or a not-shown cash box. When the hopper 113 is not full of coins, a valid coin is distributed there. On the other hand, when the hopper 113 is filled with coins, a valid coin is distributed into the cash box.
The cold cathode tube 93 functions as a backlight provided at a back of the upper image display panel 131 and the lower image display panel 141 . The cold cathode tube 93 lights based on a control signal from the main CPU 71 .
The main body PCB 110 is connected to the lamp 111 , the speaker 112 , the hopper 113 , the coin detection unit 113 S, the touch panel 69 , the bill entry 22 , the graphic board 130 , the key switch 173 S, and the data displayer 174 .
The lamp 111 lights based on a control signal outputted from the main CPU 71 . The speaker 112 outputs a sound such as background music, based on a control signal outputted from the main CPU 71 .
The hopper 113 operates based on a control signal outputted from the main CPU 71 , and pays out the number of coins determined to be paid out to a not-shown coin tray through the coin payout exit. The coin detection unit 113 S detects a coin to be paid out from the hopper 113 , and outputs a signal to the main CPU 71 .
The touch panel 69 detects a position touched on the lower image display panel 141 by a player with a finger, and outputs a signal corresponding to the position detected to the main CPU 71 .
The bill entry 22 is for detecting validity of bills T and accepts genuine bills T into the cabinet 11 . The bills T accepted into the cabinet 11 is converted into coins, and credits corresponding to the number of coins calculated are added as credits that the player has.
The graphic board 130 controls display of an image to be displayed on the upper image display panel 131 and the lower image display panel 141 , based on a control signal outputted from the main CPU 71 . The graphic board 130 has a VDP (Video Display Processor) which generates image data, a video RAM which stores the image data generated by the VDP, and the like. Note that the image data utilized when image data is generated by the VDP is included in a game program read out from the memory card 54 and stored in the RAM 73 .
Further, the graphic board 130 is provided with a VDP (Video Display Processor) for generating image data on the basis of a control signal from the main CPU 71 , a video RAM for temporarily storing the image data generated by the VDP, and the like. Note that the image data utilized when image data is generated by the VDP is included in a game program read out from the memory card 54 and stored in the RAM 73 .
The key switch 173 S is provided to the keypad 173 . The key switch 173 outputs a predetermined signal to the main CPU 71 when the player operates the keypad 173 .
Based on a control signal output from the main CPU 71 , the data displayer 174 displays data read by the card reader 172 , or data input through the keypad 173 by the player.
(Electrical Structure of PTS Terminal)
The following describes a structure of a circuitry provided to the PTS terminal 700 , with reference to FIG. 21 .
A PTS controller 720 which controls the PTS terminal 700 is connected to various functional parts as a unit controller 730 its main part. The PTS controller 720 has a CPU 731 , a communication unit 734 , a ROM 733 , and a RAM 732 .
The CPU 731 runs various programs stored in the later-described ROM 733 , executes calculation, and the like. Specifically, the CPU 731 runs a credit update program and converts credit data retrieved from the game controller 100 into cash data, adds the cash data to broken number cash data in the management server 800 , and transmits the data to the IC card 500 .
Further, the CPU 731 runs a human body detection operation program. When the credit amount based on the credit data retrieved by the game controller 100 does not equal to “0,” the CPU 731 determines whether to accept the IC card 500 into the card stacker 714 , with the human detection cameras 712 and 713 .
Further, the CPU 731 runs the authentication program to cross verify an identification code on the IC card 500 and the identification code in the management server 800 .
Further, the CPU 731 runs an audio control program to control a later-described audio control circuit unit 724 based on a result of the authentication. The audio control here refers to such a control where in the case of authentication failure, the CPU 731 controls the audio control circuit unit 724 and reports authentication failure through the speakers 707 and 708 . The communication unit 734 enables communication with the game controller 100 and the bill processing controller M 200 .
Further, the CPU 731 runs a device program to control operations of the LCD 719 , the microphones 704 and 705 , and the speakers 707 and 708 . The CPU 731 runs the LED control program to cause the LED 718 to light in accordance with the remaining number of IC cards 500 .
The ROM 733 is made of a memory device such as a flash memory. The ROM 733 stores therein permanent data to be executed by the CPU 731 . For example, the ROM 733 stores therein a credit update program which re-writes credit data stored on the IC card 500 on the basis of an instruction from the game controller 100 , a human body detection operation program, an authentication program, an audio control program, a device program, and an LED control program.
The RAM 732 temporarily stores therein data necessary for running the various programs stored in the ROM 733 . For example, the RAM 732 stores credit data to be updated, based on a signal from the game controller 100 . Further, the RAM 732 stores the time that a player is detected with the human detection cameras 712 and 713 , and the period of time which is counted from the point that the player is detected.
Further, the unit controller 730 is connected to a human detection camera control unit 722 , an LCD drive unit 723 , an audio control circuit unit 724 , a remaining card detection input unit 727 , a card insertion ejection drive unit 726 , a card detection input unit 725 , an LED drive unit 728 , and a modulator-demodulator unit 721 .
The human detection camera control unit 722 controls the operations of the human detection cameras 712 and 713 , on the basis of an instruction from the unit controller 730 .
The LCD drive unit 723 controls operations of the LCD 719 , on the basis of an instruction from the unit controller 730 .
The audio control circuit unit 724 controls operations of the microphones 704 and 705 , and the speakers 707 and 708 , on the basis of an instruction from the unit controller 730 .
The remaining card detection input unit 727 inputs to the unit controller 730 a signal for determining the remaining number of IC cards 500 stacked in the card stacker 714 determined by the remaining card detection sensor 717 . Here, the remaining card detection sensor 717 has a function of detecting the remaining number of IC cards 500 stacked in the card stacker 714 , with a not-shown infrared detection mechanism or the like, for example.
The card insertion ejection drive unit 726 controls operations of the card insertion ejection mechanism 716 , on the basis of an instruction from the unit controller 730 . Here, the card insertion ejection mechanism 716 has a mechanism for receiving an IC card 500 inside, and a mechanism for ejecting the IC card 500 to outside.
The card detection input unit 725 is for inputting a signal from the card detection sensor 715 to the unit controller 730 . Here, the card detection sensor 715 obtains various types of data such as cash data and an identification code, from the inserted IC card 500 .
The LED drive unit 728 controls operations of the LED 718 on the basis of an instruction from the unit controller 730 , to light the LED 718 .
The modulator-demodulator unit 721 converts a high frequency signal from the antenna 701 to a signal controllable by the unit controller 730 , and converts a signal from the unit controller 730 to a signal transmittable to the IC card 500 through the antenna 701 .
Note that the unit controller 730 , the card insertion ejection drive unit 726 , the card detection input unit 725 , and the modulator-demodulator unit 721 are also referred to as a card unit controller as a unit.
(Electrical Structure of IC Card)
The following describes a circuit of the IC card 500 , with reference to FIGS. 21 and 22 .
The IC card 500 has an antenna 507 , a power control circuit 504 , a modulator-demodulator circuit 508 , a display writing IC 505 , a display driver 506 , and a display portion 510 .
The antenna 507 transmits and receives various signals which belong to the PTS terminal 700 , via the antenna 701 .
The power control circuit 504 has a second voltage increase circuit 531 and a third voltage increase circuit 532 . The second voltage increase circuit 531 raises the voltage of a signal from the antenna 507 to a voltage that the later-described modem circuit 508 can handle. The third voltage increase circuit 532 raises the voltage to a voltage with which the later-described display driver 506 can be driven.
The modem circuit 508 has a transmitter 521 and a detection circuit 522 . The transmitter 521 outputs a signal having a specific frequency, and converts the signal to a signal which the later-described display writing IC 505 can handle, by mixing the signal with a signal received from the antenna 507 . The detection circuit 522 detects a signal received from the antenna 507 .
The display writing IC 505 has a CPU 553 , a credit data memory 552 , and a display controller 551 .
The CPU 553 runs a cash data rewrite and update program to rewrite and update cash data stored in the credit data memory 552 , based on cash data retrieved from the PTS terminal 700 .
Further, the CPU 553 controls the display controller 551 so as to cause the display controller 551 to use the cash data stored in the credit data memory 552 as data for displaying cash data, and to display the cash data on the display portion 510 through the later-described display driver 506 .
The credit data memory 552 stores therein the cash data rewrite and update program, and credit-related data such as cash data, an identification code and cash data for display. Note that the credit-related data stored in the credit data memory 552 is also utilized for calculation and display.
The display controller 551 , based on a control signal from the CPU 553 , retrieves credit data for display stored in the credit data memory 552 , and displays it on the display portion 510 via the display driver 506 .
The IC card 500 has a communication IC 509 . The communication IC 509 has a first voltage increase circuit 543 , a transmitter 546 , a detection circuit 545 , a transmission control unit 544 , a CPU 542 , and an authentication memory 541 . The first voltage increase circuit 543 increases the voltage of terminal-side authentication data retrieved from the PTS terminal 700 to a voltage that the CPU 542 can handle.
The transmitter 546 outputs a signal having a specific frequency, and converts it to a signal that the CPU 542 can handle, by mixing the signal with a signal received from the antenna 507 . The detection circuit 522 detects a signal received from the antenna 507 .
The CPU 542 runs an authentication routine program and transmits an identification code stored in a later-described authentication memory 541 to the PTS terminal 700 , when an authentication request is issued by the PTS terminal 700 . The authentication memory 541 stores therein an authentication routine program used by the CPU 542 and an identification code.
(Symbols, Combinations, and the Like)
The symbols 301 displayed in the display windows 7 A to 7 E of the slot machine 10 forms symbol columns, each of which having twenty-two symbols. As shown in FIG. 23 , one of code numbers 0 to 21 is assigned to each of the symbols constituting each column. Each of the symbol columns is constituted with a combination of symbols of “JACKPOT 7,” “BLUE 7,” “BELL,” “CHERRY,” “STRAWBERRY,” “PLUM,” “ORANGE,” and “APPLE.”
Three successive symbols in each of the symbol columns are respectively displayed (arranged) on an upper stage 7 a , a middle stage 7 b , and a lower stage 7 c of each of the display windows 7 A, 7 B, 7 C, 7 D, and 7 E, to forma symbol matrix of five columns and three rows. When the start button is pressed to start a game after the bet button is pressed, the symbols forming a symbol matrix start scrolling. This scrolling of the symbols stops (rearrangement) after a predetermined period from the beginning of the scrolling (rearrange).
Various kinds of winning combinations are set in advance for each symbol. A winning combination is a combination of stopped symbols on the payline which puts the player in an advantageous state. Examples of an advantageous state include: a state where coins according to a winning combination is paid out, a state where the number of coins to be paid out is added to a credit, a state where a bonus game is started.
For example, a combination on the payline including an “APPLE” symbol serves as a bonus trigger which causes a transition of a gaming mode from a basic game to a bonus game. Further, when a combination including a “CHERRY” symbol is formed on the payline in a basic game, twenty coins (values) are paid out for one bet. When a combination including a “PLUM” symbol is formed on the payline in a basic game, five coins are paid out for one bet.
Here, a bonus game is a gaming state which provides a larger advantage than a basic game. Note that another bonus game may be employed in combination, provided that the other bonus game is advantageous to a player, i.e., the other bonus game is more advantageous than a basic game. For example, a bonus game may be a state where more coins are possibly obtained than the basic game, a state where the probability of obtaining coins is higher than in the basic game, a state where fewer coins are consumed than the basic game, free game, or the like.
(Payout Control Table)
FIG. 24 is a payout control table which controls a payout awarded in accordance to a winning combination. The payout control table is stored in the ROM 242 of the main control board 71 , and a piece of information of a payout is assigned to a type of winning combination. For example, a payout for a winning combination including a “BELL” symbol is “10.” A payout for a winning combination including a “BLUE 7” is “40.” Note that payouts for a basic game and a free game are set to be the same in the present embodiment.
(Free Game Quantity Table)
FIG. 25 is a table referred to when determining the number of free games to be played for the number of points acquired in a common game of a basic game. The points awarded in a common game correspond to the number of free games to be played in the free game quantity table. For example, when the total number of accumulated points is 4, the free games are run 80 times. When the total number of accumulated points is 8, the free games are run 160 times. Thus, by succeeding in a common game in a basic game and acquiring many points, it is possible to continue a free game for a long period of time.
(Display State of Slot Game)
The following specifically describes a display state of the lower image display panel 141 while the slot machine 10 is in operation.
FIG. 26 shows an example of a normal game screen which is a display screen showing a normal game displayed on the lower image display panel 141 .
More specifically, the normal game screen is arranged in a center portion of the symbol display device 16 , and includes: the display window 150 having the five simulated reels 151 to 155 , and the payline occurrence parts 65 L and 65 R which are arranged on both sides of the display window 150 and symmetrical with respect to the display window 150 .
Above the display window 150 are: the credit amount display unit 400 , a broken number cash display unit 403 , the bet amount display unit 401 , a wild symbol count display unit 415 , a trigger symbol count display unit 416 , and the payout display unit 402 . These units 400 , 401 , 415 , 416 , and 402 are sequentially arranged in this order from the left side to the right side when viewed from a player.
The credit amount display unit 400 displays a credit amount. The broken number cash display unit 403 displays a fractional amount of cash. The bet amount display unit 401 displays a bet amount placed on the current unit game. The wild symbol count display unit 415 displays the number of wild symbols 503 a in a unit game in progress. With this, it is possible to notify the player in advance that there are five wild symbols 503 a in the normal game. The trigger symbol count display unit 416 displays the number of trigger symbols 503 b in a unit game in progress. The trigger symbol count display unit 416 displays the number of trigger symbols 503 b in a normal game in progress. The payout display unit 402 displays the number of coins to be paid out when a winning combination is achieved.
Blow the display window 150 are: a help button 410 ; a pay-table button 411 ; a bet unit display unit 412 ; a stock display unit 413 ; and a free game count display unit 414 . These units 410 , 411 , 412 , 413 , and 414 are sequentially arranged in this order from the left side to the right side when viewed from a player.
The help button 410 , when pressed by a player, activates a help mode. The help mode provides a player with information to solve his/her problem regarding the game. The pay-table button 411 , when pressed by a player, activates a payout display mode in which an amount of payout is displayed. The payout display mode displays to the player a guidance screen indicating relation of a winning combination to the payout rate.
The bet unit display unit 412 displays a bet unit (payout unit) at the current point. With the bet unit display unit 412 , the player is able to know that, for example, he/she is allowed to participate in a game with a bet by an increment of one cent.
The stock display unit 413 displays a bonus game carry-over number. Here, the “bonus game carry-over number” means the remaining number of bonus games runnable subsequently to an end of the currently-run bonus game. That is, when the stock display unit 413 displays “3,” three more bonus games are consecutively runnable after the currently-run bonus game. Note that the stock display unit 413 displays the number “0” in the normal game.
The free game count display unit 414 displays the total number of times the bonus game is to be repeated, and how many times the bonus game has been repeated. In other words, when the free game count display unit 414 displays “0 OF 0,” the total number of times free games are to be repeated (“free game total number”) is 0, that is, the game in progress is not a bonus game. Further, when the free game count display unit 414 displays “5 OF 8,” during the bonus game, the free game total number is eight, and the current game in progress is the fifth free game.
(Operation of Setting Bill Processing Unit M 1 )
The following will describe a case where the slot machine 10 having the bill processing unit M 1 is installed in a predetermined currency circulation zone, on the premise of the arrangements above.
To being with, as shown in FIG. 5 , the sizes of bills T in the currency circulation zone in which the slot machine 10 is installed are specified. The frequency of use and the type of use are estimated for each type of the bill T, and the size (stored height) corresponding to the maximum number of bills stored in the bill case M 300 is determined. For example, for frequently-used bills T, a bill case M 300 sized (i.e., having a stored height) as large as plural stages is selected.
Subsequently, for each selected bill case M 300 , the longitudinal and crosswise sizes of bills T to be stored are specified. As shown in FIG. 6 , as the longitudinal size of the bill T is specified, the attaching position of the first partition plate M 302 is adjusted so that the bill T stops at a predetermined position in the import direction A when the bill T is imported into the bill case M 300 . In the meanwhile, as the crosswise size of the bill T is specified, the opposing distance between the second partition plates M 307 is adjusted so that the bill T stops at the central position in the width direction orthogonal to the import direction A. In this connection, as shown in FIG. 6 , the second partition plates M 307 move in a line symmetrical manner about the center line O by the second partition plate supporting mechanism M 308 in the width direction. For this reason, when one of the second partition plate M 307 is moved, the other one of the second partition plate M 307 is moved in the opposite direction for the same distance. As such, the second partition plates M 307 are easily positioned.
After the setting of the bill cases M 300 is completed as above, the bill cases M 300 are attached to the storing frame M 100 A. Subsequently, the storage state of each bill case M 300 is set by means of an unillustrated input terminal, the PTS terminal 700 , or the like. That is to say, as shown in FIG. 10 , for the bill cases M 300 attached to the storing frame M 100 A, the storage stages are serially set from the uppermost stage to the lowermost stage, and the transportation function, the bill type, and the maximum number of stored bills are set. In the meanwhile, in case of a bill case M 300 dedicated for storing bills, the maximum number of stored bills T is set in advance. When the bills T are stored irrespective of the types, “0” is stored in the bill type field.
With this, for example, initial data is written to indicate that the bill case M 300 of the first stage is used for importing and exporting bills T and up to 1000 ten-dollar bills can be stored. In the meanwhile, initial data is written to indicate that the bill case M 300 of the fourth stage is dedicated to the import of bills T, and up to 300 ten-thousand-yen bills can be stored.
As such, it is possible in the bill processing unit M 1 to change the device specifications in accordance with bills T of currency circulation zones by simply changing the device specifications such that the bill cases M 300 are selected in consideration of the frequency of use and the storing capacity of bills T so that a large-capacity bill case M 300 is selected for bills T of a frequently-used currency circulation zone whereas a small-capacity bill case M 300 is selected for bills T of a less-frequency-used currency circulation zone. Therefore in the bill processing unit M 1 the frequency of the replacement of the bill cases M 300 and the collection of the bills T which are required when each bill case M 300 is fully filled with the bills T is restrained, and hence the availability of the slot machine 10 is improved.
(Process Operation of Slot Machine 10 : Boot Process)
The following describes a boot process taking place in the slot machine 1 .
When power is supplied to the slot machine 10 , a boot process routine shown in FIG. 30 takes place in the motherboard 240 and the gaming board 250 . In the present embodiment, a memory card is inserted into the card slot 253 S of the gaming board 250 , and the GAL 254 is attached to the IC socket 254 S.
First, when a power switch is turned on (power is supplied) in the power supply unit 245 , the motherboard 240 and the gaming board 250 are booted. When the motherboard 240 and the gaming board 250 are booted, different processes are respectively carried out in parallel. That is, in the gaming board 250 , the CPU 251 carries out processes of reading a preliminary authentication program stored in the boot ROM 252 , and carrying out preliminary authentication by the preliminary authentication program. Note that the preliminary authentication is a process in which the preliminary authentication program is run to confirm and verify that authentication program is not modified in advance before importing the program into the motherboard 240 (A 1 ).
Meanwhile, in the motherboard 240 , the main CPU 241 runs BIOS stored in the ROM 242 . As a result, the compressed data built in the BIOS is loaded into the RAM 243 (B 1 ). Then, the main CPU 241 runs the BIOS loaded into the RAM 243 , and diagnoses and initializes various kinds of peripheral devices (B 2 ).
Afterwards, the main CPU 241 reads, via PCI bus, the authentication program stored in the ROM 255 , and stores the read authentication program to the RAM 243 (B 3 ). During this step, the main CPU 241 drives a checksum through an ADDSUM method (a standard check function) which is adopted in standard BIOS. Thus, it is confirmed whether or not the authentication program is stored in the RAM 243 without an error.
The main CPU 241 then confirms a component connected to the IDE bus. Then, the main CPU 241 accesses to the memory card 253 inserted into the card slot 253 S via the IDE bus, to read the game program and the game system program from the memory card 253 . In this case, data constituting the game program and the game system program are read in units of four bytes. Then, the main CPU 241 confirms and verifies, according to the authentication program stored in the RAM 243 , that the read game program and the game system program are not falsified (B 4 ).
When the authentication process ends properly, the main CPU 241 writes and stores the authenticated game program and the game system program in the RAM 243 (B 5 ).
The main CPU 241 then accesses to the GAL 254 attached to the IC socket 254 S to read payout rate setting data from the GAL 254 , and stores the data in the RAM 243 (B 6 ). Afterwards, the main CPU 241 reads the country identification information stored in the ROM 255 of the gaming board 250 , and stores the information to the RAM 243 (B 7 ).
With a result of the above authentication process, the main CPU 241 determines whether the program or data is proper (B 8 ). When the program or data is not proper (B 8 , NO), an error signal including ID information to specify a slot machine 10 is output to a centralized control device (not shown). The centralized control device specifies a slot machine 10 in an error state based on the error signal. The centralized control device then instructs a staff person standing by near the slot machine 10 to deal with the error, and stores an error history information containing a date and time and a place when/where the error has occurred, or the like (B 18 ). Then, the error state is informed in the form of an audio output from the speaker 23 of the slot machine 10 , and in the form of light emitted from the light emitting portion 20 . Afterwards, the routine in the motherboard 240 ends.
On the other hand, when the program or data is proper (B 8 , YES), operations of sensors disposed to the slot machine 10 are checked successively (B 9 ). Then, whether or not all the sensors operate properly is determined (B 10 ). When an error is detected in at least one sensor (B 10 , NO), the above mentioned B 18 and B 19 are carried out, and the routine ends thereafter.
On the other hand, when all the sensors operate properly (B 10 , Yes), operations of all drive mechanisms are checked successively (B 11 ). Then, it is determined whether or not all the drive mechanisms operate properly (B 12 ). When an error is detected in at least one driving mechanism (B 12 , NO), the above mentioned B 18 and B 19 are carried out, and the routine ends thereafter. On the other hand, when all the drive mechanisms operate properly (B 12 , Yes), operations of all illuminations are checked successively (B 13 ). Then, it is determined whether or not all the illuminations operate properly (B 14 ). Then, it is determined whether or not all the illuminations operate properly (B 14 ). When an error is detected in at least one illumination (B 14 , No), the above mentioned B 18 and B 19 are carried out, and the routine ends thereafter.
On the other hand, when all the illuminations operate properly (B 14 , Yes), a boot signal indicating that all the illuminations have been booted properly is output to the centralized control device (not shown) or the like (B 15 ). Afterwards, a basic game process is carried out (B 16 ), and this routine ends. The following describes a basic game process in detail.
(Basic Game Process)
FIGS. 31 and 32 are flowcharts showing a process carried out by the main CPU 241 of the slot machine 10 during a basic game of the slot machine 10 . A unit game includes a routine shown in FIGS. 31 and 32 . Note that the slot machine 10 is booted in advance, and a variable used in the main CPU 241 on the game controller 1 side is initialized at a predetermined value. Accordingly, the slot machine 10 is constantly operated.
First, it is determined if there is a remaining credit, i.e., the remaining number of coins having been inserted by the player (S 1 ). Specifically, a credit amount C stored in the RAM 243 is read, and a process according to the read credit amount C is carried out. When the credit amount C is zero (S 1 , NO), the routine ends without any operation of a process since a game cannot be started. Meanwhile, when the credit amount C is equal to or more than one (S 1 , Yes), it is determined that there is at least one credit remaining and the process moves to S 2 .
In S 2 , it is determined whether or not the operation button 11 (bet button) is pressed (S 2 ). When the operation button 11 (bet button) is not pressed for a predetermined time (S 2 , NO), a game condition is set (S 3 ). Specifically, the number of coins to be bet on the payline in the game is determined according to the operation of the operation button 11 (bet button). During this operation, an operation signal sent upon an operation of the operation button 11 is received. According to the number of times that the operation signal is received, the bet on the payline is stored in a predetermined memory area of the RAM 243 . Then, the credit amount C written into the predetermined memory area of the RAM 243 is read. A total bet where the above bet is added is subtracted from the read credit C. The resulting number is stored in the predetermined memory area of the RAM 243 .
Afterwards, it is determined whether or not an operation button 11 (start button) is pressed (S 4 ). When the operation button 11 (start button) is not pressed (S 4 , NO), S 4 is repeated until the bet button 11 is pressed. When the operation button 11 (start button) is pressed (S 4 , YES), it is determined whether or not to start a common game (S 5 ).
On the other hand, when the operation button 11 (bet button) is pressed in S 2 (S 2 , YES), it is determined whether or not a value of the credit amount C is equal to or more than the value of the total bet in the previous game. In other words, it is determined whether or not it is possible to start a game with the operation button 11 (bet button) being pressed. Specifically, pressing of the operation button 11 (bet button) causes reading out of a bet on the payline in the previous game and a credit amount C written in a predetermined memory area of the RAM 243 . According to a relation of the read credit amount C to the bet, a process branches as follows depending on whether the value of the credit amount C is equal to or more than the value of total bet in the previous game. When it is determined that the value of the credit amount C is less than the value of the total bet of the previous game (S 16 , NO), the routine ends without any operation of a process since a game cannot be started.
Meanwhile, when it is determined that the value of the credit amount C is equal to or more than the value of the total bet of the previous game (S 16 , YES), the value of the total bet of the previous game is subtracted from the value of the credit C. Then, the resulting value is stored in a predetermined memory area of the RAM 243 . Afterwards, it is determined whether or not to start a common game (S 5 ).
When it is determined to start a common game (S 6 , YES), a common game start flag is activated (S 7 ). Specifically, data showing that the game start flag activated is written into a storage area of a common game start flag of the RAM 243 . Meanwhile, when it is determined not to start a common game (S 6 , NO), a combination determination process is carried out (S 8 ).
In the combination determination process, a combination of symbols to be stopped on the payline is determined first. Specifically, a command to generate a random number is sent to the random number generation circuit. Then, a random number within a predetermined range which is generated by the random number generation circuit, is sampled. The sampled random number is stored in a predetermined memory area of the RAM 243 .
Although a random number is generated in the random number generation circuit disposed outside the main CPU 241 in the present embodiment, a random number may be generated through an arithmetic process by the main CPU 241 , without the random number generating circuit.
Afterwards, a winning combination table for awarding a payout and a random number table stored in the ROM 242 are read. Those read winning combination table and random number table are stored in a predetermined memory area of the RAM 243 . Still-displaying of symbols is controlled for each reel in accordance with the random number table.
Then, the random number table and the winning combination table stored in the predetermined memory area of the RAM 243 are read. The random number written into the predetermined memory area of the RAM 243 is used as a parameter to refer to the random number table. A combination of symbols to be stopped on the payline is then determined.
When a winning combination is determined, the winning combination table is stored into a predetermined memory area of the RAM 243 . The random number and the winning combination table written in the predetermined memory area of the RAM 243 are read. In accordance with the random number and the winning combination table, a combination of symbols to be stopped and still-displayed are determined. During this process, the main CPU 241 reads out a symbol arrangement table stored from the ROM 242 and stores the table in a predetermined memory area of the RAM 243 . The table is then used as a reference. The determined stop symbol data is stored in a predetermined memory area of the RAM 243 . Alternatively, symbols to be stopped may be determined for each reel by using the random number table.
When a combination of symbols to be stopped on the payline is determined, it is determined whether or not the combination is a winning combination. When the combination of symbols to be stopped on the payline is a winning combination, a flag which indicates that a payout corresponding to the type of the winning combination will be awarded, is activated to generate the payout corresponding to the combination of symbols on the payline forming the determined winning combination. The activated flag indicating that a payout will be awarded, is stored in a predetermined memory area of the RAM 243 . To the contrary, when a combination of symbols to be stopped on the payline is another combination, that is, a losing combination, the flag indicating that a payout will be awarded is not activated.
After the above combination determination process is carried out, reels 30 A to 30 E rotate so as to move symbols 301 in the display windows 7 A to 7 E (S 9 ). Then, the rotation continues for a predetermined time (S 10 ). Then, the rotation of reels 30 A to 30 E automatically stops (S 11 ).
Then, it is determined whether or not a winning combination is formed through the combination determination process in S 8 (S 12 ). Specifically, this is done based on a status of the flag stored in the predetermined memory area of the RAM 243 , which flag indicates a prize according to a combination of symbols on the payline is awarded. When the flag is not activated (S 12 , NO), it is determined that a winning combination is not formed, and the routine ends.
Meanwhile, when the flag is activated (S 12 , YES), it is determined whether or not the winning combination formed in the combination determination process in S 8 includes a “Blue 7.” Specifically, when the winning combination includes a “Blue 7” (S 13 , YES), the routine ends after the number of coins are paid out in accordance to the winning combination (S 17 ).
Meanwhile, when the winning combination does not include a “BLUE 7” (S 13 , NO), it is determined whether or not a common game end flag is activated (S 14 ). Specifically, it is determined whether or not data showing that the common game end flag is activated is written into a common game end flag area of the RAM 243 . S 14 is repeated until the common game end flag is activated (S 14 NO). When the common game end flag is activated (S 14 , YES), a free game process is carried out (S 15 ). Then, the routine ends.
(Free Game Process)
The following describes a free game process with reference to FIG. 33 .
First, N denotes the number of free games (S 101 ). The number of free games is determined according to accumulated points acquired in a common game of a basic game.
Then, whether or not to start a common game is determined (S 102 ). When a common game is determined to start (S 103 , YES), a common game start flag is activated (S 104 ). Specifically, data indicating that the common game start flag is activated is written into a storage area of the RAM 243 for storing the common game start flag. Afterwards, the process moves to S 105 .
Meanwhile, when a common game is determined not to start (S 103 , NO), the process immediately moves to S 105 . Thus, a combination determination process same as above is carried out (S 105 ). A difference in this combination determination process is that the referred random number table is a free game random number table (not shown). Then, reels 30 A to 30 E start to rotate (S 106 ). After a predetermined standby time (S 107 ), an image of stopping the rotation of each of the reels 30 A to 30 E is displayed (S 108 ).
Then, whether or not a winning combination is formed is determined (S 109 ). When a winning combination is not formed (S 109 , NO), the process moves to S 111 . Meanwhile, when a winning combination is formed (S 109 , YES), a game medium according to the winning combination is paid out (S 110 ). Specifically, the number of coins to be paid out for the winning combination is calculated, referring to the payout control table. A credit amount stored in a predetermined memory area of the RAM 243 is then read out. The payout value calculated above is added to the credit. The sum is stored in a predetermined memory area of the RAM 243 , and the stored value is displayed on the credit amount display unit 9 .
In S 111 , 1 is subtracted from N (S 111 ). Then, whether or not a common game end flag is activated is determined (S 112 ). Specifically, it is determined whether or not data showing that the common game end flag is activated is written into the common game end flag area of the RAM 243 . S 112 is repeated when the common game end flag is not activated (S 112 , NO).
When the common game end flag is activated (S 112 , YES), whether N is 0 is determined (S 113 ). When N is not 0 (S 113 , NO), the operation is carried out again from S 102 . On the other hand, when N is 0 (S 113 , YES), the routine ends.
(Common Game Process)
The following describes a common game process with reference to FIG. 34 .
First, a common game screen, which is an effect screen displayed when a common game is not run, is displayed on the upper liquid crystal panel 5 A (S 201 ). Then, whether or not the common game start flag is activated is determined. Specifically, it is determined whether data showing that the common game start flag is activated is written into the game start flag area of the RAM 243 (S 202 ).
When the common game start flag is not activated (S 202 , NO), the routine is terminated. On the other hand, when the common game start flag is activated (S 202 , YES), an effect screen displayed when a common game is run is displayed on an upper liquid crystal panel 5 A (S 204 ).
Thereafter, a common game starts (S 205 ), and whether the player has won in the common game (S 206 ). More specifically, whether to succeed in a common game is determined by using a sampled random number.
Then, it is determined whether or not the player has won in the common game has been determined (S 207 ). When successful (S 207 , YES), the total number of accumulated points is counted up by 1 (S 208 ), and the total number of accumulated points is displayed (S 209 ). Then, it is determined whether or not the common game is run a predetermined number of times (S 210 ). Meanwhile, when the common game is unsuccessful (S 207 , NO), the total number of accumulated points is not counted up, and it is determined whether or not the common game is played for predetermined number of times (S 210 ).
When the common game is not played for predetermined number of times (S 210 , NO), the process is carried out again from S 203 , and a next common game starts. When a common game is repeated for, for example, ten times (S 210 , YES), the screen switches to a basic game screen (S 211 ). After determining the number of times the free game is run (S 212 ), the total number of accumulated points is reset (S 213 ). Then, after activating the common game end flag (S 214 ), this routine ends.
(Bill Storing Process)
When addition to the credit is to be done by means of bills T while the player is playing a slot game or the like as above, as shown in FIG. 1 , a bill T is placed on the bill entry 22 and is then supplied from the insertion slot 22 a to the bill processing unit M 1 . In so doing, the bill processing unit M 1 is executing the bill storing process routine as shown in FIG. 35 to determine whether the bill T has been received (S 301 ). When the bill T supplied to the bill processing unit M 1 is not regarded as a genuine bill because reasons such as it is a counterfeit, does not correspond to any one of the registered types, or is severely damaged, it is determined that the receiving of the bill T is rejected (S 301 : NO), and the routine is terminated.
On the other hand, when it is determined that the bill T supplied to the bill processing unit M 1 is a genuine bill of one of the registered types, the receiving of the bill T is permitted (S 301 : YES) and the bill type data indicating the type of the bill T having been read is obtained (S 302 ). Thereafter, with reference to the bill type field in the bill management table of FIG. 10 , a for-one-type storage stage corresponding to the bill type data is searched for (S 303 ). Then whether a for-one-type storage stage corresponding to the bill type data exists is determined (S 304 ).
When the for-one-type storage stage exists (S 304 : YES), the bill T is stored in the bill case M 300 of the for-one-type storage stage (S 305 ). Thereafter, the number of stored bills data corresponding to the for-one-type storage stage is read from the number of stored bills field of the bill management table, and “1” is added to the number of stored bills data (S 306 ). As the number of stored bills data is multiplied by the face value of the bill T, the monetary amount is calculated and the amount of money stored data in the amount of money stored field of the bill management table is updated (S 307 ).
On the other hand, when there is no corresponding for-one-type storage stage (S 304 : NO), the bill T is stored in the bill case M 300 of the for-mixed-types storage stage, which corresponds to the bill type field of the bill management table, where “0” type data is stored (S 308 ). Thereafter, the number of stored bills data corresponding to the for-mixed-types storage stage is read from the number of stored bills field of the bill management table, and “1” is added to this number of stored bills data (S 309 ).
When the bill T is stored in the for-one-type storage stage or in the for-mixed-types storage stage as described above (S 304 -S 309 ), then whether at least one of the for-one-type storage stage and the for-mixed-types storage stage is full is determined. That is to say, it is determined whether the maximum number of stored bills data in the maximum number of stored bills field of the bill management table matches the number of stored bills data having been incremented by “1” (S 310 ). When the sets of data are unmatched and no stage is full (S 310 : NO), the routine is terminated. On the other hand, when the sets of data are matched and the stage is full (S 310 : YES), a staff person is notified that the stage is full and a maintenance operation such as collection of bills T from the bill case M 300 is required (S 311 ). Then the routine is terminated.
(Bill Storing Process)
Subsequently, when the player wishes to receive the credit in the form of bills T, the collect button 32 shown in FIG. 17 is pressed. In so doing, in the bill processing unit M 1 the payout amount input process routine is being executed as shown in FIG. 36 to determine whether the payout amount input mode is set, with the assumption that a pressure signal from the collect button 32 being a trigger signal of the payout amount input mode (S 321 ). With this, until the collect button 32 is pressed, it is determined that the payout amount input mode is not set (S 321 : NO), and the routine is terminated. On the other hand, when the collect button 32 is pressed and it is determined that the payout amount input mode is set (S 321 : YES), the bill payout screen F 1 is displayed on the LCD 719 of the PTS terminal 700 as shown in FIG. 1 and FIG. 19 (S 322 ).
Thereafter, the receiving of data input through the pressing of the touch panel 720 of the PTS terminal 700 starts (S 323 ). When the data input is made, whether the operation data is an input of numerical data is determined (S 324 ). When the input data is numerical data (S 324 : YES), the bill payout screen F 1 is updated (S 325 ). For example, as shown in FIG. 27 , each time numerical data which is operation data generated when at least one of numeric key buttons “0”-“9” on the bill payout screen F 1 is input, the numerical display on the payout amount displaying portion F 3 is updated from “3” to “34” to “340”.
On the other hand, when the input operation is not an input of numerical data (S 324 : NO), then whether the input is an input of nationality data is determined (S 326 ). When the input is an input of nationality data (S 326 : YES), a later-described area change process is executed (S 327 ). For example, as shown in FIG. 28 , operation data generated by an input through the player's touching of a part of the selected area screen which is the entirety of the currency selection portion F 5 is determined as nationality data, and the area change process is executed.
On the other hand, when the operation data is not nationality data (S 324 : YES), then whether the operation data is confirmation data is determined (S 328 ). When the data is confirmation data (S 328 : YES), a payout process is executed (S 329 ) and then the routine is terminated. On the other hand, when the data is not confirmation data (S 328 : NO), the routine is re-executed from S 322 . For example, as shown in FIG. 27 , until the “ENTER” key button on the bill payout screen F 1 is pressed, the receiving of data input and the processes are repeatedly made executable, and when the “ENTER” key button is pressed, it is determined that the operation data is confirmation data and the results of the processes executed based on the operation data are fixed.
(Bill Storing Process)
When the area change process (S 327 ) is executed in the payout amount input process, as shown in FIG. 37 , whether the operation data is scroll data indicating scrolling is determined (S 341 ). When the data is scroll data (S 341 : YES), after the selected area screen of the currency selection portion F 5 is moved in the scrolling direction (S 342 ), the routine is terminated. For example, as shown in FIG. 28 , when the pressurized point is moved in the crosswise direction in the figure while the pressing of the currency selection portion F 5 is maintained, it is determined that the operation data is scroll data and the selected area screen is moved in the direction in which the pressurized point moves. With this, while an area display image outside the display frame of the currency selection portion F 5 enters the display frame, an area display image having been displayed in the display frame of the currency selection portion F 5 is moved away from the frame.
In the meanwhile, when the data is not scroll data (S 341 : YES), then whether the operation data is selected area data indicating the specification of the selected area is determined (S 343 ). When the data is not selected area data (S 343 : NO), the routine is terminated. On the other hand, when the data is selected area data (S 343 : YES), an exchange rate between the payout currency area and the selected currency area is obtained (S 344 ), and the payout amount is converted based on the exchange rate (S 345 ). Thereafter, the converted payout amount is displayed on the payout amount screen F 41 of the payout amount displaying portion F 3 (S 346 ). Then the currency unit of the selected area is displayed on the currency unit screen F 42 (S 347 ). After the area display image of the selected area is highlighted (S 348 ), the routine is terminated.
With this, for example, as shown in FIG. 28 , when the U.S. national flag which is the U.S. area display image is displayed on the specific currency displaying portion F 2 and the U.S. dollar bills T are specified as the currency to be dealt with, the currency displayed on the payout amount displaying portion F 3 is changed from U.S. dollar to Japanese yen as the player clicks the Japanese national flag which is the Japanese area display image. At the same time, because the specific currency displaying portion F 2 is switched to the Japanese area display image, the change of the currency to be dealt with to Japanese bills T is emphasized. This allows the player to easily notice that the currency unit to be dealt with has been switched to the currency unit of the desired area.
(Payout Process)
As a payout process (S 329 ) is executed in the payout amount input process shown in FIG. 36 , a payout process routine shown in FIG. 38 is executed. To begin with, a payout selection screen F 7 shown in FIG. 27 is displayed (S 361 ). This payout selection screen F 7 includes a card button F 61 and a bill button F 62 . As these buttons 731 a and 731 b are pressed, the receiving of data input is started (S 362 ). Based on the operation data having been input, whether the data is bill selection data is determined (S 363 ). When it is determined that the input data is not bill selection data as the card button F 61 is pressed (S 363 : YES), a card payout process is executed (S 364 ) and an amount of money displayed on the card is transferred. Then the routine is terminated.
On the other hand, when it is determined that the input data is bill selection data as the bill button F 62 is pressed (S 363 : NO), a bill payment process is executed (S 365 ) and then the bill type and the payout amount are determined, and the number of stored bills corresponding to the bill type in bill management table shown in FIG. 10 is updated (S 367 ).
(Bill Payment Process)
When a bill payment process (S 3652 ) is executed in the payout process shown in FIG. 38 , a bill payment process routine shown in FIG. 39 is executed. To begin with, the amounts of money of all storage stages (bill cases M 300 ) corresponding to the currency to be paid out are added up, with the result that the total amount of money stored is calculated (S 381 ). Then whether a payout amount is not larger than the total amount of money stored is determined (S 382 ). When the payout amount is not larger than the total amount of money stored (S 382 : YES), the bill type and the number of bills T to be paid out are determined (S 383 ). Thereafter, a bill payout process is executed and bills T are paid out to the player (S 384 ), and then the routine is terminated.
On the other hand, when the payout amount is larger than the total amount of money stored (S 382 : NO), a payout-impossible screen F 9 shown in FIG. 29 is displayed (S 385 ). The payout-impossible screen F 9 includes a cancellation button F 72 , a staff person calling button F 71 , and a bill switching button F 73 , and the receiving of data input starts as the buttons 731 a and 731 b are pressed (S 386 ). Based on the operation data having been input, whether the input data is cancellation data is determined (S 387 ). When it is determined that the input data is cancellation data as the cancellation button F 72 is pressed ( 387 : YES), the bill payout screen F 1 shown in FIG. 27 is displayed to allow the correction of an amount of money to be paid out (S 388 ), and then the routine is terminated.
On the other hand, when it is determined that the input data is not cancellation data ( 387 : NO), then whether the input data is staff person calling data is determined (S 389 ). When it is determined that the input data is staff person calling data as the staff person calling button F 71 is pressed (S 389 : YES), a staff person calling process is executed (S 390 ) and then the routine is terminated. On the other hand, when it is determined that the input data is not staff person calling data (S 389 : NO), then whether the input data is bill switching data is determined (S 391 ).
When it is determined that the data is not bill switching data (S 391 : NO), the routine is terminated. On the other hand, when it is determined that the data is bill switching data as the bill switching button F 73 is pressed (S 391 : YES), a bill switching process is executed (S 392 ). After the image display is switched to the bill payout screen F 1 (S 393 ), the routine is terminated.
(Bill Switching Process)
As the bill switching process is executed (S 392 ), as shown in FIG. 40 , the image display is switched to a bill selection screen F 8 shown in FIG. 29 (S 401 ). Then a currency circulation zone is specified as a stored currency area based on the currency type of each payable storage stage, and an exchange rate of this stored currency area is obtained (S 402 ). An amount of money of each stored currency area is considered as an individual amount of money stored, and such an individual amount of money stored is converted based on an exchange rate of the payout currency area which is the currency circulation zone where the payout is to be conducted (S 403 ). Thereafter, a stored currency area whose individual amount of money stored is not smaller than the payout amount is specified (S 404 ).
Then whether the number of stored currency areas is not smaller than one is determined (S 405 ). When the number of stored currency areas is smaller than one (S 405 : NO), the payout selection screen F 7 is displayed (S 406 ) and the routine is terminated. On the other hand, when the number of stored currency areas is one or more (S 405 : YES), a bill selection screen F 8 shown in FIG. 29 is displayed (S 407 ). After an area change process is conducted (S 408 ), the routine is terminated.
(Bill Discharging Process)
AS the bill discharging process shown in FIG. 39 is executed (S 384 ), as shown in FIG. 41 , the bill type and the payout amount are obtained (S 421 ), and then a for-one-type storage stage corresponding to the type data is searched for (S 422 ). When a corresponding for-one-type storage stage does not exist (S 423 : NO), a staff person is notified of abnormality (S 424 ). After a game stop instruction is output to the slot machine 10 (S 425 ), the routine is terminated.
On the other hand, when a corresponding for-one-type storage stage exists (S 426 : YES), a single bill T is exported from this for-one-type storage stage (S 426 ). Then the number of stored bills in bill management table shown in FIG. 10 is decremented by “1” (S 427 ), and the amount of money stored is calculated based on the number of stored bills after the decrement (S 428 ). Thereafter, whether the storage stage is empty is determined (S 429 ). When the storage stage is empty (S 429 : YES), a staff person is notified of abnormality (S 424 ) and a game stop instruction is made (S 425 ), and then the routine is terminated. ON the other hand, when the storage stage is not empty (S 429 : NO), then whether the export of all bills has been completed is determined (S 430 ). When the export of all bills has not been completed (S 430 : NO), the routine is re-executed from S 427 . On the other hand, when the export of all bills has been completed (S 430 : YES), the routine is terminated.
The above embodiment thus described solely serves as a specific example of the present invention, and the present invention is not limited to such an example. Specific structures and various means may be suitably designed or modified. Further, the effects of the present invention described in the above embodiment are not more than examples of most preferable effects achievable by the present invention. The effects of the present invention are not limited to those described in the embodiments described above.
Further, the detailed description above is mainly focused on characteristics of the present invention to fore the sake of easier understanding. The present invention is not limited to the above embodiments, and is applicable to diversity of other embodiments. Further, the terms and phraseology used in the present specification are adopted solely to provide specific illustration of the present invention, and in no case should the scope of the present invention be limited by such terms and phraseology. Further, it will be obvious for those skilled in the art that the other structures, systems, methods or the like are possible, within the spirit of the invention described in the present specification. The description of claims therefore shall encompass structures equivalent to the present invention, unless otherwise such structures are regarded as to depart from the spirit and scope of the present invention. Further, the abstract is provided to allow, through a simple investigation, quick analysis of the technical features and essences of the present invention by an intellectual property office, a general public institution, or one skilled in the art who is not fully familiarized with patent and legal or professional terminology. It is therefore not an intention of the abstract to limit the scope of the present invention which shall be construed on the basis of the description of the claims. To fully understand the object and effects of the present invention, it is strongly encouraged to sufficiently refer to disclosures of documents already made available.
The detailed description of the present invention provided hereinabove includes a process executed on a computer. The above descriptions and expressions are provided to allow the one skilled in the art to most efficiently understand the present invention. A process executed in or by respective steps yielding one result or blocks with a predetermined processing function described in the present specification shall be understood as a process with no self-contradiction. Further, the electrical or magnetic signal is transmitted/received and written in the respective steps or blocks. It should be noted that such a signal is expressed in the form of bit, value, symbol, text, terms, number, or the like solely for the sake of convenience. Although the present specification occasionally personifies the processes executed in the steps or blocks, these processes are essentially executed by various devices. Further, the other structures necessary for the steps or blocks are obvious from the above descriptions.
REFERENCE SIGNS LIST
M 1 bill processing unit
M 2 device main body
M 3 bill transportation path
M 5 bill insertion slot
M 6 bill transportation mechanism
M 8 bill reader
M 300 bill case
M 301 storing frame
M 302 first partition plate
M 303 first partition plate supporting mechanism
F 1 bill payout screen
F 2 currency displaying portion
F 3 payout amount displaying portion
F 5 currency selection portion
F 7 payout selection screen
F 8 bill selection screen
F 9 payout-impossible screen | In order to make it easy to change the necessary device specifications when adapted to paper currencies in circulation in a plurality of countries and regions, a paper currency processing device (M 1 ) has: a paper currency slot (M 5 ) which is capable of handling the paper currency (T) of multiple currency circulation regions from the outside of the device; a paper currency transfer mechanism for transferring the paper currency (T) between the paper currency slot (M 5 ) and various locations inside the device; and a plurality of paper currency cases linked to the paper currency transfer mechanism. The paper currency transfer mechanism is controlled in such a manner that the paper currency case associated with a currency circulation area is identified, and the paper currency (T) is transferred into the identified paper currency case. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2006-068277, filed Mar. 13, 2006, 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 a behavior prediction apparatus in consideration of a social value and a method for the same.
[0004] 2. Description of the Related Art
[0005] Recently, global environment problems attract attention. In such circumstances, each company is expected to develop and provide products and services having lower environmental loads and higher social values.
[0006] When the people purchase and use the effective product and service that these companies provide, they may have spare times. If the people do a new behavior in the spare time, the unexpected environmental load that seems to exceed the environmental load reduced by the new product and service may occur. Such a situation is referred to as a rebound effect.
[0007] Accordingly, it is important to reduce not only the direct environmental load of the product and service, but also the environmental load including a behavior occurred newly or not to increase them in order to reduce the environmental load and enhance the social value throughout the entire society.
[0008] In addition, in order for various measures for reducing such an environmental load to be considered, it is necessary to predict beforehand what behavior is done in an unscheduled spare time. In this behavior prediction, since there is a difference in a sequence of behaviors occurring due to circumstances that the spare time occurs, personal preference or habit, such a factor must be considered.
[0009] A life cycle assessment (LCA) prescribed in ISO 14040 is known as a method of evaluating the whole product life cycle from a step of mining for the materials necessary for manufacturing products to a step of disposing used products in a viewpoint of the environmental load. In this LCA, the product life cycle is expressed as an evaluation scenario and evaluated. This evaluation scenario includes user information such as frequency in use as well as maker information such as material composition of a product.
[0010] However, LCA cannot evaluate the product life cycle without the scenario. Further, it has no method for creating a scenario concerning a rebound effect.
[0011] On the other hand, JP-A 2005-327134 (KOKAI) discloses an apparatus for detecting an abnormal situation of a human in a house. This apparatus accumulates behavior patterns of a senior as transition probability to detect behavior abnormality of the senior at home, for example. The apparatus comprises a region sensor to sense a human existing region, a behavior sensor to label the behavior of a human automatically using movement of a human body and a duration thereof, a calculator to calculate transition between regions and behavior transition in the regions, a data storage, and an abnormal determination unit. The abnormal determination unit compares each of a behavior transition in a region in every time zone, a transition between regions every time zone and a staying time in the region with each of normal ones to determine an abnormality from the result of comparison.
[0012] JP-A 2002-352352 (KOKAI) discloses an apparatus of detecting abnormality of a human living behavior pattern, comprising an existence detection unit, an behavior detection unit and a behavior estimation unit, wherein an operation sensing signal can be used as an ON/OFF signal of home electric appliances. The abnormal determination unit comprises an existence detection unit, an operation detection unit and a behavior estimation unit, and determines abnormality by obtaining deviance between the output produced from each unit by ON/OFF of the home electric appliance and statistical data and goodness-of-fit therebetween.
[0013] The IEEJ Trans. E, Vol. 125, No. 6, 2005, pp. 256-264 discloses an apparatus of detecting abnormal situation of a senior at home, comprising a behavior sensor, a region sensor, a behavior pattern calculator, a data storage and an abnormality determination unit. The behavior pattern of the senior is learned from hidden Markov model based on information provided from the behavior sensor and the region sensor. The abnormal determination unit determines whether or not the behavior of the senior is daily by calculating similarity between a behavior pattern and a predictive pattern.
[0014] The above related arts relate to a technique for determining whether or not the current behavior of a human is an abnormality behavior, and do not consider at all to predict a behavior considering a future social worth under a certain circumstance, or to recommend and guide a behavior.
BRIEF SUMMARY OF THE INVENTION
[0015] An aspect of the present invention provides a behavior prediction apparatus comprising: an input unit configured to input sole behaviors of a human and simultaneous occurrence probability of the behaviors; a behavior discrimination unit configured to specify a behavior pattern based on correspondence between behavior patterns including the behaviors corresponding to the simultaneous occurrence probability and input behavior patterns corresponding to actual behaviors of the human; an information generation/recording unit configured to generate behavior history information of the specified behavior pattern within a constant period, and to generate and record information of each of a behavior transition probability of changing from one behavior to another behavior, a behavior time during which the behavior is done and a behavior occurrence probability, for each of the behavior patterns, based on the behavior history information; a behavior prediction unit configured to obtain a starting behavior from the information of the behavior occurrence probability for a prediction period, select another behavior pattern for the starting behavior in order of the behavior occurrence probability based on the information of the behavior occurrence probability, and add the information of the behavior time to the selected behavior pattern to output behavior prediction information corresponding to the prediction period; and a social value calculation unit configured to obtain a social value per unit time, which is due to selection of the starting behavior, using the behavior prediction information, social value unit information prepared for beforehand and the prediction period.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0016] FIG. 1 is a schematic diagram of a behavior prediction apparatus according to a first embodiment.
[0017] FIGS. 2A and 2B are flowcharts for explaining a preprocessing/data recording process and a behavior prediction/recommendation process according to the first embodiment.
[0018] FIG. 3 is a flow chart for explaining a condition input process of a condition input unit according to the first embodiment.
[0019] FIG. 4 is a diagram of explaining an input of simultaneous occurrence condition and development to a possibility matrix according to the first embodiment.
[0020] FIG. 5 is a diagram of explaining a behavior table used for the first embodiment.
[0021] FIG. 6 is a flow chart of explaining a behavior distinction process of a behavior determination unit used for the first embodiment.
[0022] FIG. 7 is a flow chart of explaining a data recording process to a data storage used for the first embodiment.
[0023] FIG. 8 is a diagram showing behavior history data made by a behavior determination unit used for the first embodiment.
[0024] FIG. 9 is a diagram showing the number-of-behavior transition times data generated by a data recording unit used for the first embodiment.
[0025] FIG. 10 is a diagram showing behavior transition probability data generated by a data recording unit used for the first embodiment.
[0026] FIG. 11 is a diagram showing behavior time data generated by a data recording unit used for the first embodiment.
[0027] FIG. 12 is a diagram showing behavior outbreak probability data generated by a data recording unit used for the first embodiment.
[0028] FIG. 13 is a flow chart explaining a behavior prediction process of a behavior predictor used for the first embodiment.
[0029] FIG. 14 is a flow chart explaining a social value computation process of a social value calculation part used for the first embodiment.
[0030] FIG. 15 is a diagram showing an environmental load unit consumption database stored by an environmental load unit consumption data storage unit used for the first embodiment.
[0031] FIG. 16 is a flow chart explaining a recommended behavior selection process of a recommended behavior selector used for the first embodiment.
[0032] FIG. 17 is a diagram showing a screen display of the recommended behavior on a display unit used for the first embodiment.
[0033] FIG. 18 is a flow chart explaining a behavior prediction process of a behavior predictor used for a second embodiment.
[0034] FIG. 19 is a diagram of explaining the second embodiment.
[0035] FIG. 20 is a diagram showing a screen display of recommended behavior on a display unit used for the second embodiment.
[0036] FIG. 21 is a schematic diagram of a behavior prediction apparatus according to the third enforcement.
[0037] FIG. 22 is a flow chart of explaining a behavior prediction process of a behavior predictor used for the third embodiment.
[0038] FIG. 23A is a diagram of explaining a flow of cooperative processing of the third embodiment.
[0039] FIGS. 23B and 23C are diagrams showing schedule information.
[0040] FIG. 24 is a schematic diagram of a behavior prediction apparatus according to a fourth embodiment.
[0041] FIG. 25A is a diagram of explaining a flow of cooperative processing of the fourth embodiment.
[0042] FIGS. 25B and 25C are diagrams showing schedule information.
[0043] FIG. 26 is a diagram showing a consumption calorie unit consumption database stored in a consumption calorie unit consumption data storage used for a sixth embodiment.
[0044] FIG. 27 is a flow chart explaining a social value computation process of a social value calculation unit used for the sixth embodiment.
[0045] FIG. 28 is a flow chart explaining a recommended behavior selection process of a recommended behavior selector used for the sixth embodiment.
[0046] FIG. 29 is a diagram showing a domestic accident occurrence probability data stored in an accident concurrent probability database storage used for a seventh embodiment.
[0047] FIG. 30 is a flow chart of explaining a social value computation process of a social value calculation unit used for the seventh embodiment.
[0048] FIG. 31 is a flow chart of explaining a recommended behavior selection process of a recommended behavior selector used for the seventh embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0049] There will now be described embodiments in accordance with accompanying drawings hereinafter.
[0050] According to an embodiment shown in FIG. 1 , a behavior prediction apparatus comprises a condition input unit 1 , a behavior discrimination unit 2 , a signal input unit 3 , a data recorder 4 , a data storage unit 5 , a behavior predictor 6 , a society value calculator 7 , a recommendation behavior selector 8 , a result output unit 9 , a display 10 , a key input unit 11 and a memory 12 .
[0051] This behavior prediction apparatus executes preprocessing/data recording shown in FIG. 2A and a behavior prediction/recommendation process shown in FIG. 2B . According to the preprocessing/data recording shown in FIG. 2A , a condition before data recording is input in step 201 .
[0052] The condition input process will be described referring to FIG. 3 . At first, a constrain relating to simultaneous occurrence probability of behaviors is input for creating a behavior corresponding table concerning a sole behavior (step 301 ). In this case, the condition input unit 1 inputs behaviors that an object person can take solely and simultaneous occurrence probability of these behaviors, using the key input unit 11 .
[0053] Referring to FIG. 4 , the input of simultaneous occurrence condition and development to a simultaneous occurrence probability matrix will be described. As for a simultaneous occurrence probability matrix S 1 , the sole behavior of the object person, a physical constraint concerning the simultaneous occurrence behaviors and condition such as personal taste/custom are input in a form of triangular matrix. The physical constraint is a case that since instruments to be used in an actual behavior are separated in distance, they cannot be operated at the same time physically. The condition such as personal taste/custom is a case that the behaviors do not occur at the same time intentionally (for example, a person does not watch television while eating).
[0054] In the simultaneous occurrence probability matrix S 1 , since the sole behaviors that the object person can take are input to the row and column of the matrix, the data capable of occurring at the same time and corresponding to the physical constraint and the condition such as personal taste/custom are input at intersection points of row and column of the simultaneous occurrence probability matrix S 1 . For example, “1” data is input between behavior patterns capable of being occurred at the same time or behavior patterns that want to be occurred at the same time, and “0” data is input between behavior patterns incapable of being occurred at the same time.
[0055] According to an example directed to behaviors at home as shown in FIG. 4 (A), the television watching can do with one of cooking, dryer use, eating, dressing and tableware washing at the same time, and thus “1” data is input. Similarly, since radio listening can do with one of cooking, eating and tableware washing at the same time, “1” data is input.
[0056] The condition on the simultaneous occurrence behaviors is input through the condition input unit 1 from the key input unit 11 , and added as behavior patterns with simultaneous occurrence probability to a behavior corresponding table 2 a described hereinafter. In addition, if there are desired simultaneous occurrence behaviors to be brought in beforehand, they may be registered on the simultaneous occurrence probability matrix S 1 as simultaneous occurrence probability without relation to the personal taste/custom.
[0057] A simultaneous occurrence probability matrix S 2 of three or more sole behavior patterns is developed to the memory 12 (step 302 ). In this case, the simultaneous occurrence probability matrix S 1 shown in FIG. 4 (A) is developed to the simultaneous occurrence probability matrix S 2 shown in FIG. 4 (B) using a method described hereinafter.
[0058] At first, sets of the simultaneous occurrence behaviors indicated by data “1” input to the simultaneous occurrence probability matrix S 1 are added to the row of the simultaneous occurrence probability matrix S 2 . In this example, there are prepared a set of television watching and cooking, a set of television watching and dryer, a set of television watching and eating, a set of television watching and tableware washing, a set of cooking and radio listening, a set of eating and radio listening, a set of tableware washing and radio listening.
[0059] The condition input unit 1 detects sole behaviors configuring simultaneous occurrence behaviors and correspondence between the simultaneous occurrence behaviors, and inputs a value of “0” to the correspondence. Further, remaining correspondence, namely, simultaneous occurrence probability of three kinds of different behaviors is calculated as a logical product of simultaneous occurrence probabilities of sole behaviors configuring the simultaneous occurrence behaviors and a new behavior. For example, the simultaneous occurrence probability of [television watching & cooking] and dryer use shown in FIG. 4 (B) is calculated as a logical product “0” of simultaneous occurrence probabilities “1” and “0” of the set of television watching and dryer use and the set of cooking and dryer use shown in FIG. 4 (A). In this time, the same value (“0” or “1”) is input to the simultaneous occurrence probability of the same combination as the calculated combination of behaviors shown in FIG. 4 (B).
[0060] In repeating the similar calculation, the simultaneous occurrence probability matrix S 2 including three or more kinds of simultaneous occurrence behaviors is developed from the simultaneous occurrence probability matrix S 1 . After development is completed in this way, all behaviors (including simultaneous occurrence behaviors) written in the row of the simultaneous occurrence probability matrix S 2 is added to the behavior correspondence table 2 a (step 303 ).
[0061] Correspondence of the added behavior patterns (including simultaneous occurrence behaviors) with an input signal to be described below is calculated, and saved in the behavior correspondence table 2 a again (step 304 ). The input signals used here include detection signals of various sensors and operation situation signals of various devices. The various sensors may be, for example, position sensors detecting the existence position of the object person such as an acceleration sensor, a voice sensor for measuring the strength and weakness/pitch/duration of a voice, infrared sensor, pyroelectricity type sensor, GPS, RF-ID (Radio Frequency Identification).
[0062] The kinds of equipment are a refrigerator, an electric pot, a television set, a water service faucet, etc. The sense signals of these sensors and operation situation signals of the equipment are collected by the suitable number of sampling times, and the average, dispersion value, maximum of the signals are used. These input signals are taken in the apparatus through the signal input unit 3 .
[0063] The behavior correspondence table 2 a of FIG. 5 represents correspondence between the behavior pattern that the object person can take and the input signal input from the signal input unit 3 . In this case, the behavior correspondence table 2 a comprises behavior patterns (including simultaneous occurrence behaviors) written in from the simultaneous occurrence probability matrix S 2 and type of the input signal, that is, input type associated with the actual behavior of the object person (existence of the person in a living room, a kitchen, etc., and on/off of equipment such as an illumination, a refrigerator). It is determined by presence or absence of the input signal whether the object person is in each room. If the object person is in the room for a certain behavior, “1” is written in the table, and if he or her is not in the room, “0” is written therein.
[0064] The use condition of equipment also is determined in presence of the input signal, and a state code is written in the table. In this example, if the use condition is true, “1” is written in the table, and it is false, “0” is written therein. In the illustrated example, in the case that the behavior is “television watching”, assuming that the object person is in a living room and the television switch is ON, “1” indicating that the object person is in the living room is written in the table, and at the same time, “1” indicating ON of the television set is written therein.
[0065] If the input signal is quantitative data, the range thereof is written in the table. In the illustrated example, the average voice level emitted by the object person, average vertical direction acceleration, horizontal direction acceleration dispersion value representing movement of the object person, etc. are written in the table as the range.
[0066] Determination of simultaneous occurrence behaviors is included in the behavior correspondence table 2 a shown in FIG. 5 , too. In this case, correspondence between the sole behavior and the input signal is based on data input beforehand. However, by logical sum calculation of input signals in the case of the sole behavior or by setting a range of the bound pair of numerical values at a wider range, a signal input condition corresponding to arbitrary simultaneous occurrence behaviors can be derived and embeded in the behavior correspondence table 2 a . For example, when the television watching and dryer use are occurred at the same time in FIG. 5 , a signal input condition of this time is generated by making a condition encompassing both of signal input conditions in those sole behaviors. Using such behavior correspondence table 2 a , such abnormal behavior as to forgot to turn off illumination can be determined. A plurality of object persons can be determined, for example, who of family do what behavior by giving an identification code to the object person and adding the identification code to an input signal.
[0067] The behavior determination of step 202 shown in FIG. 2 is executed. The process of behavior discrimination is done with the behavior discrimination unit 2 shown in FIG. 6 . In this case, the behavior discrimination unit 2 specifies a behavior pattern from a value (1 (truth), 0 (false)) of an input signal input from the signal input unit 3 or a quantitative value and combination of these input signals, based on the behavior correspondence table 2 a in step 601 , and outputs it to the memory 12 .
[0068] Subsequently, data recording is executed in step 203 shown in FIG. 2A . The data recording process executed with the data recorder 4 will be described referring to FIG. 7 . At first the data recoder 4 sets a behavior pattern specified by the behavior discrimination unit 2 , month and date, week and time data, generates behavior history data (behavior history information) at a constant time interval decided beforehand, and saves it in the memory 12 temporarily (step 701 ).
[0069] FIG. 8 shows behavior history data generated every 5 minutes from 9:00 to 9:30 on Feb. 4, Sunday. A behavior transition probability, behavior transition time and behavior occurrence time are calculated, respectively, at a constant time interval (step 702 ).
[0070] In this case, if a predetermined constant time interval lapses, the number of times that the behavior changes from a behavior i per a time zone to a behavior j is counted using the behavior history data saved in the memory 12 in the interval.
[0071] FIG. 9 shows the number of behavior transition times. It is assumed that there are N behavior patterns where i, j=1, . . . N. If a behavior pattern is, for example, “cooking”, the number of times by which the behavior changes from the behavior i to the behavior j in a time zone from 8:00 to 10:00 is counted as one time when it changes to “eating”. The behavior transition probability Aij that the behavior changes from the behavior i to the behavior j is calculated by dividing each parameter (the number of behavior transition times) of FIG. 9 by the total number of transition times every starting behavior i.
[0072] FIG. 10 shows the calculated result of behavior transition probability. When the behavior pattern is “cooking”, the number of behavior transition times is 1. When this is divided by the total number of transition times, “1” is obtained. This behavior transition probability A ij is stored in the behavior transition probability data memory 5 a of the data storage 5 as a transition matrix [A ij ]. In this case, σ j A ij =1. The simultaneous occurrence behavior is treated as one behavior i or j.
[0073] The behavior time τ ij between which the behavior changes from the behavior i to the behavior j is measured from an interval of behavior change. For example, a time during which the behavior changes from the behavior i (cooking) to the behavior j (eating) is assumed to be 25 minutes as shown in FIG. 11 , this time becomes a time τij needed for cooking. This behavior time τ ij is calculated from the behavior history data. The average behavior time τ i per once of behavior i is calculated using this behavior time τ ij and the behavior transition probability A ij by the following equation.
[0000] t i =ΣjA ij t ij
[0074] The average behavior time t i per once in a certain time zone that is calculated in this way is recorded in the behavior time data memory 5 b of the data storage unit 5 as an average behavior time vector.
[0075] The total occurrence time of each behavior i is measured every time zone, and divided by a period of the time zone to calculate a behavior occurrence probability. FIG. 12 shows the calculation result of the behavior occurrence probability. In the case of, for example, cooking, since the total occurrence time from 8:00 to 10:00 is 25 minutes (refer to FIG. 11 ), it is possible to obtain the behavior occurrence probability pi of 0.21 by dividing it by the time zone of 120 minutes. In this way, the calculated behavior occurrence probability is stored in the behavior occurrence probability data memory 5 c of the data storage 5 as a behavior occurrence probability vector [p i ].
[0076] The process advances to step 703 of FIG. 7 to calculate an average of each data stored in the data memory 5 and update the contents of the database. In this case, the data of each of the behavior transition probability data memory 5 a , behavior time data memory 5 b and behavior occurrence probability data memory 5 c is divided into plural data in units of month/day, week and time zone. The stored past data are read out in these units, and an average of the readout past data and the new data is calculated. The average data is stored in each of the behavior transition probability data memory 5 a , behavior time data memory 5 b and behavior occurrence probability data memory 5 c of the data storage 5 again. Thereafter, the behavior prediction/recommendation process is executed as shown in FIG. 2B .
[0077] In this behavior prediction/recommendation process, at first, a condition is input in step 211 . The behavior prediction process is executed based on the condition input as shown in FIG. 13 . At first, the object person oneself inputs a spare time as a prediction period (gap time) with the key input unit 11 . This prediction period (gap time) is a period for predicting a behavior of the object person during the spare time, and is input a behavior prediction start and behavior prediction end to the condition input unit 1 as a behavior prediction condition. Concretely, the object person inputs the month, week, prediction start time TS, prediction end time TE, identification information of the object person to the condition input unit 1 (step 131 ). The behavior prediction end time may be always the end of a day, that is, 0:00 without setting it in particular.
[0078] Subsequently, the behavior prediction is executed in step 212 shown in FIG. 2B . In this case, the behavior prediction condition input to the condition input unit 1 is given to the behavior predictor 6 . The behavior predictor 6 generates a behavior pattern j occurring according to the behavior prediction condition input from the condition input unit 1 and a behavior occurrence time vector [T j ] representing the occurrence time T j . In this time, the behavior occurrence time vector [T j ] is initialized (step 132 ).
[0079] A behavior occurrence probability vector [pi] corresponding to the prediction start time point is read as an initial state provability from the behavior occurrence probability data memory 5 c . The behavior of the highest occurrence probability in the past data corresponding to the month, week, prediction start time TS, prediction end time TE given as the behavior prediction condition, that is, the behavior of the highest initial state probability pi is selected as a starting behavior i (step 133 ). The starting behavior intends a behavior to be executed after start of the behavior prediction first, and is “eating” in the example of FIG. 12 .
[0080] The most frequency path on this starting behavior i is calculated. The mode path means a chain of the behaviors to be changed at the highest probability subsequently. In this case, the behavior j to change from a certain behavior i at the maximum probability A ij is selected using the transition matrix [A ij ] stored in the behavior transition probability data memory 5 a (step 134 ).
[0081] An average behavior time t j on the behavior j is added to an item T j of the behavior pattern corresponding to the behavior occurrence vector using the average behavior time vector [t i ] stored in the behavior time data memory 5 b (step 135 ).
[0082] If the total time Σ j T j of a sequence of behaviors reaches a prediction period TP (=prediction end time TE−prediction start time TS) by the addition process, the chain calculation is stopped and an occurrence time vector [T i ] every behavior is output as behavior prediction information (step 136 ).
[0083] If the total time Σ j T j does not reach the prediction period TP, the process of selection of behavior and addition of behavior occurrence time are repeated till the total time reaches the prediction period TP by the starting behavior is replaced with j. In this case, if the number of occurrence times of a certain specific behavior reaches the number of specified times set beforehand, the behavior pattern can be removed from the prediction behavior system. For example, “eating takes three meals a day” is set. In this time, even if the prediction behavior system including the eating taking four or more meals is calculated, this can be realized by adding to the flow of FIG. 13 a process of ignoring a behavior changing to the “eating” behavior in the sequence of behaviors on and after the fourth behavior.
[0084] A social value calculation is executed in step 213 shown in FIG. 2B . FIG. 14 shows a process of the social value calculation executed with the social value calculator 7 . In this case, the occurrence time vector Tj of the behavior j calculated with the behavior predictor 6 is multiplied by the environmental load unit consumption data ej (social value unit information) read from the environmental load unit consumption data memory 5 d to calculate an environmental load due to the behavior j (step 141 ). The environmental load unit consumption data ej is, for example, emission quantity of environmental load of behavior j per time, for example, emission quantity of carbon dioxide. This is given from the environmental load unit consumption database shown in FIG. 15 and stored beforehand in the environmental load unit consumption data memory 5 d , for example.
[0085] The environmental load unit consumption database includes “activity”, “activity items” and “environmental load unit consumption”. In the case of, for example, “eating” as “activity”, “0.2893” is given as “environmental load unit consumption”. The environmental load is a negative social value. The activity can be assumed to be a behavior that the social value decreases with increase of the negative social value.
[0086] The sum total of environmental loads of all behaviors is calculated, and divided by the prediction period TP (=prediction end time TE−prediction start time TS) to output a total value Ei (social value information) of emission environment load due to selection of the starting behavior i per unit time.
[0087] Recommendation behavior selection/display is executed in step 214 shown in FIG. 2B . FIG. 16 shows a process of selecting the recommended behavior with the recommended behavior selector 8 . It is determined whether the environment load Ei per time in the sequence of behaviors whose starting behavior is assumed to be i is not more than a reference value. In this example, the reference value uses emission quantity of carbon dioxide [CO 2 -kg/hour] which is converted from an average use energy amount per time and per nation. An arbitrary reference value other than the above value may be set.
[0088] If it is determined in step 161 that the environmental load Ei is less than the reference value, the process is finished without selecting the recommended behavior. If the environmental load Ei is not less than the reference value, the process advances to step 162 . In step 162 , ID number k is updated in order of decreasing occurrence probability pj for behaviors aside from the starting behavior i, where k=1, . . . , N−1. The prediction of the behavior sequence is performed for the behavior of k=1 (“cooking” in the example of FIG. 12 ) with the behavior predictor 6 (step 163 , 164 ), like the case of assuming “eating” to be the starting behavior as described above. The social value calculator 7 calculates an environment load Ek per time about a prediction behavior sequence, and returns the result to the recommend ion behavior selector 8 (step 165 ).
[0089] If this environmental load Ek is not less than the reference value (step 166 ), the starting behavior is updated to k=k+1, and then the process returns to step 163 . The above process is repeated until the environmental load Ek becomes less than the reference value.
[0090] A difference Vik between the environment load sum total TP×Ek of the behavior sequence assuming that the behavior k obtained in this way is the starting point and the environment load sum total TP×Ei of the behavior sequence assuming that the behavior i is the starting point is calculated. This is deemed to be a social value improvement when the starting behavior is changed from the behavior i to the behavior k, and TP×Ek, TP×Eii, Vik are output (step 167 ).
[0091] The result output unit 9 converts Vik to a human-friendly form and outputs to the display 10 . In other words, the result output unit 9 outputs the result to the display 10 in the form of “If the behavior k is selected instead of the behavior i, the social value surely improves by Vik”, and outputs it by image, voice, etc.
[0092] FIG. 17 shows an example of displaying a recommendation behavior on the display 10 . It is displayed that the case (b) of (starting from “news paper reading”) is a recommendation behavior in comparison with the case (a) of (“starting from watching television”). The case (c) recommends the behavior by adding such a display that if “television watching” is stopped and “news paper reading” is started, only Vik would be preferable.
[0093] A negative society value produced by assuming that the behaviors i and k are the starting behavior may be directly output. When the recommendation behavior is unnecessary, a result is not output. The display 10 may be a voice output other than the visual output. The television which can be connected to a network may be used as the display.
[0094] According to the above embodiment, the behavior discrimination unit 2 specifies a behavior pattern based on correspondence between the behavior pattern acquired by the input of the sole behaviors of the object person input from the condition input unit 1 and the simultaneous occurrence probability of these behaviors and the input pattern of the actual behavior of the object person. The data recorder 4 forms behavior history data of a constant period about this specified behavior pattern. The data recorder 4 generates and records information of each of behavior transition probability, behavior time and behavior occurrence probability for each behavior pattern based on the history data.
[0095] The behavior predictor 6 predicts a starting behavior from the behavior occurrence probability information for a prediction period, and selects another behavior with respect to the starting behavior in order of behavior occurrence probability based on the behavior occurrence probability information. The behavior time information for these selected behaviors are added to output behavior prediction information corresponding to the prediction period. The society value calculator 7 calculates an environment load per unit time, which is due to selection of the starting behavior, from the behavior prediction information, the environmental load unit consumption information prepared for beforehand and the prediction period.
[0096] The environmental load per unit time obtained by the social value calculator 7 is compared with the reference value prepared with the recommendation behavior selector 8 beforehand. The result output unit 9 selects a recommendation behavior based on the comparison result and displays this selected recommendation behavior on the display 10 . As a result, the behavior of a to-be-predicted person within a certain prediction period can be predicted and guided in a direction in which the social value increases, thereby to make it possible to reduce drastically a future environment load.
[0097] The to-be-predicted person can take a behavior of high social value to satisfy a reference value without receiving a psychological burden. Then, a starting behavior or behavior sequence of highest social value may not be always recommended by the reference value prepared with the recommended behavior selector 8 beforehand. Rather, it is possible to recommend a starting behavior that is easy to be accepted by a user while achieving a social value reference determined in average. Therefore, the possibility that the recommendation result is ignored becomes smaller than the case that behavior recommendation taken in consideration of only the social value merely is ignored. This means that a psychological burden of the to-be-predicted person against environmental consideration behavior, diet behavior, etc. is reduced.
[0098] Further, the starting behavior or simultaneous occurrence behavior that is not seemed to be a behavior of high social value at the first glance may be recommended. This is due to selecting the starting behavior by an average society value of a behavior sequence within a prediction period. Such a result is realized by really acquiring personal behavior history data, and using an apparatus as shown in the present embodiment.
[0099] Further, since the sole behavior of the object person that is input from the condition input unit 1 while considering preference of the object person and the simultaneous occurrence probability of these behaviors are input, it is possible to make easily environment that the object person can cause positively the behavior of high social value.
(Second Embodiment)
[0100] The second embodiment will be explained subsequently.
[0101] In this the second embodiment, If the society value may be improved by promoting change (disaggregation) from the simultaneous occurrence behavior to the sole behavior or change (aggregation) from the sole behavior to the simultaneous behavior, Such a change request is output from the display 10 .
[0102] Since the behavior prediction apparatus of the second embodiment is similar to that of FIG. 1 , the second embodiment will be described referred to FIG. 1 .
[0103] In FIG. 18 , like reference numerals are used to designate like steps corresponding to those like in FIG. 13 and any further explanation is omitted for brevity's sake, but different steps will be described.
[0104] In step 181 , the occurrence probability of the simultaneous occurrence behaviors from the behavior occurrence probability data memory 5 c and probability, that the behavior is changed to the simultaneous occurrence behavior, from the behavior transition probability data memory 5 a are replaced with 0 temporarily and saved in the memory 12 . Like the process on and after step 133 executed by the behavior predictor 6 using these probability data, a behavior sequence aside from the simultaneous occurrence behavior is predicted, and the behavior occurrence time vector [T j *] corresponding to a breakdown of the behavior time is output.
[0105] Environmental loads Ei and Ei* per time are calculated by the social value calculator 7 according to the process flow of FIG. 14 , using [T j ] including the simultaneous occurrence behavior and [T j *] excluding the simultaneous occurrence behavior. According to an example of FIG. 19 , the television watching and dryer use are simultaneous occurrence behaviors.
[0106] When the object person uses a dryer while watching a television, he or she takes 10 minutes in average. In the sole behavior of only use of the dryer, use of the dryer finishes with 7 minutes in average. Environmental loads in respective behavior sequences are calculated as E i and E i *.
[0107] The recommendation behavior selector 8 determines whether E i >E i *. If E i >E i *, a result as shown in FIG. 20 is output to the display 10 from the result output unit 9 . According to the display example of the display 10 as shown in FIG. 20 , it is shown that a case (b) of carrying out “use of a dryer” and “television watching” separately is recommended in comparison with case (a) of carrying out “use of a dryer” and “television watching” at the same time. Further, a display such as (c) (shall you stop “using a dryer” while “watching a television”) is added. In this way, the starting behavior is recommended.
[0108] In this embodiment, an example to promote a change (disaggregation) to the sole behavior from the simultaneous occurrence behavior is described. However, it is possible to evaluate a social value when the sole behavior is changed to the simultaneous occurrence behaviors by replacing a certain sole behavior with the simultaneous occurrence behaviors including the sole behavior, and predicting and evaluating a behavior sequence on and after the step. If it has a higher society value than the behavior sequence configured by sole behaviors, it is displayed on the display 10 .
(Third Embodiment)
[0109] The third embodiment will be explained. In the third embodiment shown in FIG. 21 , like reference numerals are used to designate like structural elements corresponding to those like in the embodiment of FIG. 1 and any further explanation is omitted for brevity's sake, and only different elements are described.
[0110] A scheduling unit 13 for managing personal scheduling and a spare time detector 14 are provided in this embodiment. The scheduling unit 13 is connected to the spare time detector 14 and the result output unit 9 through radio or a network. The scheduling unit 13 is provided on, for example, a mobile computer, a mobile phone, etc., and manages, for example, a day's scheduling of the object person. Other is similar to FIG. 1 .
[0111] In FIG. 22 , like reference numerals are used to designate like steps corresponding to those like in FIG. 13 and any further explanation is omitted for brevity's sake, but different steps will be described.
[0112] In step 221 , the spare time detector 14 accesses the scheduling unit 13 at a constant interval (for example, every morning 6:00) (step 221 ), detects a spare time zone from schedule information of a day, and inputs a detected result to the condition input unit 1 .
[0113] The condition input unit 1 inputs the month, week, prediction start time TS, prediction end time TE, identification information of the object person, etc., as a behavior prediction condition, using the result of the spare time zone input from the spare time detector 14 (step 222 ).
[0114] The behavior predictor 6 executes a behavior prediction process similar to that of FIG. 13 , and estimates a behavior occurrence time vector [Tj] in the spare time acquired from the scheduling unit 13 , namely a time zone without a special plan.
[0115] In step 223 , the social value calculator 7 calculates a value Ei of occurrence environment load per unit time, which is due to selection of the starting behavior i. In step 224 , the recommendation behavior selector 8 a executes a recommendation behavior selection process similar to that of FIG. 16 , and determines whether another starting behavior should be recommended.
[0116] If it is desirable to recommend the another starting behavior, information of contents of the recommendation (for example, information of FIGS. 17 and 20 ) is sent back to the time zone of the scheduling unit 13 (the spare time detected by the spare time detector 14 ). This starting behavior is written at the beginning of the spare time (step 225 ).
[0117] A coordination operation between the main unit and the scheduling unit 13 will be described concretely referring to FIG. 23A . At first, the spare time detector 14 searches contents of the scheduling unit 13 at a constant interval (for example, every morning 6:00). When spare time zones (spare time zones A and B) is in a day's schedule information ( FIG. 23 ( b )) of the scheduling unit 13 , these input spare time zones A and B are read out and input to the condition input unit 1 .
[0118] The behavior prediction, social value calculation and recommendation behavior selection are executed, and the recommendation starting behavior is written in the scheduling unit 13 . In this case, recommendation starting behaviors A 1 and B 1 are registered at the beginnings of the spare time zones A and B as shown in FIG. 23C . Accordingly, even if the schedule management is done in the way, the user who manages a schedule with the scheduling unit 13 can know easily what may have only to be done in the spare time.
(Fourth Embodiment)
[0119] The fourth embodiment will be explained subsequently. The function of the spare time detector is added to the scheduling unit in this fourth embodiment. Accordingly, the scheduling unit outputs a start instruction for the main unit when a user confronts with a time zone without a specific plan, or before some minutes.
[0120] In the fourth embodiment shown in FIG. 24 , like reference numerals are used to designate like structural elements corresponding to those like in the embodiment of FIG. 1 and any further explanation is omitted for brevity's sake, and only different elements are described. In this case, a scheduling unit 15 for managing a personal time is provided. The scheduling unit 15 is connected to the condition input unit 1 through radio, a network.
[0121] The scheduling unit 15 has a spare time detection function similar to the spare time detector 14 , detects a spare time of, e.g., 10 minutes of a spare time zone from schedule information of a day shown in FIG. 25B , and inputs the information to the condition input unit 1 through radio, a network, etc.
[0122] The coordination operation between the main unit and scheduling unit 15 will be concretely described referring to FIG. 25A . When the scheduling unit 15 detects the start of spare time from the schedule information of a day before 10 minutes of the spare time A by the spare time detection function, the information of the start time t 1 and end time t 2 of this spare time is read out and is input to the condition input unit 1 . The above described behavior prediction, society value calculation and recommendation behavior selection are executed between the start time t 1 and end time t 2 of this spare time, and the recommendation starting behavior is written in the scheduling unit 15 . In this case, the recommendation starting behavior A 1 is registered at the start time t 1 of the spare time zone A as shown in FIG. 25 C. Accordingly, even if the schedule management is done in the way, the user who manages a schedule with the scheduling unit 13 can know easily what may have only to be done in the spare time.
(Fifth Embodiment)
[0123] The fifth embodiment will be explained subsequently. The above embodiment is provided for supporting a personal environmental consideration living. However, the present invention can apply to an embodiment for supporting a corporate activity of low environment load.
[0124] Since the behavior prediction apparatus of the fifth embodiment is similar to that of FIG. 1 , this embodiment will be described referred to FIG. 1 . In this case, an apparatus operation signal (ON/OFF of a lathe, for example) in a factory is written in, for example, the behavior correspondence table 2 a shown in FIG. 5 as an input signal thereto. Further, a production work (for example, cut of part A) is written in the table as a behavior pattern corresponding to an input signal.
[0125] If the behavior prediction apparatus is configured as described above, it is possible to reduce an environmental load for such a production work that the time management is entrusted by personal discretion to some extent.
(Sixth Embodiment)
[0126] The sixth embodiment will be explained subsequently. The previously described embodiments are described using an environmental load as a social value. However, a standpoint having publicity widely as well as environmental load may be taken in.
[0127] For example, corpulence is a symptom to threaten nation health in a developed nation, and this apparatus can be applied for improving this symptom.
[0128] Since the behavior prediction apparatus of the sixth embodiment is similar to that of FIG. 1 , this embodiment will be described referred to FIG. 1 . In this case, the environmental load unit consumption database stored in the environmental load unit consumption data storage unit 5 d is replaced with a consumption calorie basic unit database stored in the consumption calorie unit requirement data memory 5 e shown in FIG. 27 every behavior unit shown in FIG. 26 .
[0129] The social value calculator 7 executes a social value calculation process shown in FIG. 27 . In this case, the social value calculator 7 multiplies the occurrence time vector Tj of the behavior j calculated with the behavior predictor 6 by the consumption calorie basic unit data ej read from the consumption calorie basic unit data memory 5 e to obtain a consumption calorie consumed by the behavior j (step 271 ).
[0130] Further, the social value calculator 7 calculates the sum total of consumption calories of the entire predicted behavior sequence, and divides the sum total by the prediction period TP (=prediction end time TE−prediction start time TS) to output a value Ei (social value information) of a consumption calorie per unit time and unit volume, which is due to selection of the starting behavior i.
[0131] Subsequently, the recommendation behavior selector 8 executes a recommendation behavior selection process shown in FIG. 28 . In FIG. 28 , like reference numerals are used to designate like steps corresponding to those like in FIG. 16 and any further explanation is omitted for brevity's sake, and only different steps are described.
[0132] In step 281 , it is determined whether the value Ei of a consumption calorie per unit time and unit volume where the starting behavior is assumed to be i is not less than a reference value. The reference value in this example may be assumed to be optimal living momentum (calorie) per hour and weight calculated from the age, weight and gender of a person. In step 281 , if the value Ei is more than the reference value, the process finishes without selecting the recommendation behavior. On the other hand, if the value Ei is not more than the reference value, the process advances to on and after step 162 to execute the operation similar to that described in FIG. 16 .
[0133] According to this embodiment, by selecting a behavior sequence to exceed the reference value as a behavior sequence to be recommended, the starting behavior anticipated to cause a behavior sequence to exceed a reference consumption calorie can be predicted and provided in a certain spare time zone.
(Seventh Embodiment)
[0134] The seventh embodiment will be explained subsequently. The previously described embodiments are described using an environmental load as a social value. However, the present invention can apply for selecting and providing a starting behavior to reduce an occurrence risk of domestic accident.
[0135] Since the behavior prediction apparatus of the seventh embodiment is similar to that of FIG. 1 , this embodiment will be described referred to FIG. 1 . In this case, the environmental load unit consumption database stored in the environmental load unit consumption data storage unit 5 d is replaced with a domestic accident occurrence probability database shown in FIG. 30 and stored in an accident occurrence probability data memory 5 f shown in FIG. 30 . This domestic accident occurrence probability data is obtained by calculating an accident occurrence probability (fit/person) every unit activity based on statistical data, where fit indicates 1/10 9 times and is an index representing what number of accidents occur during 10 9 hours.
[0136] The social value calculator 7 executes the social value computation process shown in FIG. 30 . In this case, the social value calculator 7 multiplies the occurrence time vector Tj of the behavior j calculated with the behavior predictor 6 by the domestic accident occurrence probability data ej read from the accident occurrence probability data memory 5 f to obtain an accumulative accident occurrence probability occurring by the behavior j (step 301 ).
[0137] Further, the social value calculator 7 calculates the sum total of cumulative accident occurrence probabilities of the entire predicted behavior sequence, and divides the sum total by the prediction period TP (=prediction end time TE−prediction start time TS) to output a value Ei (social value information) of a cumulative accident occurrence probability per unit time, which is due to selection of the starting behavior i.
[0138] Subsequently, the recommended behavior selector 8 executes a recommendation behavior selection process shown in FIG. 31 . In this case, in FIG. 31 , like reference numerals are used to designate like steps corresponding to those like in FIG. 16 and any further explanation is omitted for brevity's sake, and only different steps are described.
[0139] In step 311 , it is determined whether the value Ei of cumulative accident occurrence probability per unit time where the starting behavior is assumed to be i is not more than the reference value. The reference value in this example uses a suitable value obtained by experience. In step 311 , if the value Ei is less than the reference value, the process is finished without selecting the recommendation behavior. On the other hand, if the value Ei is not less than the reference value, the process advances to step 162 to execute the similar operation.
[0140] According to this embodiment, by selecting a behavior sequence less than the reference value as a behavior sequence to be recommended, the starting behavior introducing a behavior sequence always less than the reference value can be predicted and provided.
[0141] According to the present invention, a behavior in a certain prediction period can be predicted in a direction increasing a social value, and guided.
[0142] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A behavior prediction apparatus includes an input unit inputting sole behaviors of a human and simultaneous occurrence probability of behaviors, a behavior discrimination unit specifying a behavior pattern based on correspondence between behaviors corresponding to simultaneous occurrence probability and actual behaviors, an information generation/recording unit generating behavior history information of the specified behavior pattern, and to generate and record information of each of a behavior transition probability, a behavior time and a behavior occurrence probability based on the behavior history information, a behavior prediction unit obtaining a starting behavior from the behavior occurrence probability, select another behavior pattern in order of behavior occurrence probability, and add the behavior time to the selected behavior pattern to output behavior prediction information, and a social value calculation unit obtaining a social value per unit time using the behavior prediction information, social value unit information and the prediction period. | 6 |
RELATED APPLICATIONS
This application is a continuation in part of application Ser. No. 08/401,263, filed Mar. 9, 1995, now U.S. Pat. No. 5,570,590, which in turn is a continuation of application Ser. No. 08/019,659, filed Feb. 19, 1993, and now abandoned.
FIELD OF THE INVENTION
The present invention is directed to a method and apparatus for separation of refrigerant from a purge gas mixture of refrigerant and non-condensible gas.
BACKGROUND OF THE INVENTION
Refrigerant recovered from refrigeration systems must be reprocessed with little or no release of the refrigerant to the atmosphere. In systems for purifying and reclaiming of refrigerant, in particular by emptying or renewal of old refrigeration systems, it is relevant to collect the volatile liquid, e.g. R-12, R-22 and R-134A, upon the refrigerant being brought from its gaseous phase to its liquid phase in a condenser, such that the collected refrigerant may be reused.
In principle, the condensate may be filled into a collector tank without the latter having to be vented, because the vapor or gas of the condensate in the upper tank space will maintain its gas pressure also when this space is narrowed by the progressive charging of liquid condensate into the tank. As the condensate rises in the tank the gas will diffuse or condense down into the liquid, such that the gas pressure above the liquid will remain constant when the temperature is constant. Normally, however, there will occur a certain separation of non-condensible gas, mainly of atmospheric air, and as the tank is filled this gas will give rise to increased pressure in the tank concurrently with a further pressure built-up due to the separation of non-condensible gas from the currently introduced condensate.
Non-condensible gas must be separated from the recovered refrigerant as one of the purity requisites of recycled refrigerant. The increased pressure caused by the non-condensible gas also gives rise to some problems, e.g. an increase of the condensation pressure, whereby more energy is needed for the condensation of the volatile liquid and if the collector tank is to be utilized just reasonably effectively, i.e. to be nearly filled for collecting reasonably large portions of the condensate, ready for delivery, then it is in practice imperative to carry out from time to time, a blowing off of the non-condensible gas from the tank.
It is well known that this can be done based on the use of a pressure switch controlled blow-off valve at the top of the tank for automatically initiating blowing off when the pressure in the tank has risen to a predetermined maximum. The blowing off can be interrupted when the pressure has decreased suitably optionally controlled by the hysteresis of the pressure switch. Such a pressure switch is disclosed in U.S. Pat. No. 5,467,608, the disclosure of which is hereby incorporated by reference.
However, the blowing off itself gives rise to problems in that along with the letting out or purging of the non-condensible gases, in the following named air, a certain amount of condensible refrigerant gas will inevitably be expelled. From an environmental point of view, this is very undesirable in the case of a release of considerable amounts of refrigerant gas originating from the refrigerants R-12 and R-22, for example, which have a decomposing effect on the ozone layer around the planet. Such a co-outflow of the condensible gas is particularly noticeable when the temperature is relatively high, because the concentration with the pressure contribution of the condensible gas will then be relatively high in the collector tank.
This circumstance is made even worse by the fact that during the opening time of the blow-off valve the pressure in the collector tank will be reduced such that the condensate will evaporate further, whereby towards the end of the blow-off period there will occur a further increased content of the condensible gas in the purge gas mixture of the blow-off product. Thus, the process for separating of non-condensible gas from the recovered refrigerant must minimize simultaneous release of refrigerant during the venting of non-condensible gas to the atmosphere.
A possible solution to this problem resides in mounting a cooler element in connection with a blow-out pipe from the collector tank, such that the exhausted gas will generally be cooled to the condensation temperature of the condensible gas, whereby the critical fraction of the gas is condensed and falls back into the tank without getting out to the atmosphere. However, experiments have shown that in practice this solution is unrealisticly expensive for it to be reasonably effective, since during the relatively brief blow-out periods a particularly intensive heat exchange with the blow-out gases must take place. There is a need for an improved method and apparatus for recovering/recycling refrigerant wherein the venting of non-condensible gas particularly air, from the collector tank can be carried out while reducing or minimizing the amount of condensible gas that will be expelled to the environment by way of the purge gas.
SUMMARY OF INVENTION
An object of the present invention is to provide an improved method and apparatus for purging refrigerant and collecting the purged refrigerant which more closely control the amount of refrigerant released during the venting of non-condensible gas from the collected, purged liquid to provide higher efficiencies in recovery and recycling of refrigerant. Further, an object of the present invention is to provide an improved method and apparatus for separation of non-condensible gas from recovered refrigerant in a more environmentally safe manner, minimizing the simultaneous release of refrigerant during venting of non-condensible gas to the atmosphere.
These and other objects are attained by the method of the invention for separation of non-condensible gas from refrigerant recovered from a refrigerant system, wherein the method comprises collecting refrigerant recovered from a refrigerant system in a collector tank, intermittently blowing-off non-condensible gas from the collector tank which has separated from the refrigerant in the collector tank, directing the non-condensible gas in the blow-off gas from the collector tank to an accumulator wherein the non-condensible gas is processed in a manner which results in gravity separation of non-condensible gas from refrigerant liquid and vapor thereof mixed with the non-condensible gas in the blow-off gas from the collector tank, and removing the separated non-condensible gas and refrigerant liquid and vapor thereof through respective outlets in the accumulator. According to a disclosed, preferred embodiment of the method of the invention, the method further includes the step of controlling the removing of the separated non-condensible gas in the accumulator and the introduction of the gas blown off from the collector tank to the accumulator in accordance with the timing of the intermittent blowing-off of non-condensible gas from the collector tank.
The apparatus of the invention for separation of non-condensible gas from a refrigerant recovered from a refrigerant system, comprises a collector tank for collecting refrigerant recovered from the refrigeration system, a gas blow-off valve for intermittently blowing off non-condensible gas from the collector tank which has separated from the refrigerant in the collector tank, and an accumulator for receiving the blown-off gas from the collector tank via the gas blow-off valve. The accumulator includes means for causing gravity separation of non-condensible gas from refrigerant liquid and vapor thereof mixed with the non-condensible gas received from the collector tank by the accumulator. The accumulator also includes first and second outlets for respective outflow of gravity separated non-condensible gas and refrigerant liquid and vapor thereof which are separated from each other in the accumulator.
In the disclosed embodiment, a vent conduit is provided in communication with the first outlet of the accumulator for outflow of non-condensible gas from the accumulator. A vent valve is mounted in the vent conduit. Means are provided for controlling the vent valve for intermittent venting of the accumulator with the intermittent blow off of non-condensible gas from the collector tank. The vent conduit further includes a check valve therein to inhibit return flow through the vent conduit into the accumulator but not flow from the accumulator.
The accumulator includes an internal impingement plate which obstructs an incoming flow of non-condensible gas and volatile liquid and vapor which may be mixed therewith from the blowing off of gas from the collector tank and encourages separation of the volatile liquid and vapor from the non-condensible gas in the accumulator. The second outlet of the accumulator is communicated with an inlet circuit of an apparatus for purging the volatile liquid recovered from the refrigerant system and returning the purged volatile liquid to the collector tank. The means communicating the second outlet of the accumulator with this inlet circuit includes a fluid passage and a check valve in the passage to inhibit the flow through the fluid passage into the accumulator but not from the accumulator. A further feature of the invention is that the inlet and outlet circuits for fluid flow to and from the accumulator of the apparatus include capillary tubes for restricting the flow to permit a relatively controlled reaction of a means for intermittently blowing off non-condensible gas from the collector tank.
An apparatus for purging refrigerant and collecting the purged refrigerant in a collector tank according to the invention comprises an inlet for receiving refrigerant, a collector tank, a condenser unit in a delivery connection with the collector tank; a purging system arranged in an in-line connection between the inlet and the condenser unit and operable to deliver purged refrigerant in a gaseous phase to the condenser unit and a gas blow-off valve mounted in a blow-off conduit connected with the top of the collector tank. The gas blow off valve is controllable in dependence upon condensate vapor pressure in the collector tank to effect an intermittent blow-off of non-condensible gas separated from the condensate. The control is by means for at least one of measuring or indicating a differential pressure between the actual condensate vapor pressure of the condensed liquid and a total gas pressure in the collector tank, with the valve being opened when a total pressure exceeds the condensate vapor pressure by a predetermined value. The apparatus further includes an accumulator of the aforementioned type for receiving the blow-off gas from the collector tank via the blow-off conduit when the gas blow-off valve is opened. As noted above, the accumulator is configured to permit gravity separation of non-condensible gas from volatile liquid refrigerant and vapor thereof mixed with a non-condensible gas in the blow-off gas received in the accumulator from the collector tank. First and second outlets are provided in the accumulator for respective outflow of separated non-condensible gas and refrigerant.
These and other objects, features and advantages of the present invention will be more apparent from the following detailed description of disclosed embodiments of the invention taken with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic view for illustration of the invention,
FIG. 2 is a more detailed view of a portion of a preferred form of an apparatus according to the invention,
FIG. 3 is a similar view of a portion of a modified embodiment,
FIG. 4 is a cross sectional view of the non-condensible gas accumulator of the invention and
FIG. 5 is a schematic view of the preferred embodiment showing additional details of the purification system.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 1 illustrates an apparatus of the invention for purging volatile liquids, particularly refrigerant, and collecting the refrigerant in a collector tank and separating non-condensible gas from the recovered refrigerant so as to minimize release of the purged liquid during venting of non-condensible gas to the atmosphere. More particularly, in FIG. 1 there is indicated a purification system 2 for refrigerant supplied from a source 4, e.g. the refrigeration system of a case to be scrapped. In the system 2 the refrigerant will be cleaned for different substances, mainly water, but not for non-condensible gases, and the refrigerant, in gaseous phase, is delivered to a condenser 6, from which the condensate is conveyed further through a conduit 8 to a connector stub 10 at the bottom of a collector tank 12. The bottom stub 10 is also, through a valve 16, connected with a discharge conduit 16. Details of the system 2 are shown in FIG. 5.
The tank 12 at its top, has a blow-out pipe 18 provided with a valve 20, viz. a solenoid valve controlled by a pressostat P. The latter is a differential pressostat, which, through a switch K, controls the opening and closing of the valve 20 in dependence of a pressure applied to a connector stub R1 being higher or lower than a pressure applied to another connector stub R2. Through a conduit 22 the connector stub R1 is connected directly with the space inside the tank, while the connector study R2, through a conduit 24, is connected with a capsule 26 inside the tank.
The capsule 26 is filled with a liquid that is widely equivalent or identical with the condensate liquid in its pure condition, e.g. one of the refrigerants R-12, R-22 or R-134A, and it will thus be the vapor pressure from this clean liquid that will be transferred to the input stub R2 of the pressostat. To the stub R1 will be transferred the total pressure in the tank 12, i.e. the vapor or gas pressure both from the condensate in the tank at the same temperature and from the further pressure source constituted by the non-condensible gas and the air as separated from the condensate, mainly atmospheric air. This air is compressed all according to the raising of the liquid level in the tank, so it will provide for a relatively increasing pressure on the input stub R1.
Inside the pressostat P the input stub R1 is connected to a bellow B1, which, through a rod 28, exerts a pressure on another bellow B2 connected to the stub R2. The switch K is controlled by the rod 28, such that the switch will be closed and cause the blow-off valve 20 to open, when the overpressure from the separated air in the tank 12 reaches a certain, preset value. The pressostat exhibits a certain hysteresis, such that the valve 20 will not be closed until after a noticeable pressure drop in the tank 12 and thereafter will not be reopened until after a following noticeable increase of the pressure in the tank. Therefore, with a suitable adjustment of the pressostat it is possible to achieve quite ideal conditions for the discussed blow-off of the air without any compromising blow-off of condensible gas. However, a certain associated blow-off of the latter will be inevitable, even with a correctly adjusted system. According to the invention this blow-off gas is subjected to a separation process after being vented from the collector tank 12 to lower even further the amount of refrigerant released to the atmosphere by this venting.
The amount of refrigerant released during the venting process is more closely controlled, resulting in higher efficiencies for total recycled refrigerant, according to the invention by conveying the blow-off gas from the collector tank 12 to and through a circuit comprising a non-condensible gas accumulator 61, capillary tubes 62 and 63, check valves 64 and 65 and solenoid valves 20 and 66.
The accumulator 61 is provided with an internal impingement plate 67 for enhancing the efficiency of separation of the non-condensible gas from refrigerant in the accumulator 61. Refrigerant, being heavier than non-condensible gas, tends to settle to the bottom of the accumulator 61. The impingement plate 67 obstructs the flow of the non-condensible gas/refrigerant mixture entering the accumulator through inlets 68 downstream of capillary tube 62 and further encourages refrigerant to be separated from the non-condensible gas.
The capillary tubes 62 and 63 on the inlet and outlet circuits of the accumulator 61 restrict the flow permitting more controlled reaction of the differential pressure switch K to changes in pressure. The solenoid valves 20 and 66 in series with these capillary tubes stop and start flow as controlled by the differential pressure switch K.
The access port or outlet 69 at the bottom of the accumulator 61 is connected to the inlet circuit of the recovery/recycling purification system 2 as shown in FIG. 1. In particular, return line 70 for the outlet 69 returns the separated refrigerant from accumulator 61 to a location upstream of a suction accumulator of the system 2 is illustrated in FIG. 5. During a venting cycle for venting the blow-off gas from the collector tank 12, the return line 70 returns the refrigerant from the accumulator to the suction accumulator where it is reprocessed and further purified by the system. The check valves 64 and 65 are employed to inhibit reverse flow into the accumulator 61.
The operation of the non-condensible gas accumulator circuit is as follows. When a typical recover/recycle procedure is started, the non-condensible gas accumulator 61 will be at, or slightly below atmosphereic pressure. When the differential pressure switch K in the collector tank 12 initially activates, the flow of non-condensible gas and refrigerant mixture is in the blow-off gas from the tank 12 flowing into the accumulator 61 via the capillary tube 62 and solenoid valve 20. As the incoming mixture hits the impingement plate 67, the refrigerant and non-condensible gas will tend to separate. Due to the relatively large volume of accumulator 61 and the relatively low flow rate, very little, if any flow will occur through the outlet 71 towards the inlet side of the purification system 2 or through solenoid valve 66 to the non-condensible gas vent 72.
During the time between the first and second venting cycles,, the contents of the accumulator 61 through gravity and condensation, will begin to separate. Refrigerant will setttle to the bottom and non-condensible gas will rise to the top. When subsequent venting cycles for the internal cylinder/collector tank 12 occur, the non-condensible gas at the top of the accumulator 61 will be vented through solenoid 66 and the capillary tube 63 to the atmosphere by way of vent 72. Proper sizing of the capillary tube will limit flow to an acceptable level. In the disclosed embodiment, the volume of the accumulator 61 is approximately 30 in. 3 and the capillary tubes 62 and 63 each have a inside diameter of 0.060 inch and a length of approximately 16 inches. Refrigerant at the bottom of the accumulator 61 will be forced to the end of the suction accumulator of the purification system 2 and reprocessed through the system as noted above.
In the disclosed embodiment, the accumulator 61 is a cylindrical metal vessel with integral interior mounted impingement plate 67. The accumulator is provided with one inlet 68 and two outlet ports, 69 and 71, which allow connection to the supporting circuitry referred to above. A mounting stub 73, FIG. 4 on top of the accumulator permits mounting to the main frame of the recovery machine. The inlet capillary tube 62 is connected to the inlet 68 of the accumulator 61 downstream of the solenoid valve 20. The outlet capillary tube 63, after solenoid valve 66 is connected to the vent 72 for the accumulator 61. The apparatus and method of the invention permit the closer control of the amount of refrigerant, at least during the venting process and result in higher proficiencies for totaled recycled refrigerant.
In the embodiment shown in FIG. 2 it is illustrated by way of example that the switch K is a micro switch 30, which is mounted on a carrier plate 32 and has an actuation knob 34 that is depressible for operating the switch by means of a pivot arm 36 hinged at 38 and having a free end portion 40, which is depressible by a side cam 42 on the connector rod 28 between the bellows B1 and B2. By an adjustment of the carrier plate 32 upwardly or downwardly it will then be possible to adjust the level of the differential pressure to which the pressostat responds, and by adjusting the switch 30 horizontally on the carrier plate 32 an adjustment of the hysteresis function of the pressostat, given by the larger or smaller distance between the switch cam 34 and the pivot axis of the switch arm 36, will be effected. Thus, the pressostat will be adjustable to different optimized manners of reaction.
The capsule 26, which in FIG. 1 is shown located inside the tank, is in FIG. 2 shown located in a bore in a tank head block 46 of aluminum or a correspondingly well heat conducting material, whereby this particular temperature/pressure sensor will be in close contact, in a constructively simple manner, with the operatively significant area of the tank, viz. the upper blow-off area, the temperature of which will be decisive for the blow-off pressure. Alternatively, as shown by dotted lines, the sensor capsule or pocket 26' may be constituted by a capillary tube 48 wound about the upper end of the tank 12 in the heat conducting connection therewith. The capillary tube connections to the two input stubs of the pressostat should have approximately equal lengths.
The supply pipe for letting the condensate into the tank 12, according to FIG. 2 may have its mouthing 50 located at a relatively high level in the tank, whereby the supplied liquid during its introduction and following downfall gets good possibilities for separation of air and other non-condensible gases to be blown off later on.
Suitably the tank is filled up to only some 80% of its volume, e.g. as represented by the filling level shown in FIG. 2, with the supply mouthing 50 located slightly thereabove. By a still higher filling level there may tend to be an increased concentration of condensible gas in the blow-off product.
It should be mentioned that the aim of mounting, as in FIG. 2, the sensor pocket 26' in indirect contact with the tank chamber is to achieve that the sensor will not react to sudden, brief temperature variations in the supplied condensate, but rather react to the present average temperature. With the use of the capillary tube 48 wound about the tank a heat insulation should be arranged at the outside.
FIG. 3 shows a modified system, having the same main units 6, P and 12 as in FIGS. 1-2. In this embodiment the sensor capsule, here designated 26"', is mounted externally of the tank 12, housed in a housing 52, the lower end of which is in permanent connection with the top of the tank 12 through a pipe 54. The upper end of the housing 52 is connected to the inlet side of the blow-out valve 20 through a capillary pipe 56, which is thus connected to the valve 20 in parallel with the outlet stub 18 of the tank 12.
It is an important aspect of this embodiment that the tank 12 is an easily exchangeable unit, which can be shifted or replaced whenever it is filled, while the housing 52 with the sensor 26"' can remain as a stationary unit in the reclaiming apparatus.
The external arrangement of the housing 52 accounts for a less efficient temperature transfer between the tank 12 and the sensor 26"' within the housing 52, but advantage is taken of the Freon gases themselves being well heat-conductive, such that through the relatively wide pipe or hose 54 the temperature of the gas in the tank 12 will be transferred to the housing 52 and thus to the sensor 26"'.
Preferably the housing 52 is made of a material having good heat conducting properties, such that the sensor 26"' is subjected to substantially the same temperature all over its length. The housing 52 may be externally heat insulated in order to promote this effect.
The capillary tube 56 between the top of the housing 52 and the inlet end of the valve 20 will result in a certain throughflow of the gas in the housing 52 every time the valve 20 is opened. Hereby the gas in the housing 52 will be replaced by "fresh gas" from the container 12, whereby the temperature of the sensor 26"' will be adjusted accordingly. In typical cases such adjustments will take place with intervals of few minutes only, such that generally the temperature of the housing 52 and therewith of the sensor 26"' will be the same as the temperature in the upper end of the tank 12, just as desirable.
The conduit between the outlet stub 18 and the valve provided as a capillary tube 58, which will promote a slow and well controlled blowout of the gas.
Of course, all of the pipes or hoses communicating with the tank 12, including the pipe or hose 54, should be easily releasable arranged in order to enable the tank 12 to be easily shiftable.
As mentioned, the sensor pocket should contain the same liquid as the condensate in its pure state, this providing for the highest degree of optimizing of the blow-off function. This, however, will not exclude that a slightly deviating liquid be used, if according to experience it will provide for a result with a desired, sufficient degree of optimizing. Besides, with the embodiment according to FIG. 1 it will be relatively easy to readjust the device to the handling of another liquid, because the sensor pocket and its connection to the pressostat will be easy to replace by a corresponding set containing the new liquid.
The invention, of course, will also comprise a system or unit, in which the blow-off valve 20 is controlled manually, when the pressostat is alternatively used for a suitable signalling, e.g. by the switch K operating to control the operation of a signal lamp.
The manual operation of the blow-off valve 20 also results in a connection of solenoid valve 66 for allowing flow into and out of the accumulator 61.
While we have disclosed only several embodiments of the invention, the invention is not limited thereto but is susceptible to use in other forms without departing from the basic invention disclosed herein and claimed in appended claims, as will be apparent to the skilled artisan. | A method and apparatus are disclosed for separation of non-condensible gas from recovered refrigerant collected in a collector tank. Non-condensible gas is intermittently vented from the collector tank. The vented non-condensible gas is directed to an accumulator which processes the vented non-condensible gas in a manner which allows gravity separation of the non-condensible gas from refrigerant liquid and vapor which may be mixed therewith in the vented gas from the collector tank. The gravity separated non-condensible gas and refrigerant in the accumulator are removed from the accumulator through respective outlets in the accumulator. The refrigerant is recycled in a refrigerant recovery apparatus and the gravity separated non-condensible gas is released to the atmosphere. The method and apparatus reduce release of refrigerant to the atmosphere as a result of venting of the collector tank. | 5 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This patent application is related to application Ser. No. 10/916,688 entitled “Gate Section and Base for a Safety Rail System” filed on Aug. 11, 2004, now U.S. Pat. No. 6,902,153, which is a divisional of application Ser. No. 10/319,992 entitled “Gate Section and Base for Safety Rail System” filed Dec. 16, 2002, now U.S. Pat. No. 6,845,970, which is a continuation-in-part of application Ser. No. 09/595,794 entitled “Safety Rail System” filed Jun. 16, 2000, now U.S. Pat. No. 6,554,257.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention pertains to a safety rail system, and more particularly, pertains to a collapsible safety rail system for providing a portable or permanent protective barrier to provide for fall prevention from elevated or other work areas.
[0004] 2. Description of the Prior Art
[0005] Prior art safety rail systems or other fall prevention systems have been provided to prevent workers or other personnel from falling off an elevated work area, such as a rooftop, or to prevent personnel from falling into open work pits. Some fall prevention systems are only used occasionally and the temporary erection of a fall prevention system, such as at the edge of a building roof, can prove to be costly and time consuming. Often, aesthetics require that safety rail/guard rail systems be out of sight or that the systems be completely removed as to not detract from the beauty or aesthetics of a building or other publicly viewed area when not in use. One method of keeping a fall prevention system out of sight is by providing a low profile mounted horizontal lifeline in close proximity to a roof surface. Both ends of a horizontal lifeline are firmly anchored into structure underlying the waterproof region of a roof. A workman then dons a harness having a safety line and attaches the distant end of the safety line to the span of the lifeline to traverse the length of the horizontal lifeline. While being out of sight, the horizontal lifeline offers fall protection; however, a secure and waterproof installation of the horizontal lifeline can be difficult and expensive. Additionally, a horizontal lifeline system is an active fall prevention system requiring that an individual must actively don a harness having a safety line which then must be connected to the span of the horizontal lifeline. If an individual neglects to don the harness and connect the safety line, then the attributes of such an active system are not realized. A passive fall prevention system such as provided by the present invention does not require, after erection of the rails, any further action or connective maneuver by any personnel member. Protection is provided for all personnel, not just those who are connected such as to a lifeline.
SUMMARY OF THE INVENTION
[0006] The general purpose of the present invention is to provide a collapsible safety rail system which is portable and which is intended to be used to provide for fall protection from elevated or other work areas where human safety is an issue. The collapsible safety rail system is a portable system which can be broken down to a plurality of individual collapsible safety rail assemblies and a plurality of heavy and substantial cast iron bases which support the collapsible safety rail assemblies. The collapsible safety rail assemblies include a plurality of rails and end posts where a pivot assembly comprises the lower portion of each end post. Each pivot assembly includes a slotted tubular base which is stationary and a multi-radius mounting fixture pivotably secured to the upper region of the slotted tubular base. A pivot pin secures between an upper region of the slotted tubular base and through a pivot pin hole in a reduced radius shaft portion of the mounting fixture. A detent pin secures between an upper region of the slotted tubular base and through a detent pin hole in the reduced radius shaft portion of the mounting fixture. The lower region of the slotted tubular base aligns and secures within a post receiver in the cast iron base and can be rotated therein. The lower portion of an end post of the collapsible safety rail assembly aligns over and suitably secures about an end post mount at the upper portion of the mounting fixture. The collapsible safety rail assembly can be pivoted horizontally about the pivot pins subsequent to removal of the detent pins to a substantially horizontal and flat orientation, thereby reducing the viewable profile of the collapsible safety rail system and positioning the collapsible safety rail system completely out of view provided that the lower structure of the invention is located on an otherwise nonviewable area.
[0007] The bases of substantial weight are vital components of the collapsible safety rail system and enable the system to be as versatile as described herein. A base according to this invention has four post receivers so as to enable as many as four assemblies or devices including the collapsible safety rail assembly, as well as other patented devices by the inventor, such as, but not limited to, rail sections, latching posts, gate posts, or related devices, to be engagingly incorporated at any one time. Designed into each of the post receivers are strategically positioned slots, being horizontally aligned and being elongated. These slots align with at least two spaced holes in the lower region of the end posts of the collapsible safety rail assembly. This alignment enables the safety rail assemblies to be secured to the base at infinite positions along a 360° rotation with a locking pin. Thus, the collapsible safety rail system has the versatility to align to multiple protected work areas defined by the base placement. The base also incorporates four symmetrically positioned holes to enable a permanent mount to a surface via some form of anchor bolts, if desired. Further, the base includes cutouts and recesses which form recessed handles for manual grasping when it is necessary to move or carry the base. All edges of the recesses and the upper edges of the cutouts are rounded to eliminate sharp corners that could prove to be uncomfortable when the recessed handles are gripped. Yet another feature of the base is a stacking feature. Specifically, the base includes stacking recesses on its planar bottom surface in alignment with the post receivers. These stacking recesses receive the upper ends of the post receivers for stacking of bases when not in use. Drain holes coaxial with the post receivers and the stacking recesses extend through the base. Although collapsibility and portability of the collapsible safety rail system are major attributes of the invention, provisions are also made for continual use of the invention where the invention can be permanently secured and permanently utilized as a fixed but collapsible structure.
[0008] According to one or more embodiments of the present invention, there is provided a collapsible safety rail system which includes one or more collapsible safety rail assemblies having pivot assemblies and a plurality of bases. The pivot assemblies at the lower portions of the collapsible safety rail assemblies allow the collapsible safety rail assemblies to maintain an upright protective position or to allow the collapsible safety rail assemblies to be pivoted about the pivot assemblies to maintain a low and unobtrusive profile. The safety rail assemblies and plurality of substantial heavy bases provide for stability of the collapsible safety rail system to provide a robust structure which denies access to a hazard area or work area which is substantially unmovable when acted upon by any off balance, falling, or misdirected human form.
[0009] One significant aspect and feature of the present invention is a collapsible safety rail system incorporated to prevent access to hazardous areas or to prevent falls from roofs or other elevated structures or falls into hazardous areas.
[0010] Another significant aspect and feature of the present invention is a collapsible safety rail system which can surround or be located adjacent to a work area.
[0011] A further significant aspect and feature of the present invention is collapsible safety rail system having pivot assemblies which allow collapsible safety rail assemblies to be maneuvered to a low profile unobtrusive position.
[0012] A still further significant aspect and feature of the present invention is a collapsible safety rail system which, by the use of common bases, can also accommodate other rail sections, latching posts, gate posts, or related devices to be incorporated at any one time.
[0013] Still another significant aspect and feature of the present invention is the use of a pivot assembly between a heavy base and an end post of a collapsible safety rail assembly.
[0014] Yet another significant aspect and feature of the present invention is a pivot assembly having a slotted tubular base which pivotally accommodates a mounting fixture.
[0015] Yet another significant aspect and feature of the present invention is a mounting fixture having an end post mount and a reduced radius shaft.
[0016] Yet another significant aspect and feature of the present invention is a reduced radius shaft maximally sized to provide for suitable robustness.
[0017] A still further significant aspect and feature of the present invention is a collapsible safety rail system which can incorporate other rail sections, latching posts, gate posts, or related devices, some or all or none of which can include a pivot assembly.
[0018] Yet another significant aspect and feature of the present invention is a reduced radius shaft having a semispherical-shaped end to provide for suitable robustness.
[0019] Another significant aspect and feature of the present invention is a collapsible safety rail system which is portable.
[0020] Another significant aspect and feature of the present invention is a collapsible safety rail system which is portable, but which can be permanently mounted.
[0021] Yet another significant aspect and feature of the present invention is a collapsible safety rail system which uses heavy bases to provide for overall stability and robustness.
[0022] A still further significant aspect and feature of the present invention is a collapsible safety rail system which can be freestanding, but which can be permanently secured to a suitable mounting surface or structure utilizing mounting hardware extending through holes in the bases, if desired.
[0023] A still further significant aspect and feature of the present invention is a collapsible safety rail system having bases which are user-friendly for the purposes of manual handling, and which are stackable.
[0024] Having thus briefly described embodiments of the present invention and having mentioned some significant aspects and features of the present invention, it is the principal object of the present invention to provide a collapsible safety rail system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
[0026] FIG. 1 is an isometric view showing the use and structure of the collapsible safety rail system, the present invention;
[0027] FIG. 2 is an exploded view of a pivot assembly in relationship to the lower portion of an end post;
[0028] FIG. 3 is an assembled view of the pivot assembly connected to the lower portion of the end post;
[0029] FIG. 4 is a front view of the assembled components of FIG. 3 with the lower portion of the end post depicted in phantom;
[0030] FIG. 5 is a cross section view of the pivot assembly substantially along line 5 - 5 of FIG. 4 showing the mounting fixture and connected end post pivoted about the pivot pin to position the end post of the collapsible safety rail assembly to provide for minimum viewable profile;
[0031] FIG. 6 is a cross section view of the pivot assembly along line 6 - 6 of FIG. 4 ;
[0032] FIG. 7 is an isometric view of a base;
[0033] FIG. 8 shows a pivot assembly and a portion of an attached end post aligned vertically in the post receiver prior to pivoting of the mounting fixture and attached end post;
[0034] FIG. 9 illustrates the pivoting of the mounting fixture and attached end post to and beyond the horizontal position during positioning of a collapsible safety rail assembly;
[0035] FIG. 10 , an alternative embodiment, is an exploded view of a pivot assembly in alignment with an end post;
[0036] FIG. 11 is an assembled view of elements of FIG. 10 ; and,
[0037] FIG. 12 is a cross section view of a pivot assembly substantially along line 12 - 12 of FIG. 11 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] FIG. 1 is an isometric view of the collapsible safety rail system 10 , the present invention, including a plurality of similarly constructed collapsible safety rail assemblies 12 a - 12 d and a plurality of bases 14 a - 14 e of substantial weight and size, each connectively associated with one or more collapsible safety rail assemblies 12 a - 12 d . For purposes of illustration and example, the collapsible safety rail system 10 is shown in use for protection along the edge of a wall section 13 extending above the top surface of a roof 15 where the collapsible safety rail system 10 is shown partially in the protective mode and partially in the collapsed mode. Collapsible safety rail assemblies 12 a and 12 b are shown in the protective mode of operation being vertically erected with respect to the bases 14 a - 14 c for prevention of access across the collapsible safety rail assemblies 12 a and 12 b . Collapsible safety rail assemblies 12 c and 12 d are shown in the collapsed mode of operation being substantially horizontally oriented with respect to the bases 14 c - 14 e to provide for minimum viewable profile.
[0039] The similarly constructed collapsible safety rail assemblies 12 a - 12 d each includes opposed left and right end posts 16 and 18 , a top horizontal rail 20 extending from the left end post 16 to the right end post 18 , and a bottom horizontal rail 22 extending between the left end post 16 and the right end post 18 . An accessible instruction storage tube 23 is located on each bottom horizontal rail 22 . Individual pivot assemblies designated 24 a and 24 b , as described in detail as pivot assembly 24 in FIG. 2 , are located at the ends of the left and right end posts 16 and 18 nearest the bottom horizontal rail 22 , respectively, of each of the collapsible safety rail assemblies 12 a - 12 d . A slotted tubular base 26 ( FIG. 2 ), which is stationary, is located at the lower region of each of the pivot assemblies 24 a and 24 b and secures in the bases 14 a - 14 e , as later described in detail.
[0040] FIG. 2 is an exploded view of the pivot assembly 24 , multiply designated as pivot assemblies 24 a and 24 b in FIG. 1 , in relationship to the lower portion of an end post 18 . The pivot assembly 24 has major structural components including a stationary slotted tubular base 26 and a pivotable multi-radius mounting fixture 28 , and also includes a pivot pin 30 and a detent pin 32 having a spring-loaded ball 33 , the latter of which is secured to the slotted tubular base 26 by a lanyard 34 and ring 35 . Also shown is another locking pin 36 including suitable hardware for securing of the pivot assembly 24 to one of the bases 14 a - 14 e.
[0041] The slotted tubular base 26 includes a slot 38 in vertical orientation intersecting the wall of the slotted tubular base 26 at the upper region of the slotted tubular base 26 . Opposed pivot pin holes 40 extend through the upper region of the slotted tubular base 26 for accommodation of the pivot pin 30 , and opposed detent pin holes 42 aligned above the opposed pivot pin holes 40 extend through the upper region of the slotted tubular base 26 for accommodation of the detent pin 32 . Four or another suitable number of locking pin holes 44 extend through the lower region of the slotted tubular base 26 for accommodation of the locking pin 36 when securing the pivot assembly 24 to a base 14 a - 14 e . The multi-radius mounting fixture 28 includes a round end post mount 46 and a round reduced radius shaft 48 having a semispherical-shaped end 50 extending from the end post mount 46 . The radius of the reduced radius shaft 48 is nearly as large as the radius of an inside surface 27 (see also FIG. 6 ) of the slotted tubular base 26 . Such a relationship allows for robustness and maximizes the structural integrity of the mounting fixture 28 by providing sufficient structural mass about a pivot pin hole 52 extending through the lower portion of the reduced radius shaft 48 . The pivot pin hole 52 accommodates the pivot pin 30 , and a detent pin hole 54 aligned above the pivot pin hole 52 extends through the upper portion of the reduced radius shaft 48 for accommodation of the detent pin 32 .
[0042] FIG. 3 is an assembled view of the pivot assembly 24 attached to the lower portion of the end post 18 . The end post mount 46 can be a close tolerance fit for suitable accommodation by the lower portion of the end post 18 and can be secured therein such as by swaging the end post 18 at one or more locations, such as is shown by one or more swages 56 , or by other suitable methods, such as, but not limited to, welding, press fitting, the use of fasteners, and the like. The reduced radius shaft 48 is shown aligned vertically within the top region of the slotted tubular base 26 and secured therein by the pivot pin 30 which extends through the opposed pivot pin holes 40 in the slotted tubular base 26 and through the pivot pin hole 52 in the reduced radius shaft 48 and by the detent pin 32 which extends through the opposed detent pin holes 42 in the slotted tubular base 26 and through the detent pin hole 54 in the reduced radius shaft 48 .
[0043] FIG. 4 is a front view of the assembled components of FIG. 3 with the lower portion of the end post 18 depicted in phantom. Shown in particular is the accommodation of the pivot pin 30 and of the detent pin 32 , as described with reference to FIG. 2 . One end of the pivot pin 30 is peened over at 53 to permanently maintain the position of the pivot pin 30 . The spring-loaded ball 33 maintains the position of the detent pin 32 to ensure the upright positioning of the end post 18 when the collapsible safety rail assemblies 12 a - 12 d are in the upright position.
[0044] FIG. 5 is a cross section view of the pivot assembly 24 substantially along line 5 - 5 of FIG. 4 showing the mounting fixture 28 and connected end post 18 (and 16 ) pivoted about the pivot pin 30 such as to position the end posts 18 of the collapsible safety rail assemblies 12 c - 12 d , as shown in FIG. 1 , to provide for minimum viewable profile. The semispherical-shaped end 50 of the reduced radius shaft 48 is easily accommodated by and maintains clearance with the inside surface 27 of the slotted tubular base 26 to permit sufficient rotation of the mounting fixture 28 therein, as there is no interfering or conflicting geometry. The vertical dimension of the slot 38 is of sufficient length to allow rotation of the mounting fixture 28 below the horizontal aspect to allow the top horizontal rail 20 of the collapsible safety rail assemblies 12 c - 12 d to contact and rest upon the general horizontal surface upon which the collapsible safety rail system 10 is utilized.
[0045] FIG. 6 is a cross section view of the pivot assembly 24 along line 6 - 6 of FIG. 4 . Shown in particular is the relationship of the reduced radius shaft 48 to the interior surface 27 of the slotted tubular base 26 , wherein clearance is provided for pivotal rotation therein.
[0046] FIG. 7 is an isometric view of the base 14 a , one of the identical bases 14 a - 14 e according to the present invention. The bases 14 a - 14 e can weigh between 100-120 pounds for purposes of example, and can be of cast iron or welded plate and tube to support safety rail sections or assemblies without tipping. The identically constructed bases 14 a - 14 e include four post receivers 58 a - 58 d which extend perpendicularly and upwardly from planar top portion or surface 60 , any of which can appropriately accommodate the left or right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 d , as well as other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers, which can also include one or more pivot assemblies 24 . Each of these post receivers 58 a - 58 d includes a plurality of horizontally aligned pin receivers, such as slots 62 a - 62 n , best shown on post receiver 58 b . Left and right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 d , as well as other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers, all incorporate the plurality of locking pin holes 44 ( FIG. 2 ) for receiving locking pins 36 ( FIG. 2 ) to hold the left and right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 d , as well as other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers in place in the post receivers 58 a - 58 d of the bases 14 a - 14 e . The left or right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 d or other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers, are secured to the post receivers 58 a - 58 d of one or more individual bases 14 a - 14 e by the use of locking pins 36 extending through opposed locking pin holes 44 and the slots 62 a - 62 n . Such a relationship allows the left or right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 n , as well as other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers, to pivot as required about the vertical axes of the post receivers 58 a - 58 d . In the alternative, a base 14 a - 14 e can also be pivoted about the lower region of a left or right post 16 and 18 , respectively, in order to align and utilize other post receivers 58 a - 58 d or other suitably fashioned components. Each base 14 a - 14 e may accommodate a maximum of four of the following components in various combinations: left and right end posts 16 and 18 of the collapsible safety rail assemblies 12 a - 12 d and other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers. Each can be locked in any position within its range of motion about a vertical axis by various utilizations of the holes 44 , the pin receivers in the form of slots 62 a - 62 n , and the locking pins 36 , all of which together constitute locking means or means for locking the various posts or other suitably fashioned components to the post receivers. It is to be understood that the slots 62 a - 62 n may be replaced with multiple holes at different heights to accommodate other variously located holes in the lower region of a post, but holes will not allow the infinite 360° range in which the left or right end posts 16 and 18 , as well as other suitably fashioned components, such as, but not limited to, unshown latching posts, gate posts, or locking couplers, can be angularly oriented and locked. It is also to be understood that slots, such as slots 62 a - 62 n , can be included at other levels along and about the post receivers 58 a - 58 d , as well as at various locations about the circumferences of the post receivers 58 a - 58 d , to maintain 360° positionable capabilities of any member which engages the interior of the post receivers 58 a - 58 d.
[0047] The bases 14 a - 14 e include cutouts 64 a - 64 d , whereby handling of the bases 14 a - 14 e is readily facilitated in a manual fashion. Each base 14 a - 14 e is constructed in the same manner having identical parts including the planar top portion or surface 60 with cutouts 64 a - 64 d on four opposing sides creating built-in recessed handles 66 a - 66 d for manual transporting or lifting of the bases 14 a - 14 e . The bases 14 a - 14 e include a continuous curved or radiused upper edge 68 about the planar top portion or surface 60 . The recessed handles 66 a - 66 d are fashioned to accommodate manual handling and include features making the gripping of the recessed handles 66 a - 66 d accessible and comfortable. The upper and outer regions of the recessed handles 66 a - 66 d are formed by portions of the curved or radiused upper edge 68 , and the remaining edges forming the recessed handles 66 a - 66 d have edges which are curved or radiused to eliminate any edges which could prove to be uncomfortable given the weight of the bases 14 a - 14 e . It is to be appreciated that all of the upper edges of the cutouts 64 a - 64 d are curved or radiused. Downwardly extending recesses 70 a - 70 d beneath the recessed handles 66 a - 66 d provide for manual access under the recessed handles 66 a - 66 d without first lifting the bases 14 a - 14 e . There is also a centrally located lifting bar 72 which allows the user to hook the bases 14 a - 14 e to a pulley, a dolly, or other labor saving device to more easily move the heavy bases 14 a - 14 e . There are provided holes 74 a - 74 d which can accommodate anchor bolts for securing the bases 14 a - 14 e to a work surface, such as a concrete floor or roof top, if permanent mounting is desired.
[0048] Stacking recesses (not shown) are recessed into a planar bottom surface of the bases 14 a - 14 e which align with the upper regions of other post receivers 58 a - 58 d extending from the planar top portion or surface 60 . The stacking recesses are utilized for stacking or storage of bases 14 a - 14 e when not in use. Also included are drain holes (not shown) extending through the bases 14 a - 14 e and co-located between the post receivers 58 a - 58 d and the stacking recesses.
Mode of Operation
[0049] FIGS. 8 and 9 best illustrate the mode of operation. FIG. 8 shows a pivot assembly 24 and a portion of an attached end post 18 aligned vertically in the post receiver 58 a prior to pivoting of the mounting fixture 28 and attached end post 18 (and 16 ), as well as the rest of a collapsible safety rail assembly 12 c - 12 d to the collapsed position in a fashion shown in FIG. 1 ; and FIG. 9 illustrates the pivoting of the mounting fixture 28 and attached end post 18 to and beyond the horizontal position. The locking pin 36 is not shown engaged in the locking position for purposes of brevity.
[0050] In FIG. 8 , the detent pin 32 and the pivot pin 30 engage both the slotted tubular base 26 and the mounting fixture 28 of the pivot assembly 24 , and the pivot assembly 24 engages the post receiver 58 a of the base 14 a . Such an arrangement causes the mounting fixture 28 and connected end post 18 to maintain a vertically oriented position, thereby keeping a collapsible safety rail assembly 12 a - 12 b in the erect and protective mode of operation.
[0051] In FIG. 9 , the detent pin 32 is shown disengaged from the holes 42 of the slotted tubular base 26 and from the detent pin hole 54 of the reduced radius shaft 48 to allow pivoting of the mounting fixture 28 about the co-located pivot pin hole 52 of the reduced radius shaft 48 and the pivot pin 30 . Such pivoting allows repositioning of the mounting fixture 28 and connected end post 18 of a collapsible safety rail assembly 12 c - 12 d to a collapsed and minimum viewable profile position, as shown in FIG. 1 . Understandably, parallel operation and manipulation at another of the bases 14 a - 14 e at the other end of an associated collapsible safety rail assembly 12 c - 12 d would occur simultaneously to allow such repositioning of a collapsible safety rail assembly 12 c - 12 d . Erection of the collapsible safety rail assembly 12 c - 12 d is accomplished in reverse order. The use of pivot assemblies 24 can also be incorporated into use with the post receivers 58 a - 58 d of the bases 14 a - 14 d to provide for collapsing of other related structures, such as, but not limited to, unshown latching posts, gate posts, and the like.
[0052] FIG. 10 , an alternative embodiment, is an exploded view of a pivot assembly 80 which could be utilized in lieu of pivot assemblies 24 a and 24 b of FIG. 1 shown in relationship to the lower region of an end post 82 which can be utilized in lieu of end post 18 (and 16 ) to, in part, form collapsible safety rail assemblies generally similar to collapsible safety rail assemblies 12 a - 12 d . The pivot assembly 80 has major structural components including a stationary tubular base 84 and a vertically aligned mounting fixture 86 resembling a channel having panels 86 a , 86 b and 86 c . Opposed pivot pin holes 88 extend through the upper region of the panels 86 a and 86 c , respectively. A pivot pin 30 a extends through the opposed pivot pin holes 88 a . A detent pin 32 a is secured to the mounting fixture 86 by a lanyard 34 a and ring 35 a . Opposed detent pin holes 90 align above the opposed pivot pin holes 88 and extend through the upper regions of the panels 86 a and 86 c , respectively, for accommodation of the detent pin 32 a . The detent pin 32 a includes a spring-loaded ball 33 a . Also shown is another locking pin 36 a including suitable hardware for securing of the pivot assembly 80 to one of the bases 14 a - 14 e.
[0053] The end post 82 includes opposed pivot pin holes 92 at the lower edge thereof and opposed detent pin holes 94 aligned above the opposed pivot pin holes 92 . The lower portion of the end post 82 includes radiused edges 96 a and 96 b which accommodate rotation of the lower region of the end post 82 to provide clearance with the panel 86 b at the rear of the mounting fixture 86 .
[0054] The tubular base 84 includes locking pin holes 44 a which extend through the lower region of the tubular base 84 for accommodation of the locking pin 36 a when securing the pivot assembly 80 to a base 14 a - 14 e . The radius of the tubular base 84 and of the end post 82 is nearly as large as the distance between inside surfaces of the panels 86 a and 86 c of the mounting fixture 86 . Such a relationship allows for robustness and maximizes the structural integrity about the mounting fixture 86 by providing sufficient structural mass about the opposed pivot holes 92 extending through the lower portion of the end post 82 . The opposed pivot holes 92 accommodate the pivot pin 30 a and the opposed detent pin holes 94 provide for accommodation of the detent pin 32 a.
[0055] FIG. 11 is an assembled view of elements of FIG. 10 where the tubular base 84 is attached to the mounting fixture 86 , such as by welding, riveting, the use of fasteners, or other suitable methods. The tubular base 84 attaches to the bases 14 a - 14 e by use of the locking pin 36 a in a manner previously described. The end post 82 secures to the mounting fixture 86 by the use of the pivot pin 30 a which extends through the opposed pivot pin holes 88 of the mounting fixture 86 and the opposed pivot pin holes 92 of the end post 82 and is peened over to secure therein. The detent pin 32 a assists in securing of the end post 82 to the mounting fixture 86 . The detent pin 32 a extends through the opposed detent pin holes 90 of the mounting fixture 86 and through the opposed detent pin holes 94 of the end post 82 and is secured therein by the spring-loaded ball 33 a.
[0056] FIG. 12 is a cross section view of the pivot assembly 80 substantially along line 12 - 12 of FIG. 11 showing the relationship of the mounting fixture 86 , the attached end post 82 , and the attached tubular base 84 . The end post 82 is pivoted about the pivot pin 30 a as shown in dashed lines to position the end post 82 in the same manner shown for the collapsible safety rail assemblies 12 c - 12 d as illustrated in FIG. 1 , to provide for minimum viewable profile. The radiused edges 96 a and 96 b of the end post 82 are easily accommodated by and maintain clearance with the panel 86 b of the mounting fixture 86 to permit sufficient rotation of the end post 82 within mounting fixture 86 , as there is no interfering or conflicting geometry. The vertical spacing between the top of the tubular base 84 and the end post 82 is of sufficient dimension to allow rotation of the end post 82 below the horizontal aspect to allow the top horizontal rail of the collapsible safety rail assemblies which are generally similar to collapsible safety rail assemblies 12 a - 12 d to contact and rest upon the general horizontal surface upon which the collapsible safety rail system 10 is utilized.
[0057] Operation of the alternative embodiment is similar in many fashions to the operation of the preferred embodiment. The detent pin 32 a is removed to allow pivoting of the end post 82 about the pivot pin 30 a in order to maneuver a collapsible safety rail assembly similar in most respects to the collapsible safety rail assemblies 12 a - 12 d.
[0058] Various modifications can be made to the present invention without departing from the apparent scope hereof.
Parts List
[0059]
10
collapsible safety
rail system
12a-d
collapsible safety
rail assemblies
13
wall section
14a-e
bases
15
roof
16
end post
18
end post
20
top horizontal rail
22
bottom horizontal
rail
23
instruction storage
tube
24
pivot assembly
24a-b
pivot assemblies
26
slotted tubular base
27
inside surface
28
mounting fixture
30
pivot pin
30a
pivot pin
32
detent pin
32a
detent pin
33
spring-loaded ball
33a
spring-loaded ball
34
lanyard
34a
lanyard
35
ring
35a
ring
36
locking pin
36a
locking pin
38
slot
40
pivot pin hole
42
detent pin hole
44
locking pin hole
44a
locking pin hole
46
end post mount
48
reduced radius shaft
50
semispherical-shaped
end
52
pivot pin hole
53
peen
54
detent pin hole
56
swage
58a-d
post receivers
60
planar top portion or
surface
62a-n
slots
64a-d
cutouts
66a-d
recessed handles
68
curved or radiused
upper edge
70a-d
recesses
72
lifting bar
74a-d
holes
80
pivot assembly
82
end post
84
tubular base
86
mounting fixture
86a-c
panels
88
pivot pin hole
90
detent pin hole
92
pivot pin hole
94
detent pin hole
96a-b
radiused edges | A collapsible safety rail system for providing a portable or permanent protective barrier to provide for fall prevention from elevated or other work areas. Lockable pivot assemblies are located between heavy bases and the end posts of collapsible safety rail assemblies. Removable detent pins are utilized to lock the pivot assemblies to maintain the erected position of the collapsible safety rail assemblies in protective vertical orientation or are removed to allow maneuvering of the collapsible safety rail assemblies to a minimum viewable profile position when not required for personnel protection. | 4 |
FIELD OF THE INVENTION
The invention relates to a device for recovering energy in working machines. The device has at least one power drive actuatable to move a load mass back and forth, and an energy storage system absorbing the energy released in the movement of the load mass in one direction and permitting a subsequent movement in the other direction.
BACKGROUND OF THE INVENTION
Devices of this type for recovery of potential energy in working machines are prior art; see, for example, WO 93/11363 or EP 0 789 816 B1. As energy storage systems, such devices have pressure accumulators storing the released potential energy as pressure energy of a working gas. It is crucial for the efficiency of these devices that the lowest possible energy losses occur in operation. The losses involve primarily losses of thermal energy of the accumulator gas. Generally, a large part of the thermal energy forming when the working gas is compressed is released via the outer walls of the hydraulic accumulator used in the prior art as an energy storage system. The large-area contact region between the working gas and the exterior can lead to considerable heat losses for the relatively large surface of the accumulator housing (preferably of steel) under consideration.
SUMMARY OF THE INVENTION
An object of the invention is to provide an improved energy recovery device characterized by a greatly improved energy balance with an especially simple and money-saving design.
According to the invention, this object is basically achieved by a device comprising an energy storage system in the form of an accumulator cylinder. The accumulator cylinder is mechanically coupled to the load mass and stores pneumatic pressure energy for movement in one direction. For movement in the other direction, the accumulator cylinder acts as an auxiliary working cylinder supporting the power drive and converting the stored pressure energy into driving force.
Preferred, the accumulator cylinder as the auxiliary working cylinder is coupled to a load mass to be raised and lowered and stores potential energy released in lowering processes in the form of pneumatic pressure energy.
The use of an energy storage system in the form of an accumulator cylinder as a replacement of conventional hydraulic accumulators improves the energy balance in more than one respect. On the one hand, the direct mechanical coupling of the accumulator cylinder to the load mass allows the stored pressure energy to be converted directly into lifting force so that the accumulator cylinder acts as an additional power drive, and results in the elimination of the hydraulic system required in the prior art between the hydraulic accumulator and power drive. The associated energy losses, which otherwise occur, are then eliminated. Furthermore, an accumulator cylinder, when compared to a hydraulic accumulator, affords considerably more design options for reducing the direct heat loss of the working gas.
This direct heat loss can be reduced quite significantly and especially advantageously, when the piston rod of the accumulator cylinder is a hollow, end-side open part forming the piston whose cavity in the position fully retracted into the cylinder contains essentially the entire volume of the working gas. In this construction of the piston, generation of heat takes place when the piston rod is lowered within the piston, that is, in a region isolated from the cylinder wall by the wall of the hollow piston. The piston is dimensioned such that in its cavity it contains essentially the entire volume of the working gas. When the piston is fully retracted in this operating state corresponding to the strongest compression, and to the greatest generation of heat, the piston wall extends over the entire length of the cylinder so that it is double walled in this state of greatest generation of heat. Heat loss is thus minimized.
On the other hand, in this construction, as a result of the specific overall length of the piston, in the fully extended position its wall with a corresponding flat portion is outside the cylinder wall. In this fully extended position, the working gas has cooled in response to the expansion. At the same time, for this piston position the wall surface exposed to the exterior and formed from a cylinder surface and the exposed jacket surface of the piston, has a maximum value. Accordingly, the thermal resistance of the total wall area is minimal so that a relatively large amount of thermal energy is absorbed from the ambient air and is released to the cooled working gas. This construction results in an optimal energy balance.
Not only does the double wall arrangement present in certain sections contribute to optimization of the thermal energy balance, but also of the working or operating medium enclosed in the double wall, for example, in the form of a working gas and/or in the form of hydraulic oil.
The accumulator cylinder can be formed in the shape of a cup having closed bottom with a filler port for the working gas, such as N 2 .
In especially advantageous exemplary embodiments, on the open end of the accumulator cylinder, opposite the bottom, a guide is formed to guide the outside of the piston at a distance from the inner wall of the cup, which distance forms an oil gap.
Preferably, on the open end of the piston, a second guide is formed guiding the end of the piston while maintaining the oil gap. In this way, the piston can be guided without problems.
In particular, together with an oil charge located in the oil gap, a high pressure sealing system can be formed working reliably in long-term operation even in applications with high pressures, for example, of more than 100 bar.
To accommodate the oil that is displaced when the piston is extended and with the resulting reduction of the length of the oil gap and to make it available again upon retraction, a hydraulic accumulator can be connected to the oil gap. The accumulator then compensates for changes of the volume of the oil gap when the piston moves.
In especially advantageous exemplary embodiments, the accumulator cylinder is used as an auxiliary working cylinder mechanically shunted to a hydraulic working cylinder which can be actuated by the hydraulic system and which is used as a power drive. This structure enables an especially simple construction, especially for hoists, crane booms, and the like, where hydraulic cylinders are provided as a power drive acting directly on the load mass.
Since the prior art recovered energy is available in the form of hydraulic pressure energy from a hydraulic accumulator, the recovered energy can be used only for hydraulic power drives such as working cylinders or hydraulic motors. In contrast, the invention can be used in conjunction with any power drives which need not be able to be hydraulically actuated, for example, in spindle drives, cable pulls, or the like, which are activated by an electric motor and which are provided for the lifting of loads.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses preferred embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a schematically simplified, side elevational view of a crane boom, provided with one exemplary embodiment of the device according to the invention for recovering potential energy;
FIG. 2 is a side elevational view, symbolically representing an accumulator cylinder in mechanical shunting to a working cylinder for explaining the operating principle of the invention;
FIG. 3 is a schematically simplified, side elevational view in section of an accumulator cylinder according to a first exemplary embodiment of the invention;
FIG. 4 is a schematically simplified, side elevational view in section of an accumulator cylinder a second exemplary embodiment of the invention;
FIG. 5 is a schematically simplified, side elevational view in section of an accumulator cylinder according to a third exemplary embodiment of the invention; and
FIG. 6 is a schematically simplified, side elevational view in section of an accumulator cylinder according to a fourth exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
The invention is explained below using exemplary embodiments in which a crane boom 2 forms a load mass 4 ( FIG. 2 ). The boom 2 can be raised by a power drive in the form of a hydraulic working cylinder 6 . More specifically, boom 2 can be pivoted around a coupling point 8 . The working cylinder 6 is a hydraulic cylinder which can be actuated by a hydraulic system 10 symbolically represented only in FIG. 2 . The hydraulic system 10 is only shown with a control valve arrangement 12 and a hydraulic pump 14 in FIG. 2 , can be, in particular, of a design that is conventional for working machines, so that it need not be described in detail.
An accumulator cylinder 16 is mechanically shunted to the working cylinder 6 forming the power drive. Specifically the piston rod 18 of the accumulator cylinder 16 , like the piston rod 20 of the working cylinder 6 , acts directly on the load mass 4 (boom 2 ).
FIG. 3 , in a separate representation, shows details of the accumulator cylinder 16 . As is apparent, the accumulator cylinder has the shape of a cup 22 with a closed bottom 24 . Bottom 24 has a filler port, (not shown) for a working gas, in this example N 2 . In the illustrated example, the end of the piston rod 18 forms the piston 26 in the form of a hollow body with an inner cavity 30 opening on the piston end 28 . In the fully retracted position of the piston 26 , when the piston end 28 is on the bottom 24 of the cup 22 , piston 26 contains the entire volume of working gas. FIG. 3 shows the piston 26 more or less in the middle position in which the gas volume is composed of the inner space of the cup 22 free of the piston 26 and the cavity 30 of the piston 26 .
The piston 26 is guided on the inner wall of the cup 22 of the accumulator cylinder 16 such that there is an oil gap 32 on the outside of the piston 26 . For this purpose, a guide 36 for the piston 26 is on the open end 34 of the cup 22 . On the open piston end 28 , a second guide 38 is provided. Both guides 36 , 38 ensure preservation of the oil gap 32 during piston movements. They are additionally each provided with a seal arrangement 40 so that together with oil filling of the oil gap 32 not only piston lubrication, but also a high pressure sealing system are formed. To compensate for the volume of the oil gap 32 , which varies during piston movements, a hydraulic accumulator 42 is connected to the oil gap 32 and accommodates the oil displaced when the piston 26 is extended and releases it again when the piston 26 is retracted.
As mentioned, in FIG. 3 the piston 26 is in a middle position at which the load mass 4 is partially lowered. If the load mass 4 is completely lowered, the piston 26 moves in the direction of the bottom 24 of the cup 22 so that the piston end 28 in the end position of the lowering motion approaches the bottom 24 . When the piston 26 is retracted, the working gas is compressed to a volume corresponding to the volume of the cavity 30 of the piston 26 in the fully retracted position. In this way, the potential energy of the load mass 4 released during lowering is converted into pressure energy in the accumulator cylinder 16 . The fully retracted position of the piston 26 corresponds to the state of strongest compression and thus to the maximum heating of the working gas. At the same time, in the invention in this operating state, the heated working gas is enclosed double walled, because the piston wall 44 in this position extends over the entire length of the cup 22 along the cup wall 46 . In addition, the medium collected in the oil gap 32 and extending essentially over the entire length of the cup 22 forms an additional insulating layer between the cup wall 46 and piston wall 44 .
In the state of maximum heating, the accumulator cylinder 26 is thus at the same time in the state of best heat insulation. On the other hand, in the fully extended position of the piston 26 , that is, a state in which as a result of expansion the working gas is in the most heavily cooled state, the piston 26 with almost the entire length of its piston wall 44 is outside the cup 22 . Specifically, during the “supercooled” operating state, the accumulator cylinder 16 exhibits the highest value of the wall surface exposed to the exterior. The essentially entire surface of the cup wall 46 and the piston wall 44 is exposed so that a relatively large amount of heat can be absorbed from the ambient air. Therefore, the energy balance is good overall due to the low heat release for the “superheated” state and the high heat absorption for the “supercooled” state of the working gas in the invention.
FIG. 4 shows a second exemplary embodiment where there is no external hydraulic accumulator connected at the oil gap 32 . Instead, the oil gap 32 does not contain a complete oil charge, but is divided into an oil side 62 containing an oil charge and a gas side 64 filled with nitrogen by a floating, that is, axially movable seal 60 . In the movements of the piston 26 , the oil gap thus forms a type of miniaturized hydraulic accumulator.
FIG. 5 shows a further modified example according to a third exemplary embodiment, in which, with the hydraulic accumulator 42 connected to the oil gap 32 , the accumulator's gas side is connected to the interior of the piston 26 via a charging line 66 . The filling pressure of the accumulator 42 is then automatically held at the pressure level of the working cylinder 16 . Pressure limitation and/or check valves (not shown) can be provided in the charging line 66 to dictate the filling pressure of the hydraulic accumulator 42 or convey it in one direction, if so desired. In a modification of this solution, line 66 can be advantageously connected to the bottom 24 of the accumulator cylinder 16 , and not in the region of the upper, head-side cover of the piston rod 18 , to provide a direct fluid-carrying connection between the interior of the working cylinder 16 and the accumulator 42 , specifically, on the side of the accumulator 42 opposite the outlet site of the line leading to the space 32 .
FIG. 6 shows a fourth version in which the interior of the accumulator cylinder 6 is connected to a supply source 70 for working gas via a supply line 68 . Moreover, to further improve heat insulation, the inner cavity 30 of the piston 26 is completely filled with a large-pore foam material 72 which can partially also accommodate the working gas.
In the highly schematically simplified representations of FIGS. 3 to 6 , which illustrate only the operating principle, design details have been omitted. For example, a divided configuration of the open end 34 of the cup 22 enabling installation of the piston 26 or connections for delivery of the media into the oil gap 32 is not shown.
While various embodiments have been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. | A device recovers energy in working machines with at least one power drive actuated to move a load mass back and forth and with an energy storage system ( 16 ) absorbing the energy released in the movement of the load mass in one direction and making it available for a subsequent movement in the other direction. The energy storage system includes an accumulator cylinder ( 16 ) mechanically coupled to the load mass and storing pneumatic pressure energy for movement in one direction. For movement in the other direction, the accumulator cylinder acts as an auxiliary working cylinder supporting the power drive and converting the stored pressure energy into driving force. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of co-pending U.S. Provisional Application No. 60/589,942, filed Jul. 21, 2004, which is hereby incorporated herein.
BACKGROUND OF THE INVENTION
[0002] (1) Technical Field
[0003] The present invention relates generally to the field of fermentation devices and more specifically to a fermentation chamber and mixing apparatus.
[0004] (2) Description of Related Art
[0005] The development and commercialization of many processes in the fields of medicine, chemistry, and agriculture require the use of fermentation devices or “bioreactors.” Cell culturing, for example, is often carried out in vessels that permit the mixing of cells with nutritive media and oxygen. In industrial applications, such processes are often carried out in very large vessels, often greater than 50 liters in capacity. During research and development, however, it is generally desirable to test such processes on a much smaller scale. Historically, fermentation devices and bioreactors with volumes of 50 liters or less have suffered from various deficiencies.
[0006] Many problems with existing devices lie with the mixing mechanisms employed. Some processes use enzymes immobilized on the surfaces of particles within a liquid medium. As a result, most of the enzymatic activity is limited to the surfaces of the particles. Any method of mixing the liquid medium that causes abrasion of the particles will necessarily reduce enzymatic activity. Similar damage can be caused to cells or microorganisms within a liquid medium.
[0007] Magnetic stirrers, for example, are inapplicable to some processes, including the culturing of cells or microorganisms, due to the tendency of the magnetic stirrer, which necessarily contacts an interior surface of the vessel, to damage delicate components, such as living cells and microorganisms, that become trapped between the magnetic stirrer and the vessel wall. Attempts have been made to alleviate this disadvantage through the use of superconductive materials. TC Tech Corp. (www.tc-tech.com), for example, markets a mixing device wherein a disposable impeller is levitated above the vessel's bottom, thereby eliminating the potential for entrapment of cells or microorganisms between the impeller and the vessel wall. Such devices are, however, expensive to use, due to their need to operate at superconducting temperatures.
[0008] U.S. Patent Application Publication No. 2003/0008389 to Carll describes a disposable cell culture vessel with a hollow sleeve in its interior, into which is placed a magnetic stirrer. In some embodiments, the sleeve is fitted with a flexible blade. Such a device also reduces or eliminates the tendency of magnetic mixers to damage delicate components. However, due in part to the fact that the mixing action of the device is provided by the simple rotation of a magnetic bar, the device is incapable of providing greater agitation or aeration of the liquid medium. Rather, the placement of a magnet within the hollow sleeve “allows the gentle rotation of the impeller and the subsequent undulation of the flexible blades when an adjustable magnetic force, such as a magnetic stir plate, is applied to the vessel. This creates a gentle stirring of the cells, which keeps the cells in suspension and prevents the cells from shearing.” ¶ 17. Where more vigorous agitation or greater aeration of the liquid medium is needed, such a device is inadequate.
[0009] Other devices utilize blades or similar mechanisms to mix their liquid contents. U.S. Pat. No. 3,468,520 to Duryea et al., for example, describes a paddle-like mechanism residing within a bottle, which is designed to agitate a suspension of cells. Such devices, however, require the introduction of a foreign object, in the form of the mixing mechanism, into the liquid medium. This greatly increases the possibility of contamination of the medium by substances or organisms residing on the mixing mechanism. Avoidance of such contamination requires thorough cleaning and sterilization of the mixing mechanism before each use, which can greatly increase not only the burden and expense of using such devices, but also the level of technical experience required by its users.
[0010] Others have attempted to integrate the mixing mechanism into the vessel itself. U.S. Pat. No. 3,432,149 to Stalberg et al., for example, describes an apparatus for stirring a liquid having internal wings, wherein rotation of the device along its longitudinal axis exerts a dragging action on the liquid. However, such a device is capable of exerting a dragging action on only a small portion of the liquid. “The height of the liquid-dragging part of the vessel is at the most half of the intended liquid level, suitably no more than one-third thereof and preferably about one-fourth thereof.” Col. 2, lines 43-46. In addition, such a device is incapable of aerating the liquid by, for example, projecting a portion of the liquid above the level of the standing liquid, thereby creating turbulence between the surface of the liquid and a gaseous layer above it.
[0011] Attempts have been made to eliminate the need for internal mixing mechanisms altogether. U.S. Pat. No. 4,373,029 to Nees, and U.S. Pat. No. 3,540,700 to Freedman et al., for example, describe devices for pivotally rotating vessels containing cells and a nutrient medium. There is a limit, however, to the degree of mixing attainable with such devices. For example, Nees notes that “acceleration magnitudes are essentially determined only by the gravity of the microcarrier in the earth's gravitational field, reduced by the viscosity of the nutrient solution.” Col. 2, lines 11-14. Thus, for processes requiring a greater degree of mixing or agitation, including, for example, processes requiring greater aeration of the liquid medium, such devices are not useful.
[0012] A need exists, therefore, for a device that avoids the above limitations. Specifically, there is a need for a fermentation chamber and mixing apparatus that (1) will not damage delicate components of the liquid medium, such as living cells and microorganisms, (2) can provide sufficient agitation of the liquid medium to ensure proper mixing and/or aeration, (3) is inexpensive to produce and use.
SUMMARY OF THE INVENTION
[0013] The claimed invention provides a fermentation chamber that is inexpensive to produce and use and is capable of providing sufficient agitation of the liquid medium to ensure proper mixing and/or aeration without damaging delicate components. The invention further provides a mixing apparatus for agitating one or more such fermentation chambers. When used in processes utilizing particle-immobilized enzymes, the claimed invention permits adjustment of the degree of agitation of the liquid medium to ensure movement over surfaces of the particles with little or no grinding of the particles against each other.
[0014] The chamber of the claimed invention is applicable to a wide variety of processes, including the culturing of living cells and microorganisms. In a first embodiment, the claimed invention provides a fermentation chamber comprising: a rigid top portion; a rigid bottom portion; and a flexible member connecting the rigid top portion and the rigid bottom portion.
[0015] In a second embodiment, the claimed invention provides a fermentation chamber comprising: a rigid bottom portion; at least one arm; and at least one pin adjacent the at least one arm for attaching the fermentation chamber to a mixing apparatus.
[0016] In a third embodiment, the claimed invention provides a mixing apparatus comprising: a drive mechanism; a first mixing bar; a second mixing bar; and a fermentation chamber having: a rigid bottom portion; at least one arm; and at least one pin adjacent the at least one arm for attaching the fermentation chamber to a mixing bar.
[0017] In a fourth embodiment, the claimed invention provides a fermentation chamber comprising: a rigid top portion; a flexible bottom portion; and a receptacle for the flexible bottom portion.
[0018] In a fifth embodiment, the claimed invention provides a fermentation chamber comprising: a flexible top portion; a flexible bottom portion; and a receptacle for at least one of the flexible top portion and the flexible bottom portion.
[0019] The foregoing and other features of the invention will be apparent from the following more particular description of embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The embodiments of this invention will be described in detail, with reference to the following figures, wherein like designations denote like elements, and wherein:
[0021] FIG. 1 shows a side elevational view of one embodiment of the invention, wherein the chamber comprises a rigid top portion and a rigid bottom portion connected by a flexible member.
[0022] FIG. 2 shows a cross-sectional view of a rigid bottom portion of the claimed invention with internal projections formed by different methods.
[0023] FIG. 3 shows a side elevational view of an alternative embodiment of the rigid top portion of the claimed invention with elements for adding materials to or removing materials from the chamber.
[0024] FIGS. 4A and 4B show a side elevational view and cross-sectional view, respectively, of an alternative embodiment of the claimed invention.
[0025] FIG. 5 shows a side view of an alternative embodiment of a fermentation chamber according to the present invention.
[0026] FIG. 6 shows a mixing apparatus for use with fermentation chambers of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Reference will now be made in detail to the preferred embodiments of the claimed invention, several examples of which are illustrated in the accompanying drawings. Additional information can be found in Appendices A and B, which are herein incorporated by reference.
[0028] As used herein, the term “fermentation” means a process for the production of a product by culturing cells or microorganisms, the process of culturing cells or microorganisms, or a process for the bioconversion of one material to another.
[0029] The term “chamber” means a container capable of holding a particular liquid medium. In addition, when sealed, said chamber is capable of holding a particular gaseous medium.
[0030] Referring to FIG. 1 , one embodiment of a fermentation chamber 1 of the claimed invention is shown. Top portion 10 and bottom portion 30 are of a rigid material and connected by flexible member 20 . Top portion 10 and bottom portion 30 may be of any rigid material known in the art, including, for example, a metal, a ceramic, a glass, polyethylene, polystyrene, a polyester, or polypropylene. Flexible member 20 may be of any flexible material known in the art, including, for example, polyethylene, a polyester, polypropylene, silicon, or rubber. Flexible member 20 may be joined to top portion 10 and bottom portion 30 by any number of means, including, for example, adhesives, clamps, stitching, threaded members, and thermal attachment (i.e., melting a portion of one or both components at a point where they are to be joined). Preferably, the attachment of flexible member 20 to top portion 10 and bottom portion 30 permits the easy sealing and unsealing of chamber 1 , where, for example, top portion 10 is a cap which threads onto flexible member 20 .
[0031] Bottom portion 30 may be provided with at least one projection 32 on its inner surface. Although projections 32 are shown in a vertical orientation along the inner vertical walls of bottom portion 30 , it should be noted that such projections need not be orientated vertically and may be positioned on any inner surface of bottom portion 30 , including its horizontal bottom surface. As depicted in FIG. 1 , projections 32 correspond to indentations 34 in an outer surface of bottom portion 30 . Such projections and indentations can be found in what are commonly called “blow molded” bottles, and are generally composed of a glass or plastic material.
[0032] When chamber 1 is rotated back-and-forth about its longitudinal axis, liquid 40 naturally rotates at a slower rate than chamber 1 , due to fluid inertia. Projections 32 obstruct the movement of liquid 40 , and particularly so upon the periodic reversal of the direction of rotation of chamber 1 . This obstruction of the movement of liquid 40 results in its mixing and aeration. The back-and-forth rotation of chamber 1 may be provided by any means known in the art, including, for example, an eccentric or piston drive.
[0033] In addition, the complete or substantial immobilization of top portion 10 increases the mixing and/or aeration of liquid 40 . Top portion 10 may be immobilized by any number of means, including, for example, clamps, brackets, and rods. Such immobilization also permits easier sampling or monitoring of the contents of chamber 1 , as will be described in detail below with reference to FIG. 3 .
[0034] In another embodiment of the invention, the need for projections 32 on an inner surface of bottom portion 30 is obviated by the non-circular cross-sectional shape of bottom portion 30 . The non-circular shape of bottom portion 30 results in obstruction of the movement of liquid 40 , providing mixing and/or aeration of liquid 40 . Many non-circular shapes are capable of obstructing the movement of liquid 40 , although elliptical and rectangular shapes are particularly useful. An example of a suitable cross-sectional shape is depicted in FIG. 4B , described below with reference to a third embodiment of the invention.
[0035] FIG. 2 shows a cross-sectional view of bottom portion 130 . As shown, projections 132 on an inner wall 138 may be produced by the formation of an indentation 134 on an outer wall 136 or by the formation or attachment of additional material to an inner wall 138 . Such additional material may be part of the original molding of bottom portion 130 , where bottom portion 130 is a molded product. Alternatively, such additional material may be attached to an inner wall 138 of bottom portion 130 by any means known in the art, including, for example, adhesives, screws, bolts, friction connections, and thermal attachment.
[0036] Referring now to FIG. 3 , an alternative embodiment of top portion 210 is shown with optional additional elements. First external element 212 and first internal element 214 comprise interconnected hollow vessels for the introduction of materials to or the removal of materials from the interior of the chamber. Optionally, first internal element 216 may terminate in a submersible element 216 , which may comprise any number of devices, including, for example, a sensor, a heating element, a cooling element, and a diffuser for the introduction of gaseous bubbles into liquid 40 . Sensors include those known in the art, including, for example, pH electrodes, thermometers, turbidity probes, or dissolved oxygen electrodes. Where submersible element 216 is a sensor, a heating element, a cooling element, or similar device, materials need not necessarily be introduced to or removed from the chamber. Rather, first external element 212 and first internal element 214 may provide a pathway to submersible member 216 , for the provision of device components, such as electrical wires or heating and cooling fluids.
[0037] Optionally, top portion 210 may include, in addition to or in place of the elements described above, second external element 218 and second internal element 220 , also interconnected hollow vessels. Unlike first internal element 214 , which ideally descends into the liquid contents of the chamber, second internal element 220 terminates at a point above the standing level of liquid in the chamber. Second external element 218 and second internal element 220 , therefore, may be used to add materials to the chamber or to remove gaseous materials from the chamber. Optionally, second internal element 220 may terminate in a device such as submersible element 216 , which is used to monitor or alter a physical or chemical property of the gaseous contents of the chamber. Any of the optional elements described above may be of a material or combination of materials known in the art, including, for example, glass, metal, polyethylene, polypropylene, a polyester, silicon, or rubber.
[0038] Referring now to FIGS. 4A and 4B , an alternative embodiment of the claimed invention is shown, wherein chamber 301 is comprised of rigid top portion 310 and flexible bottom portion 320 . Thus, a substantial portion of chamber 301 is comprised of a flexible bag-like structure. As such, bottom portion 320 is capable of adapting its shape in response to the volume of its fluid contents, the shape of an external body, or both. Receptacle 330 , for example, is a hollow non-circular member capable of supporting bottom portion 320 . The non-circular shape of receptacle 330 results in obstruction of the movement of the liquid contents of chamber 301 , obviating the need for internal projections. Such projections may optionally be included, either on an inner surface of bottom portion 320 or on an inner surface 332 of receptacle 330 . In the latter embodiment, bottom portion 320 will adapt its shape to conform to projection 334 . Optionally, both the top portion and the bottom portion of the chamber may be composed of flexible materials.
[0039] Referring to FIG. 5 , an alternative embodiment of a fermentation chamber according to the present invention is shown, wherein chamber 401 is comprised of rigid top portion 410 , rigid bottom portion 430 , flexible member 420 , and cap member 440 . Preferably, cap member 440 includes a cap 442 adapted to threadably engage a threaded neck (not shown) of rigid bottom portion 430 . As such, rigid bottom portion 430 may be disposable or recyclable while rigid top portion 410 , flexible member 420 , and cap member 440 may be reusable. Rigid top portion 410 , flexible member 420 , and cap member 440 preferably comprise an integrated unit.
[0040] As described above, rigid cap member 410 may include one or more apertures (not shown) to facilitate the sampling, monitoring, etc. of the contents of chamber 401 or the introduction of materials to chamber 401 . Of course, where sampling, monitoring, etc. of chamber contents is unnecessary, an alternative embodiment my include only rigid bottom portion 430 and cap member 440 . That is, flexible member 420 and rigid top portion 410 are unnecessary if entry into an interior of rigid bottom portion 430 is not required. In such an embodiment, cap 442 would preferably include a closed or closable top.
[0041] Cap member 440 comprises cap 442 , one or more laterally extending arms 444 , and one or more pins 446 extending from each arm 444 . Such an arrangement of arms 444 and pins 446 permits chamber 401 to be mixed via a mixing apparatus, which will be described below.
[0042] Referring now to FIG. 6 , a mixing apparatus 501 is shown for providing an agitating motion to one or more fermentation chambers 401 . Mixing apparatus 501 comprises mixing bars 552 , 554 and, optionally, a stabilizing bar 556 . Mixing apparatus 501 may further comprise a drip pan 560 for collecting any liquids that may escape from chambers 401 during mixing, sampling, monitoring, etc.
[0043] One or more fermentation chambers 401 are arranged between mixing bars 552 , 554 . Preferably, each chamber has a form similar to chamber 401 as shown in FIG. 5 , such that arms 444 and pins 446 align with mixing bars 552 , 554 . Alternatively, arms 444 and pins 446 may be included on rigid bottom portion 430 rather than cap 442 . Of course, chambers having other forms, such as those shown in FIGS. 1 and 4 A, may be adapted for use with mixing apparatus 501 . For example, one or more arms 444 and pins 446 may be incorporated into or secured to bottom portion 30 ( FIG. 1 ) or receptacle 330 ( FIG. 4A ) using a clamp, adhesive, etc.
[0044] Arms 444 , pins 446 , and/or mixing bars 552 , 554 may include any number of apparatuses (not shown) for securing chambers 401 to mixing bars 552 , 554 . One suitable apparatus includes holes or slots in mixing bars 552 , 554 adapted to receive pins 446 , although other apparatuses are possible, as would be known to one of ordinary skill in the art.
[0045] A drive mechanism (not shown) provides a back and forth motion M to one or more arms 444 . Any known or later developed drive mechanism may be used, including, for example, an eccentric drive, a piston drive, etc. In one embodiment, first mixing bar 552 is immobile while second mixing bar 554 is connected to a drive mechanism. The back and forth motion M of second mixing bar 554 provides agitation to chambers 401 and their contents. In an alternative embodiment, both first mixing bar 552 and second mixing bar 554 are connected to a drive mechanism, which provides back and forth motion M to each. In such an embodiment, the relative degree and/or speed of back and forth motion M may be reduced as compared to an embodiment wherein only second mixing bar 554 is agitated.
[0046] In a situation where contents of chamber 401 will be monitored, sampled, etc., mixing apparatus 501 may further comprise a stabilizing bar 556 to which the rigid top portion 410 of each chamber 401 may be secured. Such an arrangement permits the connection and/or insertion of a line 570 to rigid top portion 410 , whereby flexible portion 420 permits the agitation of rigid bottom portion 430 without agitation of rigid top portion 410 . Line 570 may include any number of apparatuses, including wires, tubing, etc., as described above. Rigid top portion 410 may be secured to stabilizing bar 556 by any known or later developed methods, including, for example, clamps, rings, straps, screws, bolts, magnets, hooks and loops, etc.
[0047] While this invention has been described in conjunction with the specific embodiments outlined above, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, the embodiments of the invention as set forth above are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention as defined in the following claims. | The claimed invention provides a fermentation chamber that is inexpensive to produce and use and is capable of providing sufficient agitation of the liquid medium to ensure proper mixing and/or aeration without damaging delicate components. The invention further provides a mixing apparatus for agitating one or more such fermentation chambers. In a first embodiment, the claimed invention provides a fermentation chamber, comprising: a rigid top portion; a rigid bottom portion; and a flexible member connecting the rigid top portion and the rigid bottom portion. | 2 |
FIELD OF THE INVENTION
[0001] The present invention relates to a process and apparatus using wood wool or any other ribbon lignocellulosic type material as furnish for the production of low density composite panels with improved moisture or/and water resistance. More specifically it relates to the fabrication of commercial composite panels of very low density and to the panels so produced. Furthermore, thick panel products i.e. panels with a target thickness greater than ¾ inch (19 mm) may benefit greatly from this invention.
DESCRIPTION OF THE PRIOR ART
[0002] Wood-based panel composites including oriented strand board (OSB) and medium density fibreboard (MDF) are widely employed as substitutes for solid wood in many applications. To produce wood-based composite panels, resin and wax are applied onto furnish prior to mat formation followed by hot pressing for resin curing panel consolidation. The purpose of hot pressing is first to density the panel then to provide sufficient energy to the resin to polymerise it and hence develop an effective bond for panel consolidation. The wax performs at least two important roles in the composite wood panel. Besides improving the flowability of the resin during hot pressing, the wax improves the dimensional stability of the resultant panel.
[0003] There is no doubt that the cost and speed of production of composite panel products is time and furnish dependent, and, there has been observed a significant increased interest in this subject through the advances in resin and manufacturing technologies. However wood is low in heat conductivity, limiting the heat transfer efficiency from the platen to the core of panel. Hence longer hot pressing periods are required particularly for thick panels. For example, to produce a good quality ¾ inch thick OSB panel will usually require a press cycle of more than 5 minutes.
[0004] It has been recognised that furnish compaction ratio, which is directly related to furnish bulk density, plays an important role in the mechanical properties of the finished panel. The mechanical properties of panels made from high compact ratio density are generally better than panels made from low compact ratio furnish.
[0005] It also been recognised in the art that steam is very good in heat conductivity and that the pressing time for particle board or like products can be drastically reduced by passing pressurised steam through the pressed panel, or simply by increasing the furnish moisture content. Special resins, however, are required here to prevent resin from being hydrolysed or washed-out during hot pressing.
SUMMARY OF THE INVENTION
[0006] The invention provides a method for manufacturing a low density composite wood panel, comprising:
[0007] (a) providing a feed stock comprising wood strands having the following characteristics:
[0008] an average slenderness ratio of from 200 to 800;
[0009] an average aspect ratio of from 50 to 500; and
[0010] a bulk density of from 0.08 to 0.02 grams/cm 3 .
[0011] (b) blending said feed stock with a resin binder to provide a resinated furnish;
[0012] (c) forming said resinated furnish into a mat; and
[0013] (d) hot pressing said mat to form a finished panel.
[0014] The feed stock wood strands employed can be the waste product from the production of wood-wool for special applications in the packaging industry.
[0015] Acceptable dimensions of wood-wool average about 0.25 mm in thickness, 2 mm in width and up to 400 mm in length. This corresponds to a slenderness ratio of up to 1600, an aspect ratio of up to 200 and a bulk density of about 0.01 g/cm 2 .
[0016] The invention also provides a low density composite wood panel comprising a furnish mat formed from wood strands having the following composition:
[0017] an average slenderness ratio of from 200 to 800;
[0018] an average aspect ratio of from 50 to 500; and
[0019] a bulk density of from 0.08 to 0.02 grams/cm 3 ;
[0020] said mat including a resin content in the range of 3-5% by weight and being hot pressed to form a finished panel. Existing wood-wool making machines can be adjusted to provide efficient control of the thickness and the width of the wood-wool strands, but, because of the strand length breakdown during processing, are unable to control the length of the strands. Thus, a screening process to separate a product wherein the strands are of a desired range of length is required. This is done by use of a vibrated screening technique and short strands that pass through the screen holes are discarded from packaging applications. The discarded waste is reclaimed, to provide strands usable for wood-wool panels and varying in length from about 15 to about 400 mm. This wide range in length of the furnish strands utilized accounts for the broad ranges expressed above in respect of the slenderness ratio, aspect ratio and bulk density.
[0021] Preferably a hot wax is added to the furnish by spraying prior to addition of the resin, the wax content being in the range 1 to 2% by weight of the furnish. As described, the purpose of wax addition in the composite wood panel is not only to improve the flowability of the resin, but, also to improve the dimensional stability of the resultant panel.
[0022] The resin content of the furnish is a function of resin type an panel type to be made. For a typically OSB it is in the range 2 to 3% by weight, and preferably for wood-wool panel it is approximately 4%. Generally speaking, the mechanical properties of the OSB panel decrease with density, and to improve product quality a higher resin content in the range 3 to 5% is preferred.
[0023] The type of resin used is a function of the end application of the panel. For exterior grade panels MDI or high molecular phenol-formaldehyde resin is preferred. Urea-formaldehyde (UF) and melamine urea-formaldehyde (MUF) are suitable for interior grade panels.
[0024] The selection of pressing technique is independent of resin type to be employed. Both pressing methods are suitable for UF, MUF, MDI and novolac PF. Therefore, because of the high humidity condition MDI or high molecular weight PF are recommended for conventional hot pressing. This may prevent resin from being hydrolysed or washed-out during hot pressing.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The invention will further be described by way of example only, in relation to the following examples. As referred to herein the bulk density of the wood-wool strands is the volume per unit weight of the uncompressed strands at atmospheric pressure. This is preferably in the range 0.008 to 0.02 grams/cm 2 .
[0026] The furnish employed in the examples described below was reclaimed wood-wool (i.e. wood-wool discarded from the wood-wool to be used for packaging) characterised by the following specifications:
[0027] 200 to 800 slenderness ratio (the ratio of length to thickness);
[0028] 50 to 500 aspect ratio (ratio of length to width); and
[0029] about 0.008 to 0.02 g/cm 3 bulk density.
[0030] Two types of wood-wool were employed, one being made from a hard wood (aspen) having a somewhat similar density to the second which is made from a soft wood (jack pine).
[0031] Experimental panels were generally prepared as follows: reclaimed wood-wool, from industrial packaging waste, was dried to a desired target moisture content (MC), placed as a furnish into a drum-type laboratory blender where 1.5 percent of hot slack wax, based on ovendried weight, was sprayed onto the furnish, followed by the addition of resin. The resinated furnish was hand-felted into a mat where a rectangular ring of desired thickness was placed around the top periphery of the mat. The mat construction could be single or 3 layers mat. Finally, the constructed mat was placed between the two screen or caul plates prior to pressing.
[0032] a) Steam Injection Pressing Technique
[0033] The platen temperature was 210° C. and the pressing time was 160 seconds including 120 seconds of steam injection time at 150 psig of pressure and 20 seconds of steam vacuum time. The purpose of the rectangular ring referred to above mention is to seal the four edges of the panel by increasing its edges density, and, hence to systematically control the internal pressure build up during the pressing period. This approach is referred to as a “self-sealing system” and is more fully described in U.S. Pat. No. 4,850,849 Hsu assigned to the same assignee as the subject the application, and the content of which is hereby incorporated in its entirety.
[0034] For steam injection pressing, the moisture content of the furnish mat would typically be quite low, in the order of 3%, and the remainder of the moisture necessary to effect curing of the resin is provided through the injected steam.
[0035] During hot pressing, steam injected from the platens is forced to remain within the panel until the pressing operation is completed. This internal gas pressure is well controlled by panel edge density which is directly related to the thickness of the above referred to ring.
[0036] It is important to maintain the platens temperature of the press well above 100° C. to prevent condensation of steam during pressing. Typically the platens temperature is about 210° C. but platens temperature in the range of 120 to 210° C. are believed to be satisfactory.
[0037] Steam injection pressure in the range 90 to 250 psi is usually employed in the manufacture of medium density—fiberboard (MDF) and oriented strand board (OSB) panels. In the present invention because the wood-wool panel is low in density a steam pressure of about 30 psi should be sufficient to pass through the panel and cure the resin, this pressure corresponding to a saturated steam temperature of 130° C. Thus the steam injection pressure is preferably in the range 30 to 250 psi.
[0038] The pressing conditions are more dependent upon the density of the panel being made and the type of resin being used than on the panel thickness, and the ranges referred to above are suitable for forming low density wood-wool panels bonded with MUF, PF or MDI resin.
EXAMPLE 1
[0039] Boards measuring 34 in.×34 in×¾ in. with a target density of 0.53 g/cm 3 (33 pcf) were fabricated with the following parameter
resin content 4.0% furnish MC 3.0% furnish reclaimed aspen wood-wool
[0040] The results are presented in the first line in Table 1.
EXAMPLE 2
[0041] Boards measuring 34 in.×34 in×¾ in. with a target density of 0.41 g/cm 3 (25 pcf) were fabricated with the following parameters:
resin content 4.0% furnish MC 3.0% furnish reclaimed aspen wood-wool
[0042] The results are presented in the second line in Table 1.
EXAMPLE 3
[0043] Boards measuring 34 in.×34 in×¾ in. with a target density of 0.48 g/cm 3 (30 pcf) were first fabricated with the following parameters:
resin content 4.0% furnish MC 3.0% furnish reclaimed aspen wood-wool
[0044] These boards were then laminated with 2 plies of aspen veneer each of {fraction (1/16)} inch in thickness. The results are presented in the third and fourth lines in Table 1.
EXAMPLE 4
[0045] Boards measuring 34 in.×34 in×¾ in. with a target density of 0.41 g/cm 3 (25 pcf) were first fabricated with the following parameters:
resin content 4.0% furnish MC 3.0% furnish reclaimed aspen wood-wool
[0046] The samples were then laminated with 2 plies of aspen veneer each of {fraction (1/16)} inch thickness. The results are presented in fifth and sixth lines in Table 1.
EXAMPLE 5
[0047] Boards measuring 34 in.×34 in×{fraction (7/16)} in. with a target density of 0.45 g/cm 3 (28 pcf) were fabricated with the following parameters:
resin content 4.0% furnish MC 3.0% furnish reclaimed jack pine wood-wool
[0048] The results are presented in the first line in Table 2.
EXAMPLE 6
[0049] Boards measuring 34 in.×34 in×{fraction (7/16)} in. with a target density of 0.34 g/cm 3 (21 pcf) were fabricated with the following parameters:
resin content 4.0% furnish face layers MC 3.0% furnish reclaimed jack pine wood-wool
[0050] The results are presented in the second line in Table 2.
EXAMPLE 7
[0051] Boards measuring 34 in.×34 in×¾ in. with a target density of 0.37 g/cm 3 (23 pcf) were first fabricated with the following parameters:
resin content 4.0% furnish MC 3.0% furnish reclaimed jack pine wood-wool
[0052] The samples were then laminated with 2 plies of aspen veneer each of {fraction (1/16)} inch thickness. The results are presented in third and fourth lines in Table 2.
TABLE 1 Mechanical Properties of Wood Wool Board From Hard Wood (Aspen) Internal Modulus of Modulus of Thickness Water Screw Holding Density Bonding Elasticity Rupture Swelling Uptake Face Lateral g/cm 3 MPa Mpa Mpa % % KN KN 0.54 0.509 1235 10.59 7.1 35.9 0.97 0.74 0.41 0.357 637 4.60 6.6 50 0.61 0.4 0.53+ 0.335 925 5.19 — — 1.22 0.88 0.53// 0.335 6458 36.94 — — — — 0.49+ 0.444 323 5.03 — — 1.03 0.60 0.49// 0.444 8578 40.88 — — — —
[0053] [0053] TABLE 2 Mechanical Properties of Wood Wool Board From Soft Wood (Jack Pine) Internal Modulus of Modulus of Thickness Water Screw Holding Density Bonding Elasticity Rupture Swelling Uptake Face Lateral g/cm 3 MPa Mpa Mpa % % KN KN 0.45 0.15 975 5.1 7.7 23.3 0.34 0.33 0.34 0.09 652 3.1 5.6 25.2 0.25 0.31 0.39+ 0.09 823 7.2 — — 0.95 0.30 0.39// 0.09 5920 34.2 — — — —
[0054] The properties Internal bond strength (IB), modulus of rupture in bending (MOR), modulus of elasticity in bending (MOE), thickness swelling (TS) and screw holding (SH) were tested in accordance with the standard CSA CAN3-0437-93.
[0055] The binder used in the above examples can be virtually any type of commercial moisture tolerant resin, preferably novolac PF, MUF or MDI resin binder. Various waxes can be employed, but slack waxes are solid at or near room temperatures must be applied in molten form; suitable liquid waxes are preferred.
[0056] b) Conventional Pressing Technique
[0057] The key to success of conventional pressing is related to how to raise the temperature at the core of panel as fast as possible. This can be done by increasing panel internal gas pressure. Several drawback relating to the internal high gas pressure, however, been observed: for example, panel delamination, risk of explosion etc.
[0058] This invention is able to first develop a control high internal gas pressure to quickly increase the core temperature, then to avoid explosion or panel delamination by allowing the gas pressure to be efficiency released before press opening. This can also be achieved by controlling the seal at the four edges of panel, and, at the same time, decreasing the overall density of the panel. Again, similar to steam injection process, the role of the rectangular ring is to seal or to increase the density at the edges of panel, and, hence to control the internal pressure during hot pressing period. Moreover, reducing panel density creates space for the trapped steam to be freely circulated inside the panel, hence, to efficiency release the internal gas pressure.
[0059] The platen temperature used was 210° C. and the pressing time 150 seconds including a 15 second closing period and another 15 seconds opening period. Steam converted from furnish moisture is forced to remain within the panel and polymerise the resin until the pressing operation is completed.
[0060] In contrast to the steam injection process, conventional pressing conditions are more dependent upon the panel thickness and resin type being employed to make the panel rather than the panel density. In conventional pressing there is no steam injection so that a higher moisture content is required in the furnish mat typically in excess of 10% moisture by weight. | Low density composite wood panels are manufactured from a feedstock comprising wood wool strands of high average slenderness ratio and high average aspect ratio, and low bulk density. The feedstock wool strands are blended with a resin binder typically in the range of 3 to 5 percent by weight and a hot wax in the range 1 to 2 percent by weight and formed into a mat. The mat is hot pressed with steam injection to effect curing of the resin. The low density panels may include on one or both of their major faces a wood veneer layer. The wood wool strands typically comprise wood of the aspen or jack pine species. | 8 |
CROSS REFERENCE TO RELATED U.S APPLICATION
[0001] This patent application relates to, and claims the priority benefit from, U.S. Provisional Patent Application Serial No. 60/454,347 filed on Mar. 14, 2003, which is incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0002] The present invention relates to metrologic methodologies and instrumentation, in particular laser infrared photocarrier radiometry (PCR), for contamination and defect mapping and measuring electronic properties in industrial Si wafers, devices and other semiconducting materials. In particular the invention relates to the measurement of carrier recombination lifetime, τ, carrier diffusivity, D, surface recombination velocities, S, and carrier diffusion lengths, L.
BACKGROUND OF INVENTION
[0003] In recent years the development of laser-induced infrared photothermal radiometry (PTR) of semiconductors in our laboratory [1-9] and elsewhere [10] as a quantitative methodology for the measurement of transport properties of semiconductors has led to several advances in the non-contact measurement of four transport parameters: bulk recombination lifetime, (two) surface recombination velocities and carrier diffusion coefficient in Si [1-10] and GaAs [11]. Reviews of the subject matter have been presented by Mandelis [12] and Christofides et al. [13]. The major advantage of PTR over other photothermal techniques, such as photomodulated thermoreflectance (PMOR), has been found to be the higher sensitivity of PTR to the photo-excited free carrier-density-wave (the modulated-laser driven oscillating electronic diffusion wave [14]) than PMOR [15,16]. This advantage exists due to domination of the free-carrier wave over the superposed thermal-wave (TW) contributions to the PTR signal. Even so, the ever-present thermal-wave contributions due to direct lattice absorption, followed by non-radiative energy conversion and black-body (thermal infrared) emissions, have resulted in PTR signal interpretational and computational difficulties due to the large number of variables involved [5].
[0004] Therefore, confidence in the measured values of the four electronic transport properties is always accompanied by the hurdle of assuring uniqueness of the measured set of parameters in any given situation. With our development of the PTR methodology as a quantitative technique for non-destructive semiconductor diagnostics, we found [4,5] that early measurements reported without regard to computational uniqueness [17] using simplified theoretical fits to frequency-scan signals cannot be unique and therefore reliable.
[0005] Several schemes to enhance the photo-excited free carrier-density-wave (or simply “carrier-wave”, CW) contributions to the photothermal signal have been proposed, such as working in the high-frequency, CW-dominated, regime with PTR [12], or using a tightly focused pump laser beam in PMOR [18]. However, the presence of even a diminished TW component in high-frequency PTR has been shown [19] to have significant effects on the measured values of the transport parameters, to compromise sensitivity to the carrier wave and to complicate the task of physical interpretation of the signal, thus raising the question of uniqueness of the measured set of solid-state transport parameters.
[0006] On the other hand, very tight focusing of the pump laser beam in PMOR tends to give rise to usually undesirable non-linear thermal and electronic effects [15,20,21], besides being unable to sufficiently eliminate the TW component of the signal [22]. Therefore, given the fundamental and practical importance of developing an all-optical, non-destructive and non-intrusive diagnostic methodology for monitoring only the transport properties of semiconductors, we concluded that the search for a purely carrier-wave laser-based detection methodology must move in the direction of isolating and eliminating the superposition of thermal-wave contributions to the infrared emission spectrum. In view of the inability of photothermal semiconductor diagnostic methods [13,18] to eliminate the thermal-wave contributions, the development of infrared laser radiometry of semiconductors to optimize this task has been very promising, given the intrinsically higher sensitivity of its photothermal embodiment, PTR, to the photo-excited carrier density-wave than other photothermal techniques, notably PMOR [16].
[0007] In a photo-excited semiconductor of bandgap energy E G , an externally incident optical source such as a laser beam with super-bandgap energy photons hν νis /E G will be absorbed and can generate free carriers which may subsequently follow several deexcitation pathways as shown in FIG. 1 for an n-type material. Ultrafast decay to the respective bandedge (e.g. conduction band) through nonradiative transitions and emission of phonons, will raise the temperature of the semiconductor locally. The free carriers will further diffuse within their statistical lifetime and will recombine with carriers of the opposite sign across the bandgap or into impurity and/or defect states within the bandgap. The electron-hole recombination mechanism with or without phonon assistance will lead either to nonradiative energy conversion through phonon emissions (e.g. in indirect-gap semiconductors such as Si) which will further raise the temperature, or to radiative decay which will produce photons of near- or sub-bandgap energy. A table of radiative recombination lifetimes at 300 K in Si and other semiconductors has been compiled by Hall [23]. In the presence of impurity or defect states within the bandgap, free-carrier decay to one or more of those states may also occur through nonradiative or radiative transitions symbolized by dashed and full arrows, respectively, in FIG. 1. Again, the former will raise the temperature of the semiconductor crystal through phonon coupling to the lattice, whereas the latter will produce photons of energy E G −E D ≅hν IR . In actual semiconductor materials, there may be a distribution of impurity and defect states into which de-excitation may occur.
[0008] Therefore, it is more relevant to consider the full spectral range of IR emissions from a photo-excited semiconductor crystal: hν IR =hν(λ D ). If the exciting super-bandgap radiation is intensity-modulated at frequency ƒ=ω/2π, then the photo-generated free carrier density constitutes a spatially damped carrier-density wave (CW) (or carrier-diffusion wave [14]), which oscillates diffusively away from the generating source under its concentration gradient and recombines with a phase lag dependency on a delay time equal to its statistical lifetime, τ, a structure- and process-sensitive property [24]. FIG. 2 shows a virtual cross-section of a semiconductor Si wafer where an infrared emission photon distribution is produced following laser radiation absorption and carrier-wave generation. For one-dimensional geometries, such as those obtained with thin crystals and/or use of laser beams of large spotsize, only forward- and backward-emitted photons of wavelength λ are depicted. The IR power generated at λ within a spectral bandwidth dλ is given by
dP j ( z,t ;λ)={ W NR [T T ( z,t );λ]+η R W eR (λ)} j dλ;j=r,t[W] (1)
[0009] where W NR [T T (z,t);λ] is the thermal infrared power per unit wavelength generated due to temperature rise following optical absorption, as well as due to other nonradiative decays. The subscripts (r,t) indicate back-propagating (“reflected”) or forward-propagating (“transmitted”) photon power. W eR (λ) is the spectral power per unit wavelength, the product of the recombination transition rate from band to band, or from bandedge to defect or impurity state, as the case may be, multiplied by the energy difference between initial and final states. η R is the quantum yield for IR radiative emission upon carrier recombination into one of these states. T T (z,t) is the total temperature, including background temperature, temperature increase due to thermal-wave oscillation following laser-modulated absorption and optical heating, as well as other nonradiative energy conversion pathways. Therefore,
W NR [T T ( z,t );λ]= W P [T s ( z,t );λ]+(1−η R ) W eR (λ)+ W eH (λ)[ W/μm] (2)
[0010] Here, W P [T s (z,t);λ]dλ is the familiar Planck distribution function, or spectral emissive power, representing the rate of radiative recombination within dλ, and sample volume ΔV=A[α IR (λ)] −1 of emitting cross-sectional area A normal to the z-axis in FIG. 2, and depth equal to the optical absorption depth at infrared wavelength λ. α IR (λ) is the IR absorption coefficient at λ and
W P [ T s ( z , t ) ; λ ] d λ = 8 π h ( c o / n ) A d λ λ 5 { exp [ hc o / λ nk B T s ( z , t ) ] - 1 } [ W ] ( 3 )
[0011] (c o /n) is the speed of light in the medium of refractive index n. T s (z,t) is made up of only two contributions: background temperature and harmonic optical heating of the lattice at modulation frequency ƒ. The remaining symbols in Eq. (2) have the following meanings: W eH (λ) is the thermal IR photon generation power per unit wavelength due to intraband nonradiative de-excitation of hot carriers with energy hν νis −E G , FIG. 1. (1−η R ) is the nonradiative quantum yield for recombination processes which generate total power W eR (λ) per unit wavelength.
[0012] The use of Eq. (3) in describing the thermal emissive power assumes the existence of thermal equilibrium in the semiconductor, a condition known as the Principle of Detailed Balance. It states that the rate of radiative recombination at thermal equilibrium within an emission frequency interval dν, centered at frequency ν, is equal to the corresponding generation rate of electron-hole pairs by the thermal radiation field present within the semiconductor [25]. Detailed Balance is, in itself, a statement of Kirchhoff's theorem [24], according to which “for any body in (radiative) thermal equilibrium with its environment, the ratio between the spectral emissive power W(T,λ)dλ and the spectral absorptivity α(T,λ), for a given photon frequency ν=c/λ and temperature T, is equal to the spectral emissive power W P (T,λ)dλ, Eq. (3), of the blackbody for the same frequency and temperature”.
[0013] Although a semiconductor undergoing harmonic carrier generation is not strictly in thermal equilibrium, it has been shown [19] that in low laser power interactions with electronic carriers, the semiconductor can be considered to be at electronic and thermal equilibrium during the oscillation cycle of the photo-excited carrier-wave as long as i) there exist no intense electromagnetic optical or thermal gradient fields in the semiconductor to upset the quantum configuration of the energy states, driving the structure away from electronic energy equilibrium; ii) upward electronic transitions following optical absorption result in efficient radiative de-excitations with minimal temperature increase of the lattice, or iii) even if significant temperature changes occur due to nonradiative decays which may affect the background temperature of the lattice as in the case of CW generation, however, the temperature oscillation itself amounts to only minimal thermal-wave perturbations with no significant consequence in the structure of the energetic manifold of the semiconductor.
[0014] Under these conditions electronic transitions occur essentially adiabatically, with minimum thermal energy exchange interactions across well-defined electronic state densities. It also follows that the higher the oscillation frequency, the greater the adiabatic character of the transition, leading to a stricter validation of Kirchhoff's Law through complete thermal decoupling of the CW oscillator ensemble, as experimentally observed by use of PTR [4]. Therefore, despite the large ambient radiation field oscillations, Eq. (6) is expected to remain essentially valid away from free-carrier density equilibrium in PCR. The absence of cross-coupling in the emitted power of Eq. (1) is a statement of the adiabatic superposition of thermal-infrared (Planck-mediated) emissions through the W NR [T T (z,t);λ] term, and direct electronic infrared emissions through the η R W eR (λ) term under equilibrium (i.e. constant) baseline temperature and a stationary material energy state manifold characterized by a well-defined Fermi level. A by-product of adiabaticity is that the IR spectra of thermal and recombination emissions are independent of each other, a feature which is central to the realization of PCR.
[0015] [0015]FIG. 2 shows an elementary slice of thickness dz centered at depth z in a semiconductor slab. The crystal is supported by a backing, but is not necessarily in contact with the backing. A modulated laser beam at angular frequency ω=2πƒ and wavelength λ νis impinges on the front surface of the semiconductor. The super-bandgap radiation is absorbed within a (short) distance from the surface, typically, a few μm, given by [α(λ νis )] −1 where α(λ νis ) is the visible-range absorption coefficient of the pump radiation. The ensuing de-excitation processes generally involve radiative and nonradiative energy release components, resulting in the generation of an IR photon field in the semiconductor involving a relatively broad spectral bandwidth. At thermal and electronic equilibrium, assuming a one-dimensional geometry as a result of a large laser beam spotsize and/or thin sample, the emitted IR photons have equal probability of being directed toward the front or the back surface of the material.
[0016] A detailed account of all IR emission, absorption, and reflection processes [19] yields the expression for the total IR emissive power at the fundamental frequency across the front surface of the material in the presence of a backing support which acts both as reflector of semiconductor-generated IR radiation with spectrum centered at λ, and as emitter of backing-generated IR radiation centered at wavelength λb
P T ≈∫ λ 2 λ 1 dλ[ 1− R 1 (λ)]{(1+ R b (λ)[1+ R 1 (λ)])ε o (λ)∫ 0 L ΔW p ( z,ω,λ ) dz+[ (1+ R b (λ)[1+ R 1 (λ)]) W o ( T o ;λ)− W p ( T b ,λ) e ( T b ,λ)[1− R 1 (λ)]]×∫ 0 L ε ƒc ( z,ω,λ ) dz} (4)
[0017] where R 1 is the front surface reflectivity, R b is the backing support material reflectivity, ε o (λ) is the background IR emission coefficient of the material, ε ƒc (z,ω,λ) is the IR emission coefficient due to the free photoexcited carrier wave, e(T b ,λ) is the spectral emissivity of the backing material, ΔW p (z,ω,λ)dz is the harmonic IR emissive power due to the harmonically varying temperature of the sample, W o (T o ;λ) is the unmodulated emissive spectral power per unit wavelength due to both Planck-mediated [W po (T o ,λ)] and direct radiative [η R W eR (λ)] emissions, W P (T b ,λ) is the spectral emissive power per unit wavelength of the backing surface at temperature T b , and [λ 1 ,λ 2 ] is the spectral bandwidth of the detector. Much work has been done in attempts to separate out carrier-wave and thermal-wave contributions through modulation frequency filtering [2-5], however, they are always strongly mixed and can be separated out effectively only through spectral filtering at the IR detector. The present invention is concerned with the successfull separation of the carrier wave from the thermal wave and the instrumental implementation of a technique (“Photo-Carrier Radiometry”) which monitors the former wave in semiconductor materials and devices exclusively.
SUMMARY OF INVENTION
[0018] The present invention consists of the development of a complete photocarrier radiometric instrumentation hardware and software metrologic system comprising novel signal generation and analysis techniques (carrier-wave interferometry) as well as novel instrumental hardware configurations based on the physical principle of photocarrier radiometry.
[0019] i) Photocarrier Radiometry
[0020] The present invention provides a non-contact, non-intrusive, and all-optical method for imaging surface and subsurface defects, including contamination, and determining a unique set of electronic parameters of industrial Si wafers. The method comprises (a) optical excitation of the sample with a modulated optical excitation source and (b) detection of the recombination-induced infrared emission while filtering any Planck-mediated emissions.
[0021] ii) Interferometric Photocarrier Radiometry
[0022] The present invention provides an instrumental method for detecting weak inhomogeneities among semiconducting materials that are not possible to detect with conventional single-ended photocarrier radiometry. The method comprises (a) irradiating both sides of the sample with modulated optical excitation sources that are 180 degrees out of phase with respect to one another and (b) monitoring the diffusion of the interfering, separately generated carrier waves through the corresponding recombination-induced IR emissions for PCR detection, or the use of an alternative detection scheme that monitors a sample property which depends on the carrier wave transport in the sample.
[0023] The present invention provides a non destructive method for characterizing electronic properties of materials. The method comprises the steps of: irradiating at least one surface of a material with an energy beam output from a modulated or pulsed excitation source wherein a recombination-induced infrared emission is responsively emitted from the material, filtering Planck-mediated thermal emissions from the recombination-induced infrared emission to produce a filtered recombination-induced infrared emission, and detecting the filtered recombination-induced infrared emission. The method includes calculating selected electronic properties of the material by either i) fitting the detected filtered recombination-induced infrared emission to a theoretical model of the photocarrier response of the irradiated material to calculate selected properties of the material, or using suitable calibration charts or tables to extract selected electronic properties of the material by comparison of the detected filtered recombination-induced infrared emission with reference detected filtered recombination-induced infrared emissions from reference materials with known properties.
[0024] The present invention provides an apparatus for non destructive characterization of electronic properties of materials. The apparatus comprises an excitation source means for irradiating at least one surface of a material with energy beams from the optical excitation source means wherein a recombination-induced infrared emission is responsively emitted from the material, the excitation source means being a modulated or pulsed optical excitation source means. The apparatus includes a filtering means for filtering Planck-mediated emissions from the recombination-induced infrared emission to produce a filtered recombination-induced infrared emission and a detection means for detecting the filtered recombination-induced infrared emission. The apparatus includes processing means for either
[0025] i) fitting the detected filtered recombination-induced infrared emission to a theoretical model of the photocarrier response of the irradiated material to calculate selected properties of the material, or
[0026] ii) comparing the detected filtered recombination-induced infrared emission with reference detected filtered recombination-induced infrared emissions from reference materials with known properties.
BRIEF DESCRIPTION OF DRAWINGS
[0027] The following is a description, by way of example only, of the method and apparatus in accordance with the present invention, reference being had to the accompanying drawings, in which:
[0028] [0028]FIG. 1 shows n-type semiconductor energy-band diagram showing excitation and recombination processes. Energy emission processes include nonradiative intraband and interband decay accompanied by phonon emission, as well as direct band-to-band recombination radiative emissions of energy hν(λ G ) and band-to-defect/impurity-state recombination IR emissions of energy hν(λ O ).
[0029] [0029]FIG. 2 shows a cross-sectional view of contributions to front-surface radiative emissions of IR photons from a) a semiconductor strip of thickness dz at depth z; b) re-entrant photons from the back surface due to reflection from a backing support material; c) emissive IR photons from the backing at thermodynamic temperature T b . The carrier-wave depth profile ΔN(z,ω) results in a depth dependent IR absorption/emission coefficient due to free-carrier absorption of the infrared photon fields, both ac and dc.
[0030] [0030]FIG. 3 shows a schematic diagram of single-ended photocarrier radiometric microscope constructed in accordance with the present invention.
[0031] [0031]FIG. 3 a shows a schematic diagram of another embodiment of a single-ended photocarrier radiometric microscope.
[0032] [0032]FIG. 4 shows a schematic diagram of an interferometric photocarrier radiometric microscope.
[0033] [0033]FIG. 5: Comparison of normalized PTR (MCT detector) and PCR (InGaAs detector) signals from an AlGaAs quantum well array on a GaAs wafer. Incident laser power: 25 mW.
[0034] [0034]FIG. 6: PCR and PTR signal dependencies on the power of the excitation Ar-ion laser. The sample was a p-type Si wafer of resistivity ρ˜20 cm. Both phases were essentially constant within the 0-35 mW range.
[0035] [0035]FIG. 7: (a) Self-normalized PCR and PTR signal amplitudes and (b) phases from two locations on an inhomogeneous n-type Si wafer using 20-mW Ar-ion laser and 1.2-mm beam size. ∀: PCR technique; −: PTR technique.
[0036] [0036]FIG. 8: PCR frequency scans from the p-type Si wafer of FIG. 6 with air and two backing supports. Laser-beam power 25 mW. (a) Amplitudes, and (b) phases.
[0037] [0037]FIG. 9: PCR distance scans between an intact back-surface region of the Si wafer and a highly reflective aluminum foil-covered substrate. All amplitude curves have been normalized to unity at the wafer back-surface; phase curves indicate the offset (in degrees) of the experimental phase for convenience. Laser power: 24 mW.
[0038] [0038]FIG. 10: Line scans over an p-Si wafer region with back-surface mechanical damage. (a) PCR amplitude; (b) PCR phase; (c) PTR amplitude; and (d) PTR phase. The wafer is resting on a mirror support. Laser power: 24 mW.
[0039] [0039]FIG. 11: Scanning imaging of back-surface defect in the p-Si wafer using front-surface inspection. Laser beam radius: 518 μm. Frequency: 1360 Hz. (a) PCR amplitude; (b) PCR phase; (c) PTR amplitude; and (d) PTR phase.
[0040] [0040]FIG. 12: Scanning imaging of back-surface defect in the p-Si wafer using front-surface inspection. Laser beam radius: 518 μm. Frequency: 100 kHz. (a) PCR amplitude; (b) PCR phase; (c) PTR amplitude; and (d) PTR phase.
[0041] [0041]FIG. 13: Simulations of PCR signal frequency dependence in p-Si with the residual IR absorption coefficient as a parameter. (a) Amplitude; (b) phase. λ=514 nm, beam radius w=518 μm, detector radius =563 μm, wafer thickness =675 μm; τ=1 ms; D*=15 cm 2 /s, S 1 =100 cm/s, S 2 =300 cm/s.
[0042] [0042]FIG. 14: Front- and back-surface PCR frequency scans inside and outside a defect area of a p-Si wafer on aluminum backing. Detector: InGaAs; beam size: 1.4 mm; Ar-ion laser power: 20 mW. (a) Amplitudes and (b) phases. Best fit parameters:
[0043] Front intact region: τ=1 ms; D*=12 cm 2 /s, S 1 =10 cm/s, S 2 =210 cm/s.
[0044] Front inside the defect: τ=1 ms; D*=14.9 cm 2 /s, S 1 =25 cm/s, S 2 =300 cm/s.
[0045] Back intact region: τ=1 ms; D*=12 cm 2 /s, S 1 =10 cm/s, S 2 =200 cm/s.
[0046] Back inside the defect: τ=1 ms; D*=5 cm 2 /s, S 1 =450 cm/s, S 2 =130 cm/s
[0047] [0047]FIG. 15: Temperature dependence of conductivity mobility calculated from ambipolar diffusion coefficients obtained by fitting PCR frequency scans to a theoretical model. The symbols represent experimental values while the line is the best fitting using the function μ(T)=α×T b where α=(1.06±0.07)×10 9 and b=−2.49±0.01.
[0048] [0048]FIG. 16: PCR amplitude versus ion implant dose with 710 nm and 830 nm excitation for: (a) 11 B + , (b) 75 As + , (c) 31 P + , and (d) BF 2 + .
DETAILED DESCRIPTION OF THE INVENTION
[0049] A) Apparatus
[0050] i) Single-Ended Photocarrier Radiometric Instrument
[0051] A schematic diagram of a first embodiment of a novel single-ended photocarrier radiometric instrument for laser PCR for semiconductor characterization is shown at 10 in FIG. 3. The excitation source is a laser 12 capable of producing photons of energy greater than the bandgap of the sample material (hν>E G ). An acousto-optic modulator 14 is used to modulate the laser emissions resulting in a harmonic energy source or beam 16 that is directed using mirrors 18 and focused onto the sample 20 . A pair of reflecting objectives or other suitable infrared optics, such as two off-axis paraboloidal mirrors, or one paraboloidal mirror collimator and a focusing lens 22 are aligned with the focal point coincident with that of the laser beam and used to collect emitted IR photons from the sample. The collected IR emissions are focused onto a detector 24 after being passed through a filter with a narrow spectral window that ensures the Planck-mediated thermal infrared emission band (7-12 μm) will be completely excluded from the detection range, while encompassing almost the entire emission band from the free carriers, found to be below 3 μm [26]. The signal from the detector 24 is demodulated using a lock-in amplifier 26 . The entire data acquisition process is controlled using a personal computer 27 , which is also connected to an XYZ motor assembly 28 to control sample positioning.
[0052] While a preferred way of filtering out the Planck-mediated thermal infrared emission band (7-12 μm) is by way of the above-mentioned filter, it will be appreciated that one could also used a detector designed to have a sufficiently low sensitivity to the Planck mediated thermal IR emissions but a high sensitivity to the PCR wavelengths.
[0053] The optical excitation source 12 in apparatus 10 may be either a pulsed or a modulated optical excitation source 32 . While FIG. 3 shows the system configured with the excitation source being modulated using the AOM 14 , the system may be readily modified for operation in the pulsed mode whereby the AOM 14 is removed and instead the laser 12 is operated in the pulsed mode producing a train of pulses triggered by its internal circuit or by use of external electronics with pulse duration in the sub-microsecond to sub-nanosecond range and repetition rate depending on the type of laser. When operating in pulsed mode, the signal processing is performed using one of three approaches: 1) a transient scope replaces the lockin amplifier 26 and the averaged pulse data will be stored in the scope/computer for later analysis; 2) in a hybrid mode, the lock-in amplifier 26 remains and utilizes the trigger to the pulsed laser's periodic firing of pulses as its reference and displays the fundamental Fourier component of the time-domain signal; or 3) in ultrafast applications, an optical delay line and auto-correlation signal processing are used to monitor the relaxation time of carriers.
[0054] While the apparatus 10 uses a laser as the source of optical excitation, it will be understood by those skilled in the art that any other excitation source with enough energy to excite carriers in the semiconductor or optical material under examination may be used. Detector 24 may be an imaging array sensor to rapidly image a large surface area. One could enlarge the energy beam and use the array to monitor 1-D PCR signals within each pixel, with spatial resolution determined by the imager array technology. However, one could also use the array detector with a small beam and monitor the PCR emissions as a function of position. In these area imaging applications, parallel lock-in detection schemes involving capturing the full image at least 4 times per period and performing in-phase and quadrature operations, or suitable alternative lock-in schemes, will be used.
[0055] ii) Another Configuration of Single-Ended Photocarrier Radiometric Instrument
[0056] A schematic diagram of an alternative configuration for the single-ended photocarrier radiometric instrument used to perform the measurements on the industrial grade silicon wafers is shown generally at 30 in FIG. 3 a . The excitation source is a laser 32 and is capable of producing photons of energy greater than the bandgap of the sample material (hν>E G ). The laser spot size of the exciting beam 34 is between 1-to-5 microns and controlled by using a reflective objective 36 . The beam intensity at the surface of the sample is between 10-to-30 mW. A current modulator circuitry 38 is used to modulate the laser emissions resulting in a harmonic energy source that is directed using a beam splitter 40 and focused onto the sample 42 . The sample 42 is mounted on a X-Y automated stage 44 for sample positioning, mapping or scanning purposes. The reflecting objective or other suitable infrared optics 36 are aligned with the focal point coincident with that of the laser beam 34 and used to collect emitted IR photons from the sample. The collected IR emissions are directed to the spectrally matched beam splitter 40 optimized for transmission within the specific spectral emission range and focused by a suitable infrared lens 48 onto a detector 50 equipped with a suitable low-noise preamplifier and a narrow spectral window so that the combination of the spectral bandwidth of detector and filter ensures the Planck-mediated thermal infrared emission band (7-12 μm) and leakage from the optical source are completely excluded from the detection range, while encompassing almost the entire emission band from the free carriers, found to be below 3 μm [26]. The signal from the detector is demodulated using a lock-in amplifier 52 . As with the apparatus 10 in FIG. 3, the optical excitation source 32 in apparatus 30 may be either a pulsed or modulated optical excitation source 32 .
[0057] The entire data acquisition and signal generation process is controlled using a personal computer 54 , which is also connected to a CCD camera 56 and beam splitter 58 that slides in position to locate the beam spot on the sample 42 . A customised microscope tube 60 is used to hold the various optics, reflective objective 36 and IR detector 50 . This microscope tube and laser 32 are attached through arm 64 to the focus block 66 . The photodiode 68 , beam splitter 70 and focus block 66 are used to perform auto focusing by measuring the reflection of the laser beam and adjusting the sample 42 focal distance to the reflective objective 36 .
[0058] iii) Interferometric Photocarrier Radiometric Instrument
[0059] The basic components of the interferometric PCR instrument are similar to the single-ended instrument with a few significant additional components is shown generally at 80 in FIG. 4. The emissions from a single laser source 12 are split by a non-polarizing beam splitter 82 . One beam 84 follows the same path as the beam in the singled ended apparatus 10 (FIG. 3) and is focused on the front surface of the sample 20 . The second beam 86 is directed using a separate series of two mirrors 88 , modulated using a second acousto-optic modulator 90 , and focused onto the back surface of the sample 20 as beam 91 . A dual function waveform generator 92 is used to produce two waveforms of identical frequency but with one phase shifted 180 degrees with respect to the other. One of the waveforms is sent to the modulator 14 for the front surface excitation beam and the other to the modulator 90 for the beam 91 directed to the back surface of the sample 20 . This results in the two laser beams being modulated at identical frequencies with one having a phase lag of 180 degrees so that when one beam has maximum intensity the other has the minimum intensity and vice versa. The intensity of the beam 84 on the front surface is adjusted using a linear intensity attenuator 96 to ensure that the destructive interference of the two interfering carrier density waves results in a zero baseline PCR signal. The IR collection, data acquisition and sample positioning are identical to the single-ended PCR instrument. As with the apparatus 10 in FIG. 3, the optical excitation source 12 in apparatus 80 may be either a pulsed or modulated optical excitation source 12 .
[0060] B) Methods Of The Present Invention
[0061] i) Photocarrier Radiometry of Electronic Materials
[0062] a) Description of the Method
[0063] Instrumental filtering of all thermal infrared emission contributions allows for all Planck-mediated terms to be eliminated from equation (4) yielding
P (ω)≈∫ λ 2 λ 1 dλ[ 1− R 1 (λ)](1+ R b (λ)[1+ R 1 (λ)])η R W eR (λ)∫ 0 L ε ƒc ( z,ω;λ ) dz (5)
[0064] The absorption (and, equivalently, assuming Kirchhoff's Law is valid, the emission coefficient) depends on the free-carrier density as [27]
ɛ fc ( z , ω ; λ ) = α IRfc ( z , ω ; λ ) = q λ 2 4 π 2 ɛ oD c 3 n m * 2 μ Δ N ( z , ω ; λ ) = C ( λ ) Δ N ( z , ω ; α ) ( 6 )
[0065] for relatively low CW densities. Here q is the elementary charge, ε oD is the dielectric constant, c is the speed of light in the medium, n is the refractive index, m* is the effective mass of the carrier (electron or hole) and μ is the mobility. This allows the PCR signal to be expressed in the form
P (ω)≈ F (λ 1 ,λ 2 )∫ 0 L ΔN ( z,ω ) dz (7)
[0066] with
F (λ 1 ,λ 2 )=∫ λ 2 λ 1 [1− R 1 (λ)](1+ R b (λ)[1+ R 1 (λ)])η R W eR (λ) C (λ) dλ (8)
[0067] The PCR signal is the integration of equation (7) over the image of the detector on the sample and thus is directly proportional to the depth integral of the carrier density in the sample. Consequently, the relative lateral concentration of any defects that affect the carrier density, either by enhancing recombination or altering diffusion coefficients, can be determined by scanning the surface of the wafer with the PCR microscope. In addition, frequency scan techniques can be used with the appropriate carrier diffusion model to obtain quantitative values for the four transport parameters [5]. This quantitative technique can be combined with the lateral maps to provide quantitative imaging of the semiconductor sample.
[0068] The optical excitation source 12 may be either a pulsed or modulated optical excitation source. Pulsed refers to a single burst of light of short duty cycle over the laser pulse repetition period, whereas modulated is essentially a repetition of square-wave pulses and a certain frequency at approx. 50% duty cycle or of a harmonic (sinewave) nature. Typically, when using a pulsed excitation source one measures response as a function of time, i.e. time domain, (essentially watching the signal decay after the short light pulse has been terminated). For modulated experiments the surface is irradiated using a repeating excitation at a given frequency (the modulation frequency) and one monitors the signal response only at this frequency, i.e. frequency domain. Pulsed responses can also be obtained using a lock-in amplifier referenced to the pulse repetition period, which monitors the fundamental Fourier coefficient of the sample response.
[0069] When using a pulsed, rather than a modulated, excitation source the PCR signal is obtained by integrating the inverse temporal Fourier transform of equation 7 over the surface area (image) of the detector [14]. Quantitative information obtained from observation of the time response of the PCR signal can then be combined with lateral maps to provide quantitative imaging of the semiconductor sample at discrete time intervals after the cessation of the laser pulse.
[0070] b) Application To Imaging Of Electronic Defects In Si Wafers
[0071] I. Instrumentation and Signal Characteristics
[0072] The experimental implementation of laser infrared photo-carrier radiometry is similar to the typical PTR set-up for semiconductors [4-9], with the crucial difference being that the spectral window of the IR detector and/or optical filter, and the modulation frequency response of the preamplifier stage, must be tailored through spectral bandwidth matching to a combination of carrier recombination emissions and effective filtering of the Planck-mediated thermal infrared emission band and of the synchronously modulated optical source. Conventional PTR utilizes photoconductive liquid-nitrogen-cooled HgCdTe (MCT) detectors with spectral bandwidth in the 2-12 μm range. This includes the thermal infrared range, 7-12 μm, and only part of the electronic emission spectrum at shorter wavelengths. Unfortunately, the spectral detectivity responses of MCT detectors are heavily weighed toward the thermal-infrared end of the spectrum [28]. In addition, the physics of PTR signal generation involves a substantial contribution from the thermal-wave component resulting from direct absorption by the lattice and by non-radiative recombinations of photo-excited carriers [16]. The result is an infrared signal with unequal superposition of recombination and thermal emission responses with a larger weight of the thermal infrared component.
[0073] From preliminary studies with several IR detectors and bandpass optical filters it has been observed that emissive infrared radiation from electronic CW recombination in Si is centered mainly in the spectral region below 3 μm [26]. Among those, InGaAs detectors with integrated amplifiers, a visible radiation filter and a spectral response in the <1800-nm range, was found to be most suitable, exhibiting 100% efficient filtering of the thermal infrared emission spectrum from Si as well as maximum signal-to-noise ratio over InGaAs detectors with separate amplifiers and InAs detectors. Therefore, infrared PCR was introduced using an optimally spectrally matched room-temperature InGaAs photodetector (Thorlabs Model PDA255) for our measurements, with a built-in amplifier and frequency response up to 50 MHz. The active element area was 0.6 mm 2 with a spectral window in the 600-1800 nm range with peak responsivity 0.95 A/W at 1650 nm. The incident Ar-ion laser beam size was 1.06 mm and the power was 20-24 mW. The detector was proven extremely effective in cutting off all thermal infrared radiation: Preliminary measurements using non-electronic materials (metals, thin foils and rubber) showed no responses whatsoever. Comparison with conventional PTR results was made by replacing the InGaAs detector with a Judson Technologies liquid-nitrogen-cooled Model J15D12 MCT detector covering the 2-12 μm range with peak detectivity 5×10 10 cmHz 1/2 W −1 .
[0074] [0074]FIG. 5 shows two frequency responses from a test AlGaAs quantum well array on GaAs substrate using both the MCT and the InGaAs detectors. The MCT response is characteristic of thermal-wave domination of the PTR signal throughout the entire modulation frequency range of the lock-in amplifier. On the other hand, the PCR signal from the InGaAs detector/preamplifier exhibits very flat amplitude, characteristic of purely carrier-wave response and zero phase lag up to 10 kHz, as expected from the oscillation of free carriers in-phase with the optical flux which excites them (modulated pump laser). The apparent high-frequency phase lag is associated with electronic processes in the sample. The PTR signals were normalized for the instrumental transfer function with the thermal-wave response from a Zr alloy reference, whereas the PCR signals were normalized with the response of the InGaAs detector to a small fraction of the exciting modulated laser source radiation at 514 nm. Regarding the well-known non-linearity of PTR signals with pump laser power [29], FIG. 6 shows a non-linear response from the PTR system at laser powers >5 mW. The PCR system, however, exhibits a fairly linear behavior for powers >15 mW and up to 35 mW, within the range of the present experiments. The non-linear behavior below 15 mW is due to surface state annihilation associated with the semiconductor sample used for these measurements.
[0075] Unlike the readily available thermal infrared emissions from well-controlled reference samples for the purpose of instrumental signal normalization in semiconductor PTR [30], the quest for suitable reference samples for PCR is a much more difficult problem because of the absence of detector response in the thermal infrared spectral region. An indirect normalization method was introduced as shown in FIG. 7. Furthermore, a normalization procedure using a small fraction of the excitation laser beam may also be suitable, as the InGaAs detector is extremely sensitive to light intensity and its wavelength and some scattered optical source light may be allowed to leak into the detector and its intensity modulation frequency scanned to obtain the system transfer function. Therefore, frequency scans on a Si wafer with a large degree of signal variation across its surface were obtained from two such locations with very different responses, using both the MCT and the InGaAs detectors. Then the amplitude ratios and phase differences between the two locations using the same detector were plotted and the amplitude ratios were further normalized at 100 kHz, FIG. 7 a . These self-normalized data are independent of the instrumental transfer function and depend only on differences among electronic parameters (PCR) or combinations of thermal and electronic parameters (PTR) at the two coordinate locations.
[0076] Upon superposition of the self-normalized signals it was found that both amplitude and phase curves essentially overlapped within the electronic region. This implies that both detectors monitor the same electronic CW phenomena at high frequencies and thus the instrumental normalization of the PCR signal can be performed by 1) using the PTR signal from a high-electronic-quality reference Si wafer, normalized by a simple one-dimensional thermal-wave frequency scan of a homogeneous metallic solid [5]; 2) mathematically extracting the electronic component of the PTR signal [5] and adjusting the PCR signal to this component; and 3) using the PCR amplitude and phase frequency correction functions for all other signal normalizations. This indirect scheme was proven satisfactory. It will be seen in part b) of this section, however, that the small differences in the self-normalized high-frequency signals of FIG. 7 are indicative that the thermal-wave component of the PTR signal can be present even at the highest modulation frequencies and, without independent knowledge of the electronic properties of the reference semiconductor, it can affect their “true” values significantly, a conclusion we also reached about photomodulated thermoreflectance [22]. Normalizing the PCR signals with a small scattered portion of the incident optical source remains by far the easiest and most straightforward method, provided other instrumental complications do not arise.
[0077] II. Effects of Backing Material
[0078] A small area of the back surface of the Si wafer which was used for the signal linearity studies was very slightly damaged through gentle rubbing with sandpaper. PCR frequency scans were obtained from outside and inside the region with the back-surface defect. Then line scans and 2-dimensional images at fixed frequency were obtained covering the defect area. The wafer was suspended in air using a hollow sample holder, or was supported by a black rubber or by a mirror backing. FIG. 8 shows PCR frequency scans for all three backings. The PCR technique resolves the amplitudes from the three backings in the order S M >S A >S R , (M: mirror, A: air, R: rubber).
[0079] To understand the origins of the signal changes in the presence of a backing support, a highly reflecting aluminum-foil-covered backing was placed at a variable distance from the back-surface of the Si wafer across from an intact region and PCR signals were monitored, FIG. 9. It is observed that the PCR amplitude remains constant for all three frequencies up to a distance of ˜1 mm away from contacting the back surface, where it starts to increase. The curves are normalized to their value on the surface to show that the rate of increase is independent of frequency. The PCR phase remains essentially flat throughout.
[0080] To determine the origin of PCR signal variations with backing (whether due to IR photon internal reflections or backing emissivity changes [31]) the laser was turned off and a mechanical chopper was placed at some distance away from the IR detector. The lockin amplifier signals from the InGaAs detector nearly vanished at ˜5 μV, a baseline value that remained constant for all combinations of wafer, chopper, and the three substrate materials. These dc emissivity experiments with the InGaAs detector in place are clear evidence that its spectral bandwidth lies entirely outside the thermal IR (Planck) emission range of the Si wafer with or without substrate. Therefore, the PCR amplitude enhancement for mirrored and rubber backings, FIG. 8 a , is consistent with simple reflection of exiting (transmitted) CW-generated IR photons at the surface of the backing, with no possibility for thermal infrared emissivity contributions from the backing itself. The order of the PCR amplitude curves indicates that the surface of highest reflectivity (mirror) yields the strongest signal. It appears the Si-air interface is a more efficient back-scatterer of IR photons than the Si-black rubber interface, where these photons are expected to be more readily absorbed by the rubber. From Eq. (5) it is expected that the ratio of PCR signals with mirror and black rubber backings should be approximately [2+R 1 (λ)]/[1+R b (λ)[1+R 1 (λ)]]≈1.94. The measured ratio from the low-frequency end in FIG. 8 a is 1.8.
[0081] III. PCR Imaging of Deep Sub-Surface Electronic Defects
[0082] [0082]FIG. 10 shows line scans with the excitation laser beam scanning the front (polished) surface of a 20 Ωcm p-type Si wafer and the IR detector on the same side. Based on the backing results, for maximum signal strength the sample was resting on a mirror. Both PTR and PCR amplitude and phase scans were obtained and both show sensitivity to the deep defect on the back surface scratched region. However, at 100 kHz imaging can be performed only with the PCR signal. At all three selected modulation frequencies, the PCR amplitude decreases when the laser beam scans over the defect region, consistent with the expected CW density decrease as the back-surface defect efficiently traps carriers and removes them from further diffusion and potential radiative recombination. The PCR phase scan remains essentially constant at 10 Hz, FIG. 10 b , as the diffusion-wave centroid is solely determined by the ac carrier-wave diffusion length [12]
L a c ( ω ) = D * τ 1 + i ω τ ( 9 )
[0083] where τ is the lifetime and D* is the ambipolar carrier diffusion coefficient. This particular wafer was measured to have τ≅1 ms and D* ≅12 cm 2 /s, which yields an |L αc (10 Hz)|≅1.1 mm. Therefore, the CW centroid lies well beyond the thickness of the wafer (˜630 μm) and no phase shift can be observed. At the intermediate frequency of 1360 Hz, |L αc |≅373 μm, well within the bulk of the wafer. In this case, a phase lead appears within the defective region. This occurs because the CW spatial distribution across the body of the wafer in the defective region is weighed more heavily toward the front surface on account of the heavy depletion occurring at, and near, the back surface. As a result, the CW centroid is shifted toward the front surface, manifested by a phase lead. Finally, at 100 kHz, |Lαc|≅44 μm. Nevertheless, FIG. 10 a shows that there is still PCR amplitude contrast at that frequency, accompanied by a small phase lead, FIG. 10 b . For the PTR scans, FIG. 10 c shows that the overall amplitude is controlled by the CW component at 10 and 1360 Hz, and there is a small contrast at 100 kHz.
[0084] The PTR phase contrast within the region with the back-surface defect first appears as a lag at the lowest frequency of 10 Hz, as expected from a shift away from the front surface of the diffusion-wave centroid in the presence of a remote thermal-wave source which is added to the combined PTR signal. At that frequency the thermal-wave diffusion length [14] is L t /(ω)=(2D t /ω) 1/2 ≅1.7 mm, that is, the back surface is in thermal conductive communication with the front surface. Therefore, the thermal wave, rather than the carrier wave, controls the overall diffusion-wave PTR behavior of the Si wafer at 10 Hz. At 1360 Hz, however, L t ≅148 μm, therefore, there is no thermal contact with the back surface. The only signal component affected by the remote defect is the CW, and the phase behaves as in the PCR case, exhibiting a net lead within the defective region. At 100 kHz there is no PTR phase sensitivity to the defect; only a vestigial amplitude contrast, FIGS. 10 c,d.
[0085] To maximize PCR and PTR imaging contrast, differences in amplitudes and phases as a function of frequency were obtained outside and inside the defective region. It is with the help of this type of analysis that the 1360 Hz frequency was chosen for both techniques as one with the highest contrast in phase (but not in amplitude). It is clear that while the PTR contrast is generally higher at low frequencies due to the cooperative trends in both thermal-wave and carrier-wave components, however, PCR imaging contrast becomes superior above ca. 1 kHz and retains its contrast even at the highest frequency of 100 kHz. FIG. 11 shows images of the back-surface defect obtained through front-surface inspection using both techniques at the optimum contrast frequency of 1360 Hz. FIG. 12 shows the same scan at 100 kHz. At this frequency, the PTR image is dominated by noise and is unable to produce any contrast between the intact and defective regions, whereas the PCR image clearly shows the highest spatial resolution of the back-surface defect possible. The PCR phase, FIG. 12 b , shows details of the central defect as well as the radially diverging defect structures at the base of the central defect, like a “zoomed in” version of the 1360 Hz image, FIG. 11 b . Both PCR images clearly reveal internal sub-structure of the central defect, which was invisible at 1360 Hz.
[0086] In a manner reminiscent of conventional propagating wavefields, image resolution increases with decreasing carrier wavelength, |L αc |. Similar images to FIGS. 11 and 12 were obtained with air or rubber backing of the same wafer, with marginally diminished detail and contrast. The contrast for PCR imaging at 100 kHz, FIG. 12 b , is about 11% for amplitude (FIG. 10 a ) while the phase difference is only 1° (FIG. 10 b ). The very high sensitivity of PCR imaging to defect identification is apparent: despite this very small variation in phase, the defect can be clearly delineated. In the case of PTR at 100 kHz, the contrast for amplitude is about 28% (taking the sharp peak in FIG. 10 c into account). The phase difference is about 10°. An examination of FIGS. 10 c and 10 d at 100 kHz shows that this “higher contrast” is caused by fluctuations of the signal, as the PTR signal-to-noise ratio (SNR) is relatively poor, resulting in the disappearance of the back-surface defect from the images FIGS. 12 c,d . The PCR images exhibit much higher SNR and clearly reveal the defects structure.
[0087] Under front-surface inspection and precise depth profilometric control by virtue of the PCR modulation-frequency-adjustable carrier-wave diffusion length, Eq. (9), FIGS. 11 and 12 show for the first time that with today's high-quality, long-lifetime industrial Si wafers, one can observe full images of sharp carrier-wave density contrast due to underlying defects very deep inside the bulk of a Si wafer. Specifically, high frequency PCR imaging reveals so far unknown very long-range effects of carrier interactions with deep sub-surface defect structures and the detrimental ability of such structures to decrease the overall free photoexcited-carrier density far away from the defect sites at or near the front surface where device fabrication takes place. This phenomenon may be important toward device fabrication improvement through careful selection of substrate wafers with regard to deep bulk growth and manufacturing defects which were heretofore not associated with device performance. Further PCR imaging experiments with shorter lifetime Si wafers have shown that it may be beneficial to use lower quality starting substrates in order to avoid the full effects of deep sub-surface defects on the electronic quality of the upper (device-level) surface.
[0088] b) Application To Quantitative Measurements Of Electronic Transport Properties
[0089] The structure of Eq. (4), the expression for the total emitted power from a semiconductor crystal at the fundamental frequency across the field of view of the IR detector, shows depth dependence of the spatial integrals on the equilibrium IR emission coefficient ε o (λ) of the semiconductor. If this parameter is larger than 1-5 cm −1 , it introduces a weighting factor e −εo(λ)z under the integral signs of the compact expression for the total IR emission, Eq. (4), as well as for pure PCR emission, Eqs. (5) and (7). To estimate the effect of such a factor on the PCR signal, especially in the case of low-resistivity, high-residual infrared absorption Si wafers, a simulation was performed using the PCR Eq. (7) in the three-dimensional form
P ( r,ω;λ 1 ,λ 2 )≈∫ λ 2 λ 1 [1− R 1 (λ)](1+ R b (λ)[1+ R 1 (λ)])η R W eR (λ) C (λ) dλ×∫ 0 L ΔN ( r,z,ω ) e −ε o (λ)z dz (10)
[0090] The equation for ΔN(r,z,ω), the 3-D extension of ΔN(z,ω) is the solution to the photo-carrier-wave boundary-value problem. It was obtained from Ref. [14], Chap. 9, Eq. (9.106), and it is reproduced here:
Δ N ( r , z , ω ) = η Q P o α 2 π hvD * ∫ 0 ∞ - k 2 W 2 / 4 ( α 2 - ξ e 2 ) [ ( G 2 g 1 - G 1 g 2 - ( ξ e + α ) L G 2 - G 1 - 2 ξ e L ) - ξ e z - - a z + ( G 2 g 1 - G 1 g 2 - ( ξ e + α ) L G 2 - G 1 - 2 ξ e L ) - ξ e ( 2 L - z ) ] J o ( kr ) k k ( 11 ) where
g 1 ( k ) ≡ D * α + S 1 D * ξ e ( k ) + S 1 ; g 2 ( k ) ≡ D * α - S 2 D * ξ e ( k ) - S 2 ( 12 a ) with
G 1 ( k ) ≡ D * ξ e ( k ) - S 1 D * ξ e ( k ) + S 1 ; G 2 ( k ) ≡ D * ξ e ( k ) + S 2 D * ξ e ( k ) - S 2 ( 12 b )
[0091] and
ξ e ( k )≡{square root}{square root over ( k 2 +σ e 2 )} (12c)
[0092] Here, k stands for the Hankel variable of radial integration, W is the Gaussian laser beam spotsize, S 1 and S 2 are the front- and back-surface recombination velocities, L is the thickness of the semiconductor slab, α is the optical absorption coefficient at the excitation wavelength λ νis =c o /ν. η is the quantum yield for optical to electronic energy conversion and P o is the laser power. The carrier wavenumber is defined as
σ e ( ω ) ≡ 1 + i ωτ D * τ = 1 L ac ( ω ) ( 13 )
[0093] In the simulations that follow and in the theoretical fits to the experimental data, the variable r was integrated over the surface of the IR detector [4].
[0094] [0094]FIG. 13 shows simulations of the PCR frequency dependence for p-Si of (what amounts to) different resistivity with the equilibrium IR absorption coefficient as a IR-wavelength-independent (average) parameter. From Kirchhoff's law, ε o =α IRo . The curves show a decrease in amplitude, especially at low frequencies, in the carrier-diffusion-wave thin regime (|L αc (ω)|>L), as emissions throughout the bulk of the crystal are gradually impeded with increasing background carrier density (and thus IR absorption coefficient) due to self-absorption of the IR recombination photons by the background free carrier-wave density. At high frequencies, in the carrier-diffusion-wave thick regime (|L αc (ω)|<<L),little attenuation of the backward emitted IR recombination photon flux occurs because the IR-opaque sub-surface layer involved in the CW-generated emission is very thin. Therefore, all amplitude curves converge. PCR phase lags show sensitivity at high frequencies; they decrease with increasing frequency because the contributing CW centroid moves closer to the front surface with increasing IR opacity of the semiconductor. FIG. 13 shows that for typical α IRo ranges of 1-2 cm −1 [32] the effect of self-reabsorption of IR photons due to background free carrier-wave densities is minimal and therefore the approximate Eqs. (4), (5), (7), and (8) are justified.
[0095] The PCR image contrast of FIGS. 11 and 12 can, in principle, be quantified by use of the CW term in Eq. (7), appropriately modified to accommodate the defective region:
Δ P (ω)≈ F 2 (λ 1 ,λ 2 )[Δ N ( z,ω ) dz−∫ 0 L ΔN d ( z,ω ) dz] (14)
[0096] where ΔP(ω) is the difference in signal between the intact and defective regions. This is a complex quantity, so it can be separated out into amplitude and phase components. The apparent simplicity of this expression is due to the fact that the sub-surface defects considered here are on the back surface of the wafer and their presence mostly impacts the value of S 2 in Eq. (11), while the bulk parameters and the terms comprising the prefactor F(λ 1 ,λ 2 ), Eq. (8), remain essentially unaltered, including C d (τ)≈C(λ) for a thin damage layer in an otherwise homogeneous semiconductor. If these conditions are not fulfilled, then a more complete expression of the carrier recombination related emissions must be used to quantify PCR contrast due to distributed sub-surface electronic defect structures.
[0097] The mild mechanical defect on the back surface of the p-type Si wafer that generated the images of FIGS. 11 and 12 proved to be too severe for our sensitive InGaAs photodetector: upon scanning the affected surface the PCR signal vanished within the region of the defect, apparently due to the highly efficient trapping of the photogenerated free carriers by the high density of near-surface electronic defect states. Therefore, a different region of the same wafer was chosen to create a visually undetectable defect by simply touching the back surface of the wafer with paper. Then both PCR frequency scans were performed on both sides of the material, outside and inside the defect region. FIG. 14 shows the PCR frequency scan amplitudes and phases for all four spots, as well as theoretical fits to the experimental data. The signal normalization was performed by extracting the CW component of the PTR signal, i.e. the depth integral over ΔN(r,z,ω), Eq. (11), associated with the prefactor C p in the front intact region, and making it the reference PCR signal for the same region. The thus obtained PCR amplitude and phase transfer functions were subsequently used for all other measurements. The D* values those outside the defect remain constant for both sides of the wafer, however, the D* value from the back inside the defect region is relatively low.
[0098] The higher sensitivity of the InGaAs detector to the electronic state of the inspected surface is probably responsible for this discrepancy, as the theoretical phase fit is poor at high frequencies (>1 kHz) within that region, an indication of near-surface depth inhomogeneity of transport properties. FIG. 14 and the resultant theoretical fits show that PCR signals are very sensitive to the electronic state of the probed semiconductor surface and bulk. The ability to measure the diffusion coefficient D* also allows for the calculation of the conductivity mobility, μ, through the use of the Einstein relation D=(kT/q)μ where k is the Boltzmann constant, T is the temperature, and q is the elementary charge. The measured conductivity mobility of a n-type silicon wafer with resistivity ρ=10−15 Ωcm, N˜8×10 14 cm −3 , and a 980 angstrom thermally grown oxide layer is presented in FIG. 15. The temperature dependence of the conductivity mobility was found to have a relationship similar to that measured using electrical techniques [33].
[0099] In an embodiment of the method the semiconductor material is suitably and rapidly heated by a contacting thermal source and the PCR signal (controlled by the thermal emissions from the recombination-induced infrared emission) is monitored at a suitable PCR frequency such that thermal emissions occur from a defect or impurity state in the material produce a peak in the temperature scan when the material temperature is such that the thermal energy forces trapped carriers to evacuate their trap states at a rate simply related to the PCR frequency. In this manner the energy of the impurity or defect deep level is extracted from the PCR peaks in a series of temperature scans at fixed frequencies using a simple Boltzmann factor, and the PCR signal magnitude is a measure of the occupation density of the level. Alternatively, the PCR frequency is scanned for different (fixed) temperatures and the energy of the level is obtained from an Arrhenius plot of the logarithm of the (modulation period P max of the lock-in in-phase signal where a PCR peak occurs at each temperature T j times T j 2 ) vs. 1/T j . This metrology method can be suitably called PCR Deep-Level Thermal Spectroscopy and can be used for identification of electronic impurity species and/or contamination ions and for estimating their concentration in a semiconductor.
[0100] c) Application To Ion Implant Dose Monitoring in Silicon
[0101] The demonstrated sensitivity to surface defects [19] allows for the use of PCR to monitor ion implant dose. FIG. 16 shows the PCR amplitude dependence as a function of dose for (100) oriented p-type silicon wafers with a thermally grown oxide layer of 200 Å implanted at room temperature at an angle of 7° to suppress channelling with fluences from 10 10 to 10 16 cm −2 with the following species and energy combinations: 11 B + (10 keV, 50 keV, 180 keV), 75 As + (80 keV, 150 keV), 31 P + (30 keV, 80 keV, 285 keV) and BF 2 + (30 keV, 50 keV). Inspection of FIG. 16( a ) through ( d ) shows that the PCR signal dependence on dose can be broken down roughly into four regions with the actual dose defining the transition of each region depending on the mass of the implanted ion. In region I the amplitude decreases rapidly with increasing dose as the degree of damage to the lattice structure increases and electronic integrity of the surface region is compromised resulting in carrier trapping, increased surface recombination velocities, and decreased diffusivities and lifetimes. In region 11 the electronic sensitivity to dose begins to saturate and the PCR amplitude decreases slightly as the size of the damaged region increases with dose [34]. The production of amorphous phase Si brings the onset of sensitivity to the optical properties in Region III resulting in another dose range of rapidly decreasing amplitude as the absorption coefficient increases and results in a greater percentage of the photogenerated carriers being created in a region of compromised electronic integrity. For the more massive As + implants a fourth region is visible as the onset of optical saturation occurs near 10 16 cm −2 and the PCR sensitivity to dose again experiences a rapid decline. Saturation of the electrical sensitivity prior to the onset of the optical sensitivity is a result of the dependence of the carrier-diffusion-wave on electrical percolation paths and the dependence of the optical properties of the sample on relatively large volumes [35].
[0102] A key feature of the results presented in FIG. 16 is the monotonic behavior over a large range of implant dose. The only exceptions for the wafers studied were the B + and P + implanted samples that exhibited slightly non-monotonic behavior in the 5×10 12 to 10 13 cm −2 region at intermediate energy levels and the As + implanted samples that had non-monotonic behaviour above 5×10 15 cm −2 . This monotonic behaviour is an advantage over photothermal techniques such as photomodulated reflectance which exhibit non-monotonic signals over this dose range due to the competing thermal-wave and carrier-wave components that generate them [37]. Several other features of note in FIG. 16 are the PCR dependence on energy and on excitation wavelength. In general, the PCR amplitude decreases with implant energy as the depth of the damaged region increases and consumes a greater portion of the photo-generation volume. Similarly, for a given energy, the PCR amplitude decreases with the excitation wavelength as the increasing absorption coefficient results in a photo-generation volume closer to the implanted region. Both of these phenomena are the result of a modification of the weighting of the contributions to the PCR signal from the (damaged) surface region and the bulk of the sample [38, 39]. This increased dependence on the damaged region of the sample results in an increasing sensitivity of the PCR signal to dose with decreasing absorption depth (i.e. wavelength) of the excitation source [40].
[0103] ii) Interferometric Photocarrier Radiometry
[0104] a) Description of the Method
[0105] All previous photothermal and optical approaches to characterizing semiconductors have been based a single excitation source focused onto one surface of the sample. This results in a baseline signal from the homogeneous bulk that can be large relative to the contrast signal (i.e. signal variation) from any inhomogeneities. Recently, two approaches have been taken in efforts to eliminate this baseline signal from photothermal experiments in order to improve the sensitivity of the instrument.
[0106] A purely thermal-wave interferometric approach has been applied to photo-pyroelectric measurements of trace gas elements [41,42]. Also, the introduction of a dual-pulse wave form into a single excitation beam has been used to create a differential technique that amounts to a common-mode reject scheme [43,44]. Both approaches have shown that suppression of the baseline signal improves the sensitivity and dynamic range compared to the conventional single-ended equivalent. The double-ended interferometric invention, while similar in principle to the PPE interferometric approach, is a completely novel approach to the characterization of solid-state samples, and in particular semiconductors, relying on the interference of the separately generated carrier-density waves in the sample as opposed to other suggested photothermal interferometric techniques which utilize the interference patterns of optical beams interacting with the sample [45].
[0107] The instrumentation for interferometric PCR of a semiconductor sample is described above with respect to FIG. 4. Two laser beams modulated at identical frequencies with one phase shifted 180 degrees with respect to the other are focused onto opposite sides of the sample to generate two separate carrier-density waves. The PCR signal is described by equation (10) with the carrier density ΔN(r,z,ω) being the solution to the photo-carrier-wave boundary-value problem similar to equation (11) but with two excitation sources. The intensity of the laser focused on the front surface of the sample is adjusted to ensure destructive interference of the two waves and thus a zero baseline signal. As the wafer is scanned laterally any inhomogeneities or defects present in the material alter the diffusion of one or both of the photogenerated carrier density waves which no longer interfere destructively and thus produce a non-zero signal. This approach of using a zero baseline signal improves the dynamic range of the instrument and the sensitivity to inhomogeneities and thus provides enhanced imaging contrast of lateral contamination or other inhomogeneities compared to the single-ended PCR.
[0108] From these scans, maps can be produced of any inhomogeneities or defects that affect carrier density, either by enhancing recombination or altering diffusion coefficients. The theoretical model includes an effective carrier diffusion model to obtain quantitative values for the electronic and transport parameters, and combining quantitative results of the theoretical model with maps produced from spatially scanning across at least one surface of the material to provide quantitative imaging of the material. Besides the theoretical fits, maps produced from scanning at least one surface of the material can be combined with calibration curves to provide quantitative imaging of the material. The calibration curves are obtained by measuring the PCR signal from reference samples with known composition, structure and material properties. The calibration curves allow for direct correlation between the PCR signals and the material property and/or industrial process to be monitored.
[0109] This approach of using a zero baseline signal improves the dynamic range of the instrument and the sensitivity to inhomogeneities and thus provides enhanced imaging contrast of lateral contamination or other inhomogeneities compared to the single-ended PCR.
[0110] As used herein, the terms “comprises”, “comprising”, “including” and “includes” are to be construed as being inclusive and open ended, and not exclusive. Specifically, when used in this specification including claims, the terms “comprises”, “comprising”, “including” and “includes” and variations thereof mean the specified features, steps or components are included. These terms are not to be interpreted to exclude the presence of other features, steps or components.
[0111] The foregoing description of the preferred embodiments of the invention has been presented to illustrate the principles of the invention and not to limit the invention to the particular embodiment illustrated. It is intended that the scope of the invention be defined by all of the embodiments encompassed within the following claims and their equivalents.
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[0156] [45]. see for example: H. G. Walther et al., Appl. Phys. Lett. 57, 1600 (1990). | The present invention relates to metrologic methodologies and instrumentation, in particular laser-frequency domain infrared photocarrier radiometry (PCR), for contamination and defect mapping and measuring electronic properties in industrial Si wafers, devices and other semiconducting materials. In particular the invention relates to the measurement of carrier recombination lifetime, τ, carrier diffusivity, D, surface recombination velocities, S, carrier diffusion lengths, L, and carrier mobility, μ, as well as heavy metal contamination mapping, ion implantation mapping over a wide range of dose and energy, and determination of the concentration of mobile impurities in SiO 2 layers on semiconductor substrates. The present invention provides a method and complete photocarrier radiometric apparatus comprising novel signal generation and analysis techniques (carrier-wave interferometry) as well as novel instrumental hardware configurations based on the physical principle of photocarrier radiometry. The method comprises (a) optical excitation of the sample with a modulated optical excitation source and (b) detection of the recombination-induced infrared emission while filtering any Planck-mediated emissions. The present invention provides an instrumental method for detecting weak inhomogeneities among semiconducting materials that are not possible to detect with conventional single-ended photocarrier radiometry. The method comprises (a) irradiating both sides of the sample with modulated optical excitation sources that are 180 degrees out of phase with respect to one another and (b) monitoring the diffusion of the interfering, separately generated carrier waves through the corresponding recombination-induced IR emissions for PCR detection, or the use of an alternative detection scheme that monitors a sample property dependent on the carrier wave transport in the sample. | 6 |
FIELD OF THE INVENTION
The present invention relates to an unbleached paper product and the preparation method thereof. More specifically, the invention relates to the application of unbleached cereal straw pulp to preparation of an unbleached paper product as a main raw material and the unbleached paper product prepared by the same.
BACKGROUND OF THE INVENTION
Household paper is a common consumable product, but due to psychological demand for whiteness and requirement for some physical indexes, paper is usually mainly prepared from bleached wood pulp, and the prior art gives some technical schemes for preparing the household paper, for example:
CN94105089 relates to complete wheat straw high-efficiency pharmaceutical and healthcare toilet paper, and a process for the complete wheat straw high-efficiency pharmaceutical and healthcare toilet paper of the invention comprises paper manufacturing.
CN200410026132 discloses a method for preparing household paper by compounding collagen fiber and plant fiber, and specifically the method comprises mixing bleached softwood (hardwood) pulp with wheat straw pulp to attain 1-4% mass concentration of the pulp, mixing the bleached softwood (hardwood) pulp and the wheat straw pulp with collagen fiber pulp, and adding a softening agent to a machine chest; then feeding resulting pulp to a paper machine wire after mixing; and pressing, drying, reeling and processing wet paper to obtain a finished product.
Pollution from paper and pulp making industry mainly lies in two steps of treating and discharging black liquor after cooking and bleaching pulp, in which pollution from the pulp bleaching step is particularly obvious. With respect to discharge of conventional chloric bleaching wastewater, wastewater contains common aquatic environment pollution factors such as COD and BOD and other special pollutants. For example, in the case of chlorine bleaching and hypochlorite bleaching, wastewater discharged from bleaching every 1 t of bagasse pulp contains 150-250 g of chloroform produced in hypochlorite bleaching, and wastewater discharged from bleaching every 1 t of wood pulp contains 700 g of chloroform. In addition to chloroform produced in the chlorine bleaching, the wastewater also contains more than 40 organic chlorides in which chlorophenols are the most, such as dichlorophenol and trichlorophenol, and contains dioxins and chlorinated furans, a majority of which are highly toxic. AOX has teratogenetic, cancerogenic and mutagenic hazards.
Developed countries and regions such as Western Europe, Hong Kong, Taiwan, Japan and Korea provide addition of harmful substances to office paper production processes, providing that neither chloric bleacher nor fluorescer can be used, and give mandatory requirement for content of harmful substances in the production process, and Japan controls whiteness (<70%) to avoid excessive use of fluorescers. The standards are that contents of COD and AOX in the wastewater are not more than 20 Kg/t paper and not more than 0.3 Kg/t paper respectively. In order to solve water pollution problem, all enterprises and the society pay a high price.
Toilet paper or household paper is prepared from wheat straw or plant fiber as the raw material in the above reference documents, as pulping method in the prior art is relatively lagged, grass material is always cooked to low hardness during preparing pulp from grass plant as the raw material, for example, the grass materials are cooked to hardness with 11-14 potassium permanganate number. In order to achieve such low hardness, amount of cooking liquor and time of heating and insulation are necessarily much, while high-temperature cooking and insulation in high-concentration chemical liquor certainly causes degradation and damage of cellulose and hemicellulose in the grass material, and inherent length of fiber can not be kept well, thus prepared straw pulp has low strength, and then resulting toilet paper and household paper have low quality. In addition, the bleaching step is necessary in the preparation method of the toilet paper and the household paper in the prior art, produces great pollution to environment and products, and produces dioxins, adsorbable organic halide and other carcinogenic substances, which produces great damages to users; moreover, even though wood pulp is used for preparing a variety of paper in the preparation method of the prior art, the fluorescers and other substances harmful for human health are also added and remained in products more or less, which can cause damages to health of users.
Therefore, the prior art does not describe how to prepare higher-performance pulp suitable for preparing various high-quality paper products with respect to the grass material, for disadvantages of the prior art, in more detail, and for the reason, the invention is proposed.
SUMMARY OF THE INVENTION
A primary objective of the invention is to provide a grass type unbleached paper product which comprises unbleached toilet paper, unbleached towel paper, unbleached wiping paper, unbleached duplicating paper, unbleached lunch box, unbleached food wrap paper and unbleached printing paper. The paper product has high strength, and neither dioxins nor adsorbable organic halide is detected in the harmful substance detection test.
In order to achieve the objective mentioned above, the invention uses the following technical scheme:
An unbleached paper product prepared from cereal straw pulp as a raw material has a whiteness of 25-60% ISO, preferably 35-45% ISO, and the cereal straw pulp is unbleached.
The unbleached straw pulp of the invention has a breaking length of 5.0-7.5 km, tear strength of 230-280 mN, folding number of 40-90, whiteness of 25-45% ISO and beating degree of 32-38° SR and preferably has a breaking length of 6.5-7.5 km, tear strength of 250-280 mN, folding number of 65-90, beating degree of 32-36° SR and whiteness of 35-45% ISO.
The unbleached paper product of the invention comprises unbleached toilet paper, unbleached towel paper, unbleached wiping paper, unbleached duplicating paper, unbleached lunch box, unbleached food wrap paper and unbleached printing paper.
The unbleached paper product of the invention is unbleached toilet paper, pulp used for the unbleached toilet paper comprises 70-100% of unbleached straw pulp and 0-30% of unbleached wood pulp, and transverse suction range of a finished layer thereof is 30-100 mm/100 s, preferably 40-100 mm/100 s and more preferably 50-80 mm/100 s.
The unbleached toilet paper of the invention has a tensile index of 4-12 N.m/g, preferably 8-12 N.m/g; the unbleached toilet paper has a softness of 120-180 mN, preferably 120-150 mN; the unbleached toilet paper has an basis weight of 10.0-18.0 g/m 2 , preferably 11.0-13.0 g/m 2 .
The unbleached paper product of the invention is unbleached towel paper, pulp used for the unbleached towel paper comprises 70-100% of unbleached straw pulp and 0-30% of unbleached wood pulp, and longitudinal wet tensile strength of the unbleached towel paper is 22-55 N/m, preferably 30-45 N/m.
The transverse suction range of a finished layer of the unbleached towel paper of the invention is 30-100 min/100 s, preferably 40-100 mm/100 s, more preferably 50-80 mm/100 s.
The unbleached towel paper of the invention has a softness of 120-180 mN, preferably 120-150 mN, and the unbleached towel paper has an basis weight of 23.0-45.0 g/m 2 , preferably 30.0-40.0 g/m 2 .
The unbleached paper product of the invention is unbleached lunch box which is prepared from 70-100% unbleached straw pulp and 0-30% unbleached wood pulp and has performance parameter meeting requirements for Grade A product in GB 18006.1-1999.
The unbleached paper product of the invention is unbleached duplicating paper, pulp used for the unbleached duplicating paper comprises 50-80% of unbleached straw pulp and 20-50% of unbleached wood pulp, mean longitudinal and transverse breaking length of the unbleached duplicating paper is 3.2-7.5 km, preferably 4.5-7.5 km and more preferably 6.0-7.5 km.
Transverse folding number of the unbleached duplicating paper of the invention is 60-200 and preferably 80-185.
Basis weight of the unbleached duplicating paper of the invention is 60.0-75.0 g/m 2 , preferably 65.0-72.0 g/m 2 and more preferably 69.0-72.0 g/m 2 , and opacity thereof is 82.0-98.0% and preferably 90-98%.
The unbleached paper product of the invention is unbleached food wrap paper, pulp used for the unbleached food wrap paper comprises 50-70% of unbleached straw pulp and 30-50% of unbleached wood pulp, and breaking length of the unbleached food wrap paper is 3.2-7.61 cm and preferably 4.5-7.61 cm.
Basis weight of the unbleached food wrap paper of the invention is 45-65 g/m 2 and preferably 50-60 g/m 2 , and transverse folding number of the same is 90-200 and preferably 120-200.
Transverse tear strength of the unbleached food wrap paper of the invention is 300-600 mN and preferably 400-600 mN.
The unbleached offset printing paper of the invention has a whiteness of 30-60% ISO and is prepared from 65-85% of unbleached straw pulp and 15-35% of unbleached wood pulp.
Breaking length of the unbleached offset printing paper of the invention is 2.5-5.5 km and preferably 3.5-5.5 km.
Opacity of the unbleached offset printing paper of the invention is 82-98%, preferably 85-98% and more preferably 92-98%.
Folding number of the unbleached offset printing paper of the invention is 10-35 and preferably 15-35.
The unbleached paper product of the invention is unbleached wiping paper, pulp used for the unbleached wiping paper comprises 70-100% of unbleached straw pulp and 0-30% of unbleached wood pulp, and longitudinal wet tensile strength of the unbleached wiping paper is 22-55 N/m and preferably 30-45 N/m.
Transverse suction range of the unbleached wiping paper is 30-100 mm/100 s, preferably 40-100 mm/100 s, and more preferably 50-80 min/100 s.
The unbleached wiping paper has a softness of 120-200 mN, preferably 120-180 mN; and the unbleached wiping paper has an basis weight of 14.0-36.0 g/m 2 , preferably 18-28 g/m 2 .
Preparation of the unbleached straw pulp of the invention comprises cooking and washing steps, and the cooking step comprises obtaining high-hardness pulp with a potassium permanganate number of 16-28 and beating degree of 10-24° SR after cooking grass plants as the raw material; preferably the unbleached straw pulp is high-hardness pulp with a potassium permanganate number of 16-23 and beating degree of 10-24° SR after cooking grass plants as the raw material.
Preparation of the unbleached straw pulp of the invention comprises cooking and oxygen delignification steps, and the oxygen delignification comprises: pumping high-hardness pulp with the potassium permanganate number of 16-28 which is obtained after cooking to an oxygen delignification reaction tower and adding sodium hydroxide and oxygen; and allowing delignification reaction of the high-hardness pulp in the oxygen delignification reaction tower to obtain pulp with hardness being potassium permanganate number of 10-14.
Preferably, the oxygen delignification is single stage and executed in the oxygen delignification reaction tower; the high-hardness pulp is at 95-100° C. and 0.9-1.2 MPa at an inlet of the reaction tower and at 100-105° C. and 0.2-0.6 MPa at an outlet; alkali used in the oxygen delignification treatment is 2-4% of bone dry pulp based on sodium hydroxide, and oxygen added is 20-40 kg for every ton of bone dry pulp; and the high-hardness pulp reacts in the reaction tower for 60-90 min.
The straw pulp of the invention is prepared from grass plants as the raw material by cooking, washing, oxygen delignification steps, etc., and the grass material comprises one or a combination of a plurality of rice straw, wheat straw, cotton stalk, bagasse, reed or giant reed.
The unbleached paper product of the invention is prepared by beating the straw pulp as the main raw material in combination with a certain amount of unbleached wood pulp or other papermaking pulp if necessary, and then manufacturing paper with the pulp. As the straw pulp is high-quality unbleached straw pulp and has excellent performances such as high strength and high folding number, and the paper product is unbleached, strength of fiber is increased by 30%-50%, yield of fiber is increased by 10%, and strength of the paper product such as breaking length is greatly improved. The unbleached paper product can also greatly reduce pollution to environment, avoid generation of harmful substances and avoid damages to human health.
The paper product has no dioxins and adsorbable organic halide detected in a harmful substance detection test.
Another objective of the invention is to provide a preparation method of an unbleached paper product.
In order to achieve the objective mentioned above, the invention uses the following technical scheme:
A method for preparing the unbleached paper product, the method comprising:
(1 ) cooking the grass material, pressing, washing, disintegration and then performing oxygen delignification treatment to obtain the unbleached straw pulp; (2 ) beating the unbleached straw pulp and the unbleached wood pulp respectively to obtain beaten pulp; (3 ) mixing the unbleached straw pulp and the unbleached wood pulp or other papermaking pulp in step (2 ) based on parts by weight as required by the paper product, and blending the pulp even; and (4 ) manufacturing with the beaten pulp to obtain the unbleached paper product.
In the preparation method of the unbleached paper product of the invention, the step (3 ) also comprises adding other adjuvants required by paper product preparation except fluorescers during or before the mixing process. The preparation method is a conventional preparation method of various paper products in the prior art.
In the step (1 ) of the invention, the grass material is cooked to obtain high-hardness pulp with hardness of 16-28 and degree of beating of 10-24° SR.
The cooking of the invention comprises one of ammonium sulfite, anthraquinone-sodium hydroxide, sulfate or basic sodium sulfite cooking methods:
in the ammonium sulfite cooking method, ammonium sulfite used is 9-13% of the bone dry raw material;
in the anthraquinone-sodium hydroxide cooking method, alkali used is 9-15% of the bone dry raw material based on sodium hydroxide;
in the sulfate cooking method, alkali used is 8-11% of the bone dry raw material based on sodium hydroxide; and
in the basic sodium sulfite cooking method, sodium hydroxide used is 11-15% of the bone dry raw material and sodium sulfite used is 2-6% of the bone dry raw material.
The cooking of the invention comprises one of ammonium sulfite, anthraquinone-sodium hydroxide, sulfate or basic sodium sulfite cooking methods:
1 ) If the Grass Material is Cooked in a Spherical Batch Cooker or a Continuous Cooker: the ammonium sulfite cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which ammonium sulfite used is 9-13% of the bone dry raw material, and liquor ratio is 1:2-4; and
(2 ) feeding steam and heating to 165-173° C., in which time for the whole process of heating, relieving and insulating is 160-210 min;
the anthraquinone-sodium hydroxide cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which alkali used is 9-15% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:2-4, and anthraquinone added is 0.5-0.8% of the bone dry raw material; and (2 ) feeding steam and heating to 160-165° C., in which time for the whole process of heating, relieving and insulating is 140-190 min;
The sulfate cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which alkali used is 8-11% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:2-4, and sulfidity is 5-8%; and (2 ) feeding steam and heating to 165-173° C., in which time for the whole process of heating, relieving and insulating is 150-200 min;
The basic sodium sulfite cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which sodium hydroxide used is 11-15% of the bone dry raw material by weight, sodium sulfite used is 2-6% of the bone dry raw material by weight, anthraquinone used is 0.02-0.08% of the bone dry raw material by weight and cooking liquor ratio is 1:3-4; and (2 ) feeding steam and heating to 160-165° C., in which time for the whole process of heating, relieving and insulating is 140-190 min
2 ) If the Grass Material is Cooked in a Vertical Cooker:
The ammonium sulfite cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which ammonium sulfite used is 9-15% of the bone dry raw material, and liquor ratio is 1:6-10; and (2 ) filling the grass material in hot black liquor in the cooker by a filler, closing a cooker cover after the cooker is full, supplementing the cooking liquor at 130-145° C. while discharging air from the cooker and boosting to 0.6-0.75 MPa, and heating the cooking liquor to 156-173° C., in which time for heating, insulating and exchanging is 220 min; and finally pumping pulp to a blow tank;
the anthraquinone-sodium hydroxide cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which alkali used is 9-17% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:6-9, and anthraquinone added is 0.5-0.8% of the bone dry raw material; and; (2 ) filling the grass material in hot black liquor in the cooker by a charger, closing a cooker cover after the cooker is full, supplementing the cooking liquor at 130-145° C. while discharging air from the cooker and boosting to 0.4-0.6 MPa, and heating the cooking liquor to 147-165° C., in which time for heating, insulating and exchanging is 170-200 min; and finally pumping pulp to a blow tank;
the sulfate cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which alkali used is 8-13% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:6-10, and sulfidity is 5-9%; and (2 ) filling the grass material plant in hot black liquor in the cooker by a charger, closing a cooker cover after the cooker is full, supplementing the cooking liquor at 130-145° C. while discharging air from the cooker and boosting to 0.5-0.65 MPa, and heating the cooking liquor to 155-168° C., in which time for heating, insulating and exchanging is 180-220 min; and finally pumping pulp to a blow tank;
the basic sodium sulfite cooking method comprises:
(1 ) adding cooking liquor to the grass material, in which sodium hydroxide is 9-17% of the bone dry raw material by weight, sodium sulfite used is 4-8%, anthraquinone is 0.04-0.08% and cooking liquor ratio is 1:6-10; and (2 ) filling the grass material in hot black liquor in the cooker by a charger, closing a cooker cover after the cooker is full, supplementing the cooking liquor at 145° C. while discharging air from the cooker and boosting to 0.45-0.6 MPa, and heating the cooking liquor to 152-165° C., in which time for heating, insulating and exchanging is 180-220 min; and finally pumping pulp to a blow tank.
The oxygen delignification of the invention comprises:
(1 ) pumping the high-hardness pulp with hardness of 16-28 potassium permanganate number which is obtained after cooking to an oxygen delignification reaction tower, and adding sodium hydroxide and oxygen; and (2 ) allowing oxygen delignification reaction of the high-hardness pulp in the oxygen delignification reaction tower to obtain pulp with hardness of 10-14 potassium permanganate number;
Preferably, the oxygen delignification is single stage and executed in one oxygen delignification reaction tower; the high-hardness pulp is at 90-100° C. and 0.9-1.2 MPa at an inlet of the reaction tower and at 95-105° C. and 0.2-0.4 MPa at an outlet; alkali used in the oxygen delignification treatment is 2-4% of bone dry pulp based on sodium hydroxide, and oxygen added is 20-40 kg for every ton of bone dry pulp; and the high-hardness pulp reacts in the reaction tower for 60-90 min.
A use of unbleached straw pulp in preparation of the unbleached paper product according to any one of claims 1 - 3 .
The unbleached straw pulp has a breaking length of 5.0-7.5 km, tear strength of 230-280 mN, whiteness of 25-45% ISO, folding number of 40-90 and beating degree of 32-38° SR, and preferably has a breaking length of 6.5-7.5 km, tear strength of 250-280 mN, folding number of 65-90, beating degree of 32-36° SR and whiteness of 35-45% ISO.
A preparation method of the unbleached straw pulp comprises cooking, washing and oxygen delignification steps, and the cooking comprises obtaining high-hardness pulp with potassium permanganate number of 16-28 and beating degree of 10-24° SR after cooking grass plants as the raw material; preferably, the unbleached straw pulp is the high-hardness pulp with potassium permanganate number of 16-23 and beating degree of 10-24° SR after cooking grass plants as the raw material.
Preparation of the unbleached straw pulp comprises cooking, washing and oxygen delignification steps, and the oxygen delignification step comprises: pumping high-hardness pulp with the potassium permanganate number of 16-28 which is obtained after cooking to an oxygen delignification reaction tower and adding sodium hydroxide and oxygen; and allowing delignification reaction of the high-hardness pulp in the oxygen delignification reaction tower to obtain pulp with hardness being potassium permanganate number of 10-14.
Preferably, the oxygen delignification is single stage and executed in the oxygen delignification reaction tower; the high-hardness pulp is at 95-100° C. and 0.9-1.2 MPa at an inlet of the reaction tower and at 100-105° C. and 0.2-0.6 MPa at an outlet; alkali used in the oxygen delignification treatment is 2-4% of bone dry pulp based on sodium hydroxide, and oxygen added is 20-40 kg for every ton of bone dry pulp; and the high-hardness pulp reacts in the reaction tower for 60-90 min.
The cooking comprises one of ammonium sulfite, anthraquinone-sodium hydroxide, sulfate or basic sodium sulfite methods:
in the ammonium sulfite cooking method, ammonium sulfite used is 9-13% of the bone dry raw material;
in the anthraquinone-sodium hydroxide cooking method, alkali used is 9-15% of the bone dry raw material based on sodium hydroxide; and
in the sulfate cooking method, alkali used is 8-11% of the bone dry raw material based on sodium hydroxide; and
in the basic sodium sulfite cooking method, sodium hydroxide used is 11-15% of the bone dry raw material and sodium sulfite used is 2-6% of the bone dry raw material.
The washing step comprises:
(1 ) feeding the high-hardness pulp with concentration of 8-15% from an inlet of a press master, and pressing black liquor under the action of pressing force to obtain pressed pulp with concentration of 18-25%; in which the press master is preferably a single screw press master, a double screw press master or a double roll press master; and (2 ) washing the pressed pulp with one or both of black liquor with concentration of 3-6.2° Be′, pH at 8-8.3 at 70-80° C. and clean water at 70-80° C. in a vacuum pulp washer, a pressure pulp washer or a horizontal belt pulp washer.
In order to describe summary and technical schemes of the invention clearly, terms used in the invention are defined as follows, and in the case of inconsistency between definitions of any other literatures and the invention, definitions in the invention prevail as follows:
The unbleached straw pulp of the invention refers to straw pulp obtained from one or more combined raw materials of annual plants comprising, but not limited to, wheat straw, rice straw, cotton stalk, bagasse, giant reed and reed without any bleaching completely or straw pulp prepared from grass plants through oxygen delignification without other bleaching.
The unbleached paper product of the invention refers to the paper product mainly prepared by a conventional method from straw pulp which is prepared from grass plants as the raw material without any bleaching completely or the paper product mainly prepared by a conventional method from straw pulp which is prepared from grass plants as the raw material through oxygen delignification without other bleaching.
In the preparation method of the unbleached straw pulp of the invention, the prior art can be used for preparing for the grass material at first, that is, a conventional dry/wet method is used for preparing for the material to remove leaf, spike, grain, pith, kernel and other impurities, thus relieving load of the subsequent process and increasing mass of wheat straw pulp. The dry and wet material preparation can be performed by existing conventional equipment such as straw cutter, screening machine, dusting machined, wet washing and rubbing machine and oblique spiral dewaterer. The prepared and dewatered grass material can also be fine material and is bone dry grass without water in grass material, and the length of chopped straw is usually 15-30 mm, and the material preparation process is well known among those skilled in the art.
In the material preparation course of the invention, a hammer crusher can be used for dry material preparation, and the preparation course comprises:
(1 ) cutting and rubbing the grass material with the hammer crusher to obtain the cut and rubbed material;
The grass material is fed to the hammer crusher in the step, and the hammer crusher comprises a conveying and feeding segment, a crushing and rubbing segment and a scattering and discharging segment. The grass material is subject to extrusion effect, thus the grass material with round cross section is flattened to separate leaf, arista, kernel, grain, pith and other impurities from straw and then the grass material is discharged from an outlet of the hammer crusher. The discharged grass material is 20-50 mm long.
The hammer crusher of the invention is a hammer mill for existing material preparation. Speed of the hammer crusher is 500-800 rpm, the grass materials is fed to the hammer crusher at the speed of 0.5-1.3 m/s, and too low or too high feeding speed can cause a quantity of grass material not to be rubbed completely, thus affecting subsequent infiltration of the cooking liquor and further affecting quality of the straw pulp.
The grass material has a waxy layer on an outer layer and a pith layer inside stalk thereof; in a general material preparation method, when the outer layer is macerated in the cooking liquor, wax is removed rapidly, but the cooking liquor is difficult to infiltrate into the inner layer due to air existing in the inner layer of the stalk. The grass material is cut and rubbed by the hammer crusher, which benefits adequate maceration of the grass material, and high-quality straw pulp is easily obtained after the cooking.
(2 ) dedusting the cut and crushed material;
the cut and crushed material is dedusted for the reason that cut chopped straw contains dust, sandstone, grass blade, grass spike and other impurities, and most impurities are removed by dedusting treatment, thus chemical consumption for cooking can be reduced and cooking time can also be correspondingly reduced in the cooking process after the material preparation.
The dusting machine used in the dedusting treatment of the invention can be the dusting machine used for preparing for the grass material in the prior art, including roll dusting machine, double cone dusting machine and cyclone dusting machine, and the dusting machine is preferably the cyclone dusting machine. Air rate is 30000-38000 m 3 /h and air pressure is 210 mm water cylinder during dedusting by the cyclone dusting machine. Dust contained in the grass material can be largely removed under such condition, thus relieving load of subsequent cooking.
(3 ) Screening the dedusted material.
The dedusted grass material tends to carry impurities such as large chopped straw and powder, part of which are difficult to be infiltrated by the cooking liquor during cooking so as to produce undigested substances; although part of powder reacts with the cooking liquor, viscosity of the black liquor is increased, which affects cycle of the cooking liquor, causes uneven cooking and difficulty in operation and affects amount of the black liquor extracted from the paper pulp and washing quality of the pulp, thus the screening step is very important in the dry material preparation of the grass material.
The cylindrical sieve of the invention is that used for the dry material preparation of the grass materials in the prior art. The cylindrical sieve has a speed of 18-29 rpm and an inclination angle of 6-12° and is a double layer cylindrical sieve, side length of rectangular sieve pores of an internal sieve plate of the cylindrical sieve is 30-40 mm, and diameter of sieve pores of an external sieve plate is 4-6 mm; large chopped straw and other small impurities such as mud, sand and dust are screened in the screening process, thus ensuring clean paper pulp.
Removal rate of impurities of the grass material exceeds 90% after the dry material preparation method of the invention, but removal rate of impurities is 70% for a general dry material preparation method, which can reduce dust in the pulp, prepare clean pulp, achieve high yield 3-6% higher than that of the general method and lower production cost by 2-5% by the method of the invention.
The raw material can be macerated by the method of the invention before the cooking, the wheat straw material is macerated with maceration extract to attain liquor ratio of 1:2-4, insulated and mixed in a spiral macerator at 85° C. and normal pressure for more than 10 min, in which time for insulating and mixing at 85-95° C. is preferably 10-40 min. Therefore, the maceration extract is in full contact with the wheat straw material and the wheat straw material is macerated evenly and fully.
The maceration extract can be alkali solution with certain concentration, for example alkali solution containing alkali being 4% of the bone dry raw material by weight based on sodium hydroxide, and can also be mixture of the alkali solution and the black liquor which has a concentration of 11-14° Be′ (20° C.). The raw material is macerated to recycle heat and remaining alkali in the black liquor and reduce energy and resource consumption; maceration pretreatment of the raw material causes the black liquor which is extracted during heating and mainly contains parenchyma cells, hemicellulose and lignin to be separated and discharged for getting ready for the next cooking step. Maceration of the raw material belongs to a pretreatment process with the main purpose of facilitating the delignification reaction in a subsequent cooking process.
Grass pulping refers to properly removing lignin from the grass material by the action of the cooking liquor and retaining cellulose and hemicellulose as much as possible for facilitating papermaking. Actually, the lignin, cellulose, hemicellulose and other components in the raw material are subject to certain chemical changes, degradation and damage at different degrees under the action of high temperature in the cooking process, thus a change rule of the raw material in the cooking process must be studied to establish suitable cooking condition. In the pulping method of the invention, cooking is performed under a condition with cellulose and hemicellulose damage reduced as much as possible through systematic study on consumption and concentration of the cooking liquor, cooking and insulating time and cooking temperature, thus achieving the purposes of reducing production cost, saving energy source and improving pulping yield.
In the method of the invention, high-hardness pulp is obtained after cooking and has hardness being 16-28 potassium permanganate number equivalent to 24-50 Kappa number and beating degree of 10-24° SR; preferably, the high-hardness pulp has hardness being 18-27 potassium permanganate number equivalent to 29-48 Kappa number; most preferably, the high-hardness pulp has hardness being 20-25 potassium permanganate number equivalent to 34-42 Kappa number.
The high-hardness pulp prepared by the cooking in the invention is used as the raw material for preparing unbleached pulp. The preparation method by cooking in the prior art has problems of long cooking and insulating time, high cooking temperature and a large amount of cooking liquor used and long insulating time. But in the preparation method of the invention, the cooking liquor used is less and the cooking and insulating time is greatly shortened. In the cooking method of the invention, the cooking is performed under a condition with cellulose and hemicellulose damage reduced as much as possible through systematic study on consumption and concentration of the cooking liquor, cooking and insulating time and cooking temperature, thus achieving purposes of reducing production cost, saving energy source and improving pulping yield. Yield of the high-hardness pulp obtained by the cooking method is 58-68%.
In the preparation method of the invention, the obtained high-hardness pulp is kept at certain pressure which is 0.75 MPa and then blown to a blow tank after ending cooking. Diluent can be the black liquor used for the maceration above. At the moment, the high-hardness pulp in the blow tank has concentration of 8-15% and hardness being 16-28 potassium permanganate number equivalent to 26-50 Kappa number; the blow tank and the spiral press master are connected via a conveying pump, the conveying pump conveys the high-hardness pulp from the blow tank to the inlet of the spiral press master, the high-hardness pulp is fed from the inlet of the spiral press master and discharged from the outlet of the press master after being pressed, and concentration of the pulp discharged increases from 8-15% to 20-28%, and the pulp becomes high-concentration and high-hardness pulp at 70-80° C. Most black liquor is pressed out and stored in a black liquor tank while pressing the pulp. The press master used is the spiral press master for extracting the black liquor in the prior art, preferably a single spiral press master or a double spiral press master and a double roll press master with variable diameter and pitch.
As great pressing force is generated and temperature rises rapidly in the pulp pressing process while pressing pulp by the press master, fiber is forced to be separated, devillicated, fibrillated and bruised, a primary wall is damaged, the fiber absorbs enough energy and generates great stress inside and reaction performance of the high-hardness pulp is greatly improved. Meanwhile, the fiber is subject to fibrillation, epidermal organic substances and impurities in the fiber are dissolved in the black liquor and discharged from a liquor discharge tank, and fiber purity is greatly improved. Ash and impurities in the black liquor are also discharged along with the black liquor for getting fully ready for the next step. Most preferably, the press master of the invention is the spiral press master with variable diameter, and compressed pulp layers of the pulp within a slowly reducing space are unitedly dewatered internally and externally by the press master with variable diameter. After the selected single spiral press master with variable diameter of the invention presses the high-hardness pulp, beating degree of the high-hardness pulp does not change largely.
The double roll press master can also be used while pressing pulp, and double roll press master can be used in the same manner as the single spiral press master to minimize damages to the fiber, and as the double roll press master has a high black liquor extraction rate, water consumption in the subsequent washing process is greatly reduced and much less than that of the single spiral press master, and concentration of the high-hardness pulp exceeds 20% and reaches 25% at most after pressing.
In the preparation method of the invention, the high-hardness pulp obtained after the cooking or the high-concentration and high-hardness pulp obtained after the pressing is first diluted to 2.5-3.5% with the black liquor with concentration of 11-14° Be′ (20° C.) and then screened by a screening method in the prior art, for example hop screening method with a loss of 0.2-0.5% before washing the high-hardness pulp. Then, washing is performed by the vacuum pulp washer or the pressure pulp washer in the prior art. An objective of washing by the vacuum pulp washer is to easily form pressure difference between inside and outside of fibrocyte being cleaned, which is further beneficial to reach high clean degree in the washing process. In order to reach higher clean degree, washing can be performed once, twice or three times.
In the preparation method of the invention, pulp concentration is 9-11% after the washing, the pulp can be conveyed to a disintegrator by a spiral conveyer for disintegration, and the disintegrated pulp has beating degree of 26-28° SR and wet weight of 1.5-1.7 g at 65-70 ° C. The disintegrator is existing disintegration equipment such as deflaker, disc refiner or defibering machine. The disintegration can separate the fiber by rubbing and expose lignin between fiber and fiber, which benefits the following oxygen delignification step.
The high-hardness pulp obtained by the cooking or the pulp obtained after the disintegration or the pulp obtained after the washing is subject to oxygen delignification which refers to bleaching under the condition that alkali used is 2-4% of the bone dry pulp based on sodium hydroxide and oxygen added is 20-40 kg for every ton of pulp for 60-90 min. At the moment, hardness k value (potassium permanganate number) of the pulp falls to 11-13 equivalent to 12.5-17 Kappa number and beating degree is 32-36° SR. The oxygen delignification of the invention is preferably single stage and performed in an oxygen delignification reaction tower, and the high-hardness pulp is at 90-100° C. and 0.9-1.2 MPa at the inlet of the reaction tower and at 95-105° C. and 0.2-0.4 MPa at the outlet of the reaction tower. The main purpose of the single-stage oxygen delignification is to further ensure strength of the paper pulp, and the single-stage oxygen delignification has less degradation effect on cellulose relative to multistage oxygen delignification. In general, process parameters of the preferred single-stage oxygen delignification in the invention comprises low temperature and relatively long time with the purpose of more moderately performing the delignification reaction and avoiding the degradation of the cellulose as much as possible. Concentration of the high-hardness pulp is preferably 8-18% before the oxygen delignification treatment. The oxygen delignification is performed at medium concentration. The medium-concentration oxygen delignification has the main advantages of less investment, much more easy treatment of the pulp than high-concentration pulp due to successful medium and high concentration pulp mixing and pumping techniques, less equipment corrosion resulting from lower pulp concentration and no risk of burning in oxygen.
The unbleached pulp obtained from the steps has a breaking length of 5.0-7.5 km, tear strength of 230-280 mN, whiteness of 25-45% ISO, folding number of 40-90 and beating degree of 32-38° SR.
The invention has the following benefits:
(1 ) The unbleached pulp can avoid damage of chemicals used in the bleaching process to human, and the prepared unbleached paper product can not contain dioxins, adsorbable organic halide and other carcinogenic substances, thus producing no damage to human. (2 ) The unbleached straw pulp can reduce effects of the bleaching process on breaking length, tear strength and folding number, and different preparation methods generate very excellent performances of the prepared pulp, which can greatly improve quality of the unbleached paper product. (3 ) The unbleached paper product is prepared from the straw pulp as the raw material without any fluorescer, thus the prepared paper product can not be subject to secondary pollution of the substances, original properties of the paper product can be kept and no damage is produced to human. (4 ) As the preparation method of the unbleached straw pulp is improved, strength and other properties of the prepared straw pulp are greatly improved, the straw pulp can be mixed with a small amount of wood pulp or other papermaking pulp for preparing paper products and even can be directly manufactured into high-quality paper products.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE 1
Wheat straw material is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 9% of the bone dry raw material, liquor ratio is 1:3, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 30 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 22 equivalent to 35.5 Kappa number and beating degree of 11.6° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example hop screening method, with loss of 0.5%. The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is conveyed to a medium-concentration pulp pipe. The high-hardness pulp is conveyed to an oxygen delignification reaction tower via a medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.0 km, folding number of 40, tear strength of 220 mN, whiteness of 40% ISO and beating degree of 34° SR. The unbleached straw pulp is beaten to a degree of 33° SR with wet weight of 2.1 g, and additionally prepared unbleached wood pulp is beaten to a degree of 20° SR with wet weight of 12 g.
Up to 65% of the beaten unbleached straw pulp and 35% of beaten unbleached wood pulp by weight are mixed evenly and manufactured to obtain the unbleached offset printing paper. The unbleached offset printing paper has an basis weight of 69.0 g/m 2 , opacity of 85%, breaking length of 3.9 km, whiteness of 49% ISO, transverse folding number of 19, and tear strength of 258 mN.
EXAMPLE 2
Rice straw material is prepared by a hammer crusher and then put into a spherical batch cooker, cooking liquor is added to the spherical batch cooker, ammonium sulfite added is 13% of the bone dry raw material, liquor ratio is 1:4, and the mixture is heated to 120° C. for the first time, insulated at the temperature for 40 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 16 equivalent to 23 Kappa number and beating degree of 23.4° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example, hop screening method, with loss of 0.2%. The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyer. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 3.5% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 6.8 km, folding number of 50, tear strength of 250 mN, whiteness of 41% ISO and beating degree of 36° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp by weight are beaten at the beating concentration of 3.0% and 4.5% respectively in a double disc refiner, and quality standards for finished pulp obtained after beating are as follows: beating degree of 34° SR and wet weight of 1.8 g for the straw pulp and beating degree of 22° SR and wet weight of 10 g for the wood pulp. The unbleached wood pulp is that of the prior art and has a breaking length of 6.5 km, tear strength of 1000 mN, whiteness of 18% ISO and folding number of 1000.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached offset printing paper. The manufacturing comprises manufacturing the finished pulp obtained after the beating and is performed in a multi-cylinder and long-wire paper machine.
The unbleached offset printing paper has an basis weight of 70.0 g/m 2 , opacity of 84%, breaking length of 4.9 km, whiteness of 52% ISO, transverse folding number of 22, and tear strength of 229 mN.
EXAMPLE 3
Bagasse material is prepared conventionally by a dry method, has pith removed and then is put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 11% of the bone dry raw material, liquor ratio is 1:2.5, and the mixture is heated to 130° C. for the first time, insulated at the temperature for 20 min, then relieved for 20 min, heated to 165° C. for 50 min for the second time and insulated for 70 min. High-hardness pulp obtained by cooking has hardness of 21 equivalent to 32 Kappa number and beating degree of 14.2° SR and is conveyed to a double spiral press master for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 25% obtained after pressing is diluted to 2.5% with black liquor and then conveyed to the vacuum pulp washer for washing, and the obtained pulp is heated to 70° C. by a spiral conveyor and conveyed to a medium-concentration pulp pipe after concentration of the pulp reaches 10-13%. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 30 kg for 1 t pulp and alkali solution with alkali content being 3% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 0.8% of the bone dry raw material, the inlet temperature is 98° C., the inlet pressure is 1.05 Mpa, the condition is kept 85 min to allow the pulp to receive sufficient delignification reaction, temperature is 102° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 6.0 km, folding number of 70, tear strength of 230 mN, whiteness of 40% ISO and beating degree of 35° SR.
Up to 85% of the unbleached straw pulp and 15% of unbleached wood pulp by weight are beaten at the beating concentration of 3.2% and 4.0% respectively in a double cylinder refiner, and quality standards for finished pulp obtained after beating are as follows: concentration of 3.2%, beating degree of 33° SR and wet weight of 2.0 g for straw pulp and concentration of 4.0%, beating degree of 18° SR and wet weight of 11 g for wood pulp. The beaten pulp is mixed evenly and manufactured to obtain the unbleached offset printing paper. The manufacturing is performed in multi-cylinder and short and long-wire paper machines.
The unbleached offset printing paper has an basis weight of 65.0 g/m 2 , opacity of 85%, breaking length of 5.5 km, whiteness of 48% ISO, transverse folding number of 28, and tear strength of 230 mN.
EXAMPLE 4
Giant reed is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 11% of the bone dry raw material, liquor ratio is 1:3, and the mixture is heated to 140° C. for the first time, insulated at the temperature for 40 min, then relieved for 20 min, heated to 175° C. for 60 min for the second time and insulated for 90 min. High-hardness pulp obtained after cooking has hardness of 19 equivalent to 28.5 Kappa number and beating degree of 15.6° SR and is conveyed to a single spiral press master with variable diameter for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 26% is obtained after pressing, the pulp from the press master is diluted to 2.5-3.0% with diluted black liquor and then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2%, the pulp is cleared off impurities by a high-concentration deslagging machine with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 2.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 70° C. during the washing process, the pulp is conveyed to a disintegrator for disintegration, beating degree of the giant reed is 24° SR and 27° SR before and after the disintegration, and the pulp is heated to 70° C. by a spiral conveyor and conveyed to a medium-concentration pulp pipe after concentration of the pulp is adjusted to 10%. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 30 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe before being fed into the reaction tower and heated by feeding steam to the pipe. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.2 Mpa, the condition is kept 90 min to allow the pulp to receive sufficient delignification reaction, temperature is 105° C. and pressure is kept at 0.5 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 7.5 km, folding number of 80, tear strength of 280 mN, whiteness of 37% ISO and beating degree of 33° SR.
Up to 50% of the unbleached straw pulp and 50% of unbleached wood pulp by weight are beaten in a cylindrical refiner at beating concentration of 3.8%, beating pressure of 0.20 MPa and beating current of 62 A respectively, and then beaten in a double disc refiner, beating concentration is 3.4%, beating degree is 35° SR and wet weight is 2.2 g for the straw pulp, and beating concentration is 4.5%, beating degree is 19° SR and wet weight is 12 g for the wood pulp. The unbleached wood pulp is that of the prior art.
The beaten pulp is manufactured to obtain the unbleached food wrap paper. The manufacturing comprises manufacturing the finished pulp obtained after beating and is performed in a single round wire, single drying cylinder and single felt toilet paper machine, and the unbleached food wrap paper is obtained after the manufacturing. The unbleached food wrap paper has an basis weight of 60.0 g/m 2 , thickness of 79.0 μm, smoothness of 47 S for the front side and 39 S for the reverse side, whiteness of 20% ISO, opacity of 97.6%, breaking length of 6.8 km, transverse folding number of 150, transverse tear strength of 600 mN and water content of 5.2%.
EXAMPLE 5
Giant reed and reed are prepared by a hammer crusher at a mass ratio of 1:4 and then filled in hot black liquor at 135° C. into a cooker by a filler at liquor ratio of 1:7, the cooker cover is closed after the cooker is full, cooking liquor at 145° C. is added to the cooker, alkali used is 13% of the bone dry raw material based on sodium hydroxide, anthraquinone added is 0.5% of the bone dry raw material, the black liquor and air in the filler are discharged, pressure is increased to 0.6 MPa, a cooking liquor circulating pump and a tubular heater of the cooker are started to heat the cooking liquor to 155° C., and heating and insulating last 160 min. The hot black liquor is exchanged by diluted black liquor and conveyed to a hot black liquor tank, high-hardness pulp obtained after cooking has hardness of 20 equivalent to 30 Kappa number and beating degree of 15° SR and concentration adjusted to 18% and is conveyed to a disc refiner for disintegration, washed by a conventional washing method, then heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyer. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 35 kg for 1 t pulp and alkali solution with alkali content being 2.5% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 100° C., the inlet pressure is 1.2 Mpa, the condition is kept 80 min to allow the pulp to receive sufficient delignification reaction, temperature is 105° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 7.0 km, folding number of 60, tear strength of 240 mN, whiteness of 37% ISO and beating degree of 37° SR.
Up to 60% of the unbleached straw pulp and 40% of unbleached wood pulp by weight are prepared and respectively beaten in a cylindrical refiner at beating concentration of 3.8%, beating pressure of 0.20 MPa and beating current of 65 A, and then beaten in a double disc refiner at beating concentration of 3.3%, beating pressure of 0.15 MPa and beating current of 45 A, and the quality standards for finished pulp obtained after beating are as follows: beating degree is 48° SR and wet weight is 2.8 g. The unbleached wood pulp is that of the prior art and has a breaking length of 7 km, tear strength of 1000 mN, whiteness of 20% ISO and folding number above 1000. The unbleached straw pulp has beating degree of 36° SR and wet weight of 2.3 g, and the unbleached wood pulp has beating degree of 20° SR and wet weight of 12 g.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached food wrap paper. The unbleached food wrap paper has an basis weight of 45 g/m 2 , thickness of 79.0 m, smoothness of 45 S for the front side and 36 S for the reverse side, whiteness of 45% ISO, opacity of 97.6%, breaking length of 5.8 km, transverse folding number of 170, transverse tear strength of 550 mN and water content of 5.3%.
EXAMPLE 6
Giant reed is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 9% of the bone dry raw material, anthraquinone added is 0.8%, liquor ratio is 1:4, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 40 min, then relieved for 30 min, heated to 173° C. for 50 min for the second time and insulated for 60 min. High-hardness pulp obtained after cooking has hardness of 20 equivalent to 30.7 Kappa number and beating degree of 12.5° SR and is conveyed to a single spiral press master with variable diameter for extracting the black liquor in the prior art for pressing, and the high-hardness pulp with concentration of 20% obtained after pressing is washed by a conventional washing method, e.g. a pressure washer, then conveyed to a disc disintegrator for disintegration, heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 70 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.8 km, folding number of 55, tear strength of 260 mN, whiteness of 40% ISO and beating degree of 38° SR.
Up to 55% of the unbleached straw pulp and 45% of unbleached wood pulp by weight are respectively beaten in a double disc refiner, the beating degree of the reed pulp is 3.5% and that of the wood pulp is 4.5%, and quality standards for finished pulp obtained after beating are as follows: beating degree of 35° SR and wet weight of 2.0 g for the reed pulp and beating degree of 20° SR and wet weight of 12 g for the wood pulp. The unbleached wood pulp is unbleached sulfate softwood pulp of the prior art and has a breaking length of 5.0 km, tear strength of 1 100 mN, whiteness of 18% ISO, folding number above 1000 and beating degree of 39° SR.
The beaten pulp is manufactured to obtain the unbleached food wrap paper. The unbleached food wrap paper has an basis weight of 51.5 g/m 2 , thickness of 75.0 pm, smoothness of 48 S for the front side and 36 S for the reverse side, whiteness of 40% ISO, opacity of 96.8%, breaking length of 3.2 km, transverse folding number of 140, transverse tear strength of 380 mN and water content of 5.8%.
EXAMPLE 7
Cotton stalk is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 8% of the bone dry raw material based on sodium hydroxide, sulfidity is 8%, liquor ratio is 1:2, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 40 min, then relieved for 25 min, heated to 166° C. for 45 min for the second time and insulated for 75 min. High-hardness pulp obtained by cooking has hardness of 22 equivalent to 35 Kappa number and beating degree of 11.6° SR and is conveyed to a deflaker for disintegration and then to a double roll press master for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 32% obtained after pressing is diluted to 2.5% with black liquor and washed by a conventional washing method after deslagging, concentration of pulp after washing is adjusted to 15%, and then the pulp is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 3% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 90 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 4.3 km, folding number of 70, tear strength of 275 mN, whiteness of 42% ISO and beating degree of 34° SR.
Up to 80% of the unbleached straw pulp and 20% of unbleached wood pulp by weight are respectively beaten in a double disc refiner, the beating degree of the cotton stalk is 3.5% and that of the wood pulp is 4.5%, and quality standards for finished pulp obtained after beating are as follows: beating degree of 55° SR and wet weight of 2.0 g for the reed pulp and beating degree of 48° SR and wet weight of 2.6 g for the wood pulp. The unbleached wood pulp is unbleached sulfate softwood pulp of the prior art and has a breaking length of 5.0 km, tear strength of 1100 mN, whiteness of 18% ISO, folding number above 1000 and beating degree of 39° SR.
The beaten pulp is manufactured to obtain the unbleached duplicating paper. The unbleached duplicating paper has an basis weight of 60.0 g/m 2 , transverse and longitudinal mean breaking length of 4.51 mm, longitudinal stiffness of 112 mN, transverse stiffness of 72 mN and whiteness of 44.7% ISO.
EXAMPLE 8
Rice straw and wheat straw are prepared by a dry method using a hammer crusher at a mass ratio of 1:3 and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 11% of the bone dry raw material based on sodium hydroxide, sulfidity is 5%, liquor ratio is 1:4, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 20 min, then relieved for 30 min, heated to 168° C. for 40 min for the second time and insulated for 90 min
High-hardness pulp obtained after cooking has hardness of 19 equivalent to 29 Kappa number and beating degree of 14.3° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 3.0% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 70° C. during the washing process, and the pulp is conveyed to a deflaker for disintegration, the pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 7.2 km, folding number of 45, tear strength of 250 mN, whiteness of 42% ISO and beating degree of 33° SR.
Up to 50% of the unbleached straw pulp and 50% of unbleached wood pulp by weight are respectively beaten in a cylindrical refiner at beating concentration of 3.8%, beating pressure of 0.20 MPa and beating current of 62 A, and then beaten in a double disc refiner at beating concentration of 3.4%, beating pressure of 0.20 MPa and beating current of 60 A, and quality standards for the finished pulp after beating are as follows: beating degree of 48° SR and wet weight of 3.2 g. The unbleached wood pulp is that of the prior art, comprises unbleached sulfate softwood pulp, unbleached sulfite softwood pulp, etc. and has a breaking length of 6.5 km, tear strength of 1000 mN, whiteness of 20% ISO, folding number above 1000 and beating degree of 38° SR.
The beaten pulp is manufactured to obtain the unbleached duplicating paper. The unbleached duplicating paper has an basis weight of 65.0 g/m 2 , transverse and longitudinal mean breaking length of 7.5 km, longitudinal stiffness of 82 mN, transverse stiffness of 55 mN and whiteness of 41.8% ISO.
EXAMPLE 9
Rice straw is prepared by a dry method using a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 15% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:3, anthraquinone added is 0.6% of the bone dry raw material, and the mixture is heated to 120° C. for the first time, insulated at the temperature for 20 min, then relieved for 20-30 min, heated to 168° C. for 40 min for the second time and insulated for 90 min. High-hardness pulp obtained after cooking has hardness of 18 equivalent to 27 Kappa number and beating degree of 17° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 2.5% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 68-70° C. during the washing process, and the pulp is conveyed to a deflaker for disintegration, heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after adjusting concentration. The pulp is subject to thermal refining in the medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.12 Mpa, the condition is kept 70 min to allow the pulp to receive sufficient delignification reaction, temperature is 104° C. and pressure is kept at 0.5 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 4.4 km, folding number of 65, tear strength of 245 mN, whiteness of 37% ISO and beating degree of 34° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp by weight are respectively beaten in a double disc refiner, the beating concentration of the straw pulp is 3.2% and that of the wood pulp is 4.5%, and quality standards for finished pulp obtained after beating are as follows: beating degree of 55° SR and wet weight of 2.0 g for the straw pulp and beating degree of 48 ° SR and wet weight of 2.0 g for the wood pulp. The unbleached wood pulp is unbleached sulfate hardwood pulp of the prior art.
The beaten pulp is manufactured to obtain the unbleached duplicating paper.
The unbleached duplicating paper has an basis weight of 72.0 g/m 2 , transverse and longitudinal mean breaking length of 6.2 km, longitudinal stiffness of 90 mN, transverse stiffness of 56 mN and whiteness of 35.0% ISO.
EXAMPLE 10
Rice straw and wheat straw are prepared by a dry method using a hammer crusher at a mass ratio of 1:3 and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 11% of the bone dry raw material based on sodium hydroxide, sulfidity is 5%, liquor ratio is 1:4, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 20 min, then relieved for 30 min, heated to 168° C. for 40 min for the second time and insulated for 90 min.
High-hardness pulp obtained after cooking has hardness of 19 equivalent to 29 Kappa number and beating degree of 14.3° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 3.0% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 70° C. during the washing process, and the pulp is conveyed to a deflaker for disintegration, the pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 7.2 km, folding number of 45, tear strength of 250 mN, whiteness of 42% ISO and beating degree of 33° SR.
The unbleached straw pulp is beaten at the beating degree of 30° SR with wet weight of 2.3 g.
The beaten pulp is mixed evenly and the subject to post-treatment to obtain the unbleached lunch box. The post-treatment comprises adding 1.1% of an oil proofing agent, 3.3% of a water repellent and 0.15% of a catcher and drying at 0.055 MP and 180° C. for 75 s. The obtained unbleached lunch box completely meets requirements for Grade A products in GB 18006.1-1999.
EXAMPLE 11
Rice straw is prepared by a dry method using a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 15% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:3, anthraquinone added is 0.6% of the bone dry raw material, and the mixture is heated to 120° C. for the first time, insulated at the temperature for 20 min, then relieved for 20-30 min, heated to 168° C. for 40 min for the second time and insulated for 90 min. High-hardness pulp obtained after cooking has hardness of 18 equivalent to 27 Kappa number and beating degree of 17° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 2.5% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 68-70° C. during the washing process, and the pulp is conveyed to a deflaker for disintegration, heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after adjusting concentration. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.12 Mpa, the condition is kept 70 min to allow the pulp to receive sufficient delignification reaction, temperature is 104° C. and pressure is kept at 0.5 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached pulp has a breaking length of 4.4 km, folding number of 65, tear strength of 245 mN, whiteness of 37% ISO and beating degree of 34° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp are respectively beaten, the beating degree is 31° SR and wet weight is 2.2 g for the unbleached straw pulp, and the beating degree is 20° SR and wet weight is 10 g for the unbleached wood pulp.
The beaten pulp is mixed evenly and subject to post-treatment to obtain the unbleached lunch box. The post-treatment comprises adding 1.1% of an oil proofing agent, 3.3% of a water repellent and 0.15% of a catcher and drying at 0.05 MP and 178° C. for 78 s. The obtained unbleached lunch box completely meets requirements for Grade A products in GB 18006.1-1999.
EXAMPLE 12
Giant reed is prepared by a conventional dry method using a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 11% of the bone dry raw material based on sodium hydroxide, anthraquinone added is 0.8%, liquor ratio is 1:4, and the mixture is heated to 130° C. for the first time, insulated at the temperature for 40 min, then relieved for 30 min, heated to 173° C. for 60 min for the second time and insulated for 60 min. High=hardness pulp obtained after cooking has hardness of 25 equivalent to 45 Kappa number and beating degree of 12° SR and is conveyed to a single spiral press master with variable diameter for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 20% obtained after pressing is conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 2.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 68-70° C. during the washing process, and the pulp is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after adjusting concentration. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for it pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into an oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.12 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 104° C. and pressure is kept at 0.5 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.0 km, folding number of 69, tear strength of 255 mN, whiteness of 42% ISO and beating degree of 33° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp are respectively beaten, the beating degree is 32° SR and wet weight is 2.3 g for the unbleached straw pulp, and the beating degree is 20° SR and wet weight is 12 g for the unbleached wood pulp.
The beaten pulp is mixed evenly and subject to post-treatment to obtain the unbleached lunch box. The post-treatment comprises adding 1.2% of an oil proofing agent, 3% of a water repellent and 0.15% of a catcher and drying at 0.055 MP and 175° C. for 80 s.
The obtained unbleached lunch box completely meet requirements for Grade A products in GB 18006.1-1999.
EXAMPLE 13
Wheat straw material is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 9% of the bone dry raw material, liquor ratio is 1:3, and the mixture is heated to 110° C. for the first time, insulated at the temperature for 30 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 22 equivalent to 35.5 Kappa number and beating degree of 11.6° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example, hop screening method with loss of 0.5%.The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is conveyed to a medium-concentration pulp pipe. The high-hardness pulp is conveyed to an oxygen delignification reaction tower via a medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.0 km, folding number of 40, tear strength of 220 mN, whiteness of 40% ISO and beating degree of 34° SR. The unbleached straw pulp is beaten, and quality standards for the finished pulp obtained after beating are as follows: beating degree of 45° SR and wet weight of 2.8 g.
The beaten pulp is manufactured to obtain the unbleached towel paper. The manufacturing is performed in a single cylinder and long wire paper machine.
The unbleached towel paper has an basis weight of 23.0 g/m 2 , transverse suction range of 66 mm/100 s, longitudinal wet tensile strength of 36 N/m and whiteness of 41.5% ISO.
EXAMPLE 14
Rice straw material is prepared by a dry method using a hammer crusher and then put into a spherical batch cooker, cooking liquor is added to the spherical batch cooker, ammonium sulfite added is 13% of the bone dry raw material, liquor ratio is 1:4, and the mixture is heated to 120° C. for the first time, insulated at the temperature for 40 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 16 equivalent to 23 Kappa number and beating degree of 23.4° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example, hop screening method with loss of 0.2%. The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyer. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 3.5% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 6.8 km, folding number of 50, tear strength of 250 mN, whiteness of 45% ISO and beating degree of 36° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp by weight are beaten at the beating concentration of 3.0% and 4.5% respectively in a double disc refiner, and quality standards for finished pulp obtained after beating are as follows: beating degree of 50° SR and wet weight of 1.8 g for the straw pulp and beating degree of 46° SR and wet weight of 1.2 g for the wood pulp. The unbleached hardwood pulp has a breaking length of 6.5 km, tear strength of 1000 mN, whiteness of 18% ISO, folding number of 1000 and beating degree of 38° SR.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached towel paper. The manufacturing is performed in a double cylinder and long wire paper machine The unbleached towel paper has an basis weight of 38.2 g/m 2 , transverse suction range of 60 mm/100 s, longitudinal wet tensile strength of 30 N/m and whiteness of 38% ISO.
EXAMPLE 15
Bagasse material is prepared conventionally by a dry method, has pith removed and then is put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 11% of the bone dry raw material, liquor ratio is 1:2.5, and the mixture is heated to 130° C. for the first time, insulated at the temperature for 20 min, then relieved for 20 min, heated to 165° C. for 50 min for the second time and insulated for 70 min. High-hardness pulp obtained by cooking has hardness of 21 equivalent to 32 Kappa number and beating degree of 14.2° SR and is conveyed to a double spiral press master for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 25% obtained after pressing is diluted to 2.5% with black liquor and then conveyed to a vacuum pulp washer for washing, and the obtained pulp is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after concentration of the pulp reaches 10-13%. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 30 kg for it pulp and alkali solution with alkali content being 3% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 0.8% of the bone dry raw material, the inlet temperature is 98° C., the inlet pressure is 1.05 Mpa, the condition is kept 85 min to allow the pulp to receive sufficient delignification reaction, temperature is 102° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 6.0 km, folding number of 70, tear strength of 230 mN, whiteness of 40% ISO and beating degree of 35° SR.
Up to 80% of the unbleached straw pulp and 20% of unbleached wood pulp by weight are beaten at the beating concentration of 3.2% and 4.0% respectively in a double cylinder refiner and then in a double disc refiner, and quality standards for finished pulp obtained after beating are as follows: beating degree of 50° SR and wet weight of 1.8 g for the straw pulp and beating degree of 41° SR and wet weight of 1.5 g for the hardwood pulp. The unbleached wood pulp is that of the prior art, comprises unbleached sulfate softwood pulp, unbleached sulfite softwood pulp, etc. and has a breaking length of 4.5 km, tear strength of 500 mN, whiteness of 18% ISO, folding number of 1000 and beating degree of 38° SR.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached towel paper. The manufacturing is performed in a single cylinder and inclined wire paper machine. The unbleached towel paper has an basis weight of 45.0 g/m 2 , transverse suction range of 55 mm/100 s, longitudinal wet tensile strength of 28 N/m and whiteness of 41% ISO.
EXAMPLE 16
Rice straw is prepared by a dry method using a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 15% of the bone dry raw material based on sodium hydroxide, liquor ratio is 1:3, anthraquinone added is 0.6% of the bone dry raw material, and the mixture is heated to 120° C. for the first time, insulated at the temperature for 20 min, then relieved for 20-30 min, heated to 168° C. for 40 min for the second time and insulated for 90 min. High-hardness pulp obtained after cooking has hardness of 18 equivalent to 27 Kappa number and beating degree of 17° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 2.5% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 68-70° C. during the washing process, and the pulp is conveyed to a deflaker for disintegration, heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after adjusting concentration. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and alkali solution with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.12 Mpa, the condition is kept 70 min to allow the pulp to receive sufficient delignification reaction, temperature is 104° C. and pressure is kept at 0.5 MPa at the top of the tower.
The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 4.4 km, folding number of 65, tear strength of 245 mN, whiteness of 37% ISO and beating degree of 34° SR.
Up to 95% of the unbleached straw pulp and 5% of unbleached wood pulp by weight are respectively beaten in a double disc refiner, the beating concentration of the straw pulp is 3.2% and that of the wood pulp is 4.5%, and quality standards for finished pulp obtained after beating are as follows: beating degree of 55° SR and wet weight of 2.0 g for the straw pulp and beating degree of 48° SR and wet weight of 2.0 g for the wood pulp. The unbleached wood pulp is unbleached sulfate hardwood pulp of the prior art.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached toilet paper.
The unbleached towel paper has an basis weight of 18.0 g/m 2 , transverse suction range of 60 mm/100 s, tensile index of 7.0 N.m/g, softness of 130 mN and whiteness of 50% ISO.
EXAMPLE 17
Giant reed is prepared by a conventional dry method and then put into a spherical digester, cooking liquor is added to the spherical digester, alkali used is 11% of the bone dry raw material based on sodium hydroxide, anthraquinone added is 0.8%, liquor ratio is 1:4, the mixture is heated to 130° C. for the first time, insulated at the temperature for 40 min, then relieved for 30 min, heated to 173° C. for 60 min for the second time and insulated for 60 min. High-hardness pulp obtained after cooking has hardness of 25 equivalent to 45 Kappa number and beating degree of 12° SR and is conveyed to a single spiral press master with variable diameter for extracting the black liquor in the prior art for pressing, the high-hardness pulp with concentration of 20% obtained after pressing is conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 2.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 68-70° C. during the washing process, and the pulp is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyor after adjusting concentration. The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and aqueous alkali with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 102° C., the inlet pressure is 1.12 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 104° C. and pressure is kept at 0.5 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.0 km, folding number of 69, tear strength of 255 mN, whiteness of 42% ISO and beating degree of 33° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp by weight are respectively beaten in a cylindrical refiner at beating concentration of 3.8%, beating pressure of 0.15-0.20 MPa and beating current of 65 A, and then beaten in a double disc refiner at beating concentration of 3.3%, beating pressure of 0.20 MPa and beating current of 60 A, and quality standards for the finished pulp after beating are as follows: beating degree of 48° SR and wet weight of 2.8 g. The unbleached wood pulp is that of the prior art, comprises unbleached sulfate softwood pulp, unbleached sulfite softwood pulp, etc. and has a breaking length of 6 km, tear strength of 1000 mN, whiteness of 18% ISO, folding number above 1000 and beating degree of 40° SR.
The beaten pulp is manufactured to obtain the unbleached toilet paper.
The unbleached toilet paper has an basis weight of 11.0 g/m 2 , transverse suction range of 80 mm/100 s, tensile index of 10.0 N.m/g, softness of 120 mN and whiteness of 38% ISO.
EXAMPLE 18
Rice straw, wheat straw and reed are prepared by a dry method using a hammer crusher at a mass ratio of 1:3:1 and then filled in hot black liquor at 135° C. into a cooker by a filler at liquor ratio of 1:8, the cooker cover is closed after the cooker is full, cooking liquor at 145° C. is added to the cooker, alkali used is 11% of the bone dry raw material based on sodium hydroxide, anthraquinone added is 0.8% of the bone dry raw material, the black liquor and air in the filler is discharged, pressure is increased to 0.6 MPa, a cooking liquor circulating pump and a tubular heater of the cooker are started to heat the cooking liquor to 160° C., and heating and insulating last 180 min. The hot black liquor is exchanged by diluted black liquor and conveyed to a hot black liquor tank, high-hardness pulp obtained after cooking has hardness of 19 equivalent to 29 Kappa number and beating degree of 16° SR and is conveyed to a conventional single spiral press master with variable diameter for extracting the black liquor for pressing, the pulp from the press master is diluted to 3.0% with diluted black liquor, then conveyed to a hop sieve for coarse pulp screening with hop sieve loss of 0.2% and delagged by a high-concentration slag separator with loss of 0.1%, the pulp obtained after deslagging is fed into a horizontal belt pulp washer for washing, pulp concentration is 3.0% while washing, the pulp from the pulp washer has concentration of 9%, temperature is kept at 70° C. during the washing process, the pulp is conveyed to a deflaker for disintegration, and the pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and aqueous alkali with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 6.5 km, folding number of 45, tear strength of 250 mN, whiteness of 42% ISO and beating degree of 33° SR.
Up to 95% of the unbleached straw pulp and 5% of unbleached wood pulp by weight are respectively beaten in a double disc refiner at the beating concentration of 3.4%, and quality standards for finished pulp obtained after beating are as follows: beating degree of 48° SR and wet weight of 2.9 g. The unbleached wood pulp is that of the prior art, comprises unbleached sulfate softwood pulp, unbleached sulfite softwood pulp, etc. and has a breaking length of 6 km, tear strength of 1000 mN, whiteness of 20% ISO, folding number above 1000 and beating degree of 38° SR.
The beaten pulp is manufactured to obtain the unbleached toilet paper.
The unbleached towel paper has an basis weight of 13.0 g/m 2 , transverse suction range of 30 mm/100 s, longitudinal wet tensile strength of 22 N/m, softness of 140 mN and whiteness of 50% ISO.
EXAMPLE 19
Wheat straw is prepared by a hammer crusher and then put into a spherical digester, cooking liquor is added to the spherical digester, ammonium sulfite added is 9% of the bone dry raw material, liquor ratio is 1:3, the wheat straw material is heated to 110° C. for the first time, insulated at the temperature for 30 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 22 equivalent to 35.5 Kappa number and beating degree of 11.6° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example, hop screening method with loss of 0.5%. The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is conveyed to a medium-concentration pulp pipe. The high-hardness pulp is conveyed to an oxygen delignification reaction tower via a medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and aqueous alkali with alkali content being 4% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.3 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached straw pulp has a breaking length of 5.0 km, folding number of 40, tear strength of 220 mN, whiteness of 40% ISO and beating degree of 34° SR. The unbleached straw pulp is beaten, and quality standards for the finished pulp obtained after beating are as follows: beating degree of 45° SR and wet weight of 2.8 g.
The beaten pulp is manufactured to obtain the unbleached wiping paper. The manufacturing is performed in a single cylinder and long wire paper machine
The unbleached wiping paper has an basis weight of 14.0 g/m 2 , transverse suction range of 100 mm/100 s, longitudinal wet tensile strength of 55 N/m and whiteness of 45% ISO.
EXAMPLE 20
Wheat straw is prepared by a dry method using a hammer crusher and then put into a spherical batch cooker, cooking liquor is added to the spherical batch cooker, ammonium sulfite added is 13% of the bone dry raw material, liquor ratio is 1:4, the mixture is heated to 120° C. for the first time, insulated at the temperature for 40 min, then relieved for 25 min, heated to 168° C. for 60 min for the second time and insulated for 90 min. The high-hardness pulp obtained after cooking has hardness of 16 equivalent to 23 Kappa number and beating degree of 23.4° SR and is diluted to 2.5% with diluted black liquor and then screened by a screening method in the prior art, for example, hop screening method with loss of 0.2%. The high-hardness pulp is washed by a vacuum pulp washer in the prior art. The high-hardness pulp with concentration of 10% obtained after washing is heated to 70° C. and conveyed to a medium-concentration pulp pipe by a spiral conveyer.
The pulp is subject to thermal refining in a medium-concentration pulp pipe to eliminate air and to be fluidized and then conveyed to an oxygen delignification reaction tower by a centrifugal medium-concentration pulp pump. The pulp is mixed with added oxygen of 20 kg for 1 t pulp and aqueous alkali with alkali content being 3.5% of the bone dry raw material based on sodium hydroxide in the pipe and heated by feeding steam to the pipe before being fed into the reaction tower. Then, the pulp is fully mixed in a mixer and then fed into the oxygen delignification reaction tower, magnesium sulfate is used as a protectant, magnesium sulfate added is 1% of the bone dry raw material, the inlet temperature is 95° C., the inlet pressure is 0.9 Mpa, the condition is kept 75 min to allow the pulp to receive sufficient delignification reaction, temperature is 100° C. and pressure is kept at 0.4 MPa at the top of the tower. The pulp is blown to a pulp chest and diluted to obtain the unbleached pulp after finishing treatment. The unbleached pulp has a breaking length of 6.81 cm, folding number of 50, tear strength of 250 mN, whiteness of 45% ISO and beating degree of 36° SR.
Up to 70% of the unbleached straw pulp and 30% of unbleached wood pulp by weight are beaten in a double disc refiner at the beating concentration of 3.0% and 4.5% respectively, and quality standards for finished pulp obtained after beating are as follows: beating degree of 50° SR and wet weight of 1.8 g for the straw pulp and beating degree of 46° SR and wet weight of 1.2 g for the wood pulp. The unbleached hardwood pulp has a breaking length of 6.5 km, tear strength of 1000 mN, whiteness of 18% ISO, folding number of 1000 and beating degree of 38° SR.
The beaten pulp is mixed evenly and manufactured to obtain the unbleached wiping paper. The manufacturing is performed in a double cylinder and long wire paper machine. The unbleached wiping paper has an basis weight of 36.0 g/m 2 , transverse suction range of 60 mm/100 s, longitudinal wet tensile strength of 40 N/m and whiteness of 45% ISO. | Provided is an unbleached paper product made from grass type pulp, the unbleached paper product has a brightness of 35-60% ISO, the grass type pulp is unbleached. The unbleached paper product includes an unbleached toilet paper, an unbleached hand towel, an unbleached wiping paper, an unbleached duplicating paper, an unbleached meal container, an unbleached food wrapping paper and an unbleached printing paper. The paper products have a high intensity and have no detection of dioxin and absorbable organic halides in the harmful substance detection test. | 3 |
RELATED APPLICATION
[0001] This application claims priority to Provisional Application Ser. No. 60/729,676 filed Oct. 24, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates generally toward an improved method for controlling the environment inside a paint booth. More specifically, the present invention relates toward an energy efficient method of using heat generated inside the paint application building to reduce the cost associated with conditioning the environment inside the paint application booth.
BACKGROUND OF THE INVENTION
[0003] The operation of a paint application building, and more specifically, a paint application booth, has proven to be one of the most costly elements of mass producing articles that are coated with protective and/or decorative coatings. In a mass production setting, articles are conveyed through a paint application booth where atomized paint is applied to the article, such as, for example, automobile bodies, at a high rate. The increased use of environmentally friendly coating materials such as, for example, water borne base coats, urethane clear coats, and powder coatings has required a narrow psychometric condition be maintained inside the paint application booth during operation. This has resulted in increasing costs associated with achieving the preferred psychometric condition to achieve the necessary coating quality.
[0004] Presently configured paint application buildings generally make use of segregated ventilation systems for the paint application booth, working areas, and non-working or general building areas. In each case, fresh ambient air is drawn from the outside environment and treated by either heating, cooling, humidifying, or dehumidifying to obtain the desired psychometric condition. This is best represented in FIG. 1 where a conventional paint application building ventilation schematic is generally shown at 10 . The conventional application building 10 generally includes three separate areas, namely, a general building or non-work area 12 , a work space 14 , and a paint application booth 16 .
[0005] The general building area 12 includes all of the areas inside the building 10 where no significant work is performed on the articles being coated. This includes aisle ways, article accumulation areas, and article transport areas. The general building area 12 includes an independent air inlet 18 that draws air from outside the building 10 via a building air supply house 20 . In Northern regions, this air is generally heated and humidified particularly during the Winter months, and in the Southern region, this air is generally cooled and dehumidified, particularly during the Summer months. The building 10 also includes a building exhaust 22 where air is generally, continuously exhausted from the general building area 12 . Thus, air that has been conditioned in the building air supply house 20 by either heating, cooling, humidifying, and dehumidifying is exhausted back to atmosphere without making further use of the desired psychometric condition established in the building air supply house 20 .
[0006] Various work spaces 14 are also included in a conventional paint building 10 where various functions are performed on the article being painted, both before and after paint application. Some of these functions include detacification, dust and other particle removal, both dry and wet sanding, sealer application, and other necessary operations to make ready the article to be painted. Each of these processes are known to increase air temperature inside the various work spaces 14 . Each work space 14 includes a work space air inlet 24 that draws air into the work space 14 via a work space air supply house 26 . Air is generally, continuously exhausted from the work space 14 through a work space exhaust 28 . The temperature of the air exiting the work space 14 is typically greater than the air entering the work space 14 as the work being performed on the articles generates heat. This heat energy along with the energy used to condition air received from the work space air inlet 24 to reach the desired psychometric condition in the work space 14 is exhausted through the work space exhaust 28 to the atmosphere.
[0007] Air is delivered to the application booth 16 through a booth air inlet 30 via a booth air supply house 32 . The psychometric condition of the air entering the application booth 16 is defined by the processing parameters of the coating material being applied to the article. Therefore, the energy used to condition the air received from the booth air inlet inside the booth air supply house 32 to heat, cool, humidify, and dehumidify is significantly greater and more precisely controlled than the conditioning that takes place in the building air supply house 20 and the work space air supply house 26 . As stated previously, the air drawn through the booth air inlet 30 is generally heated and humidified in Northern regions primarily during the Winter months and cooled and dehumidified in Southern regions, primarily during the Summer months. The air flowing through the spray booth 16 is generally, continuously exhausted through a booth exhaust 34 where the energy used to condition the air is exhausted to the atmosphere.
[0008] The conventional paint building design set forth above has proven to use an excessive amount of energy to condition air for each of the building 12 , the work space 14 and the application booth 16 . In each case, air is exhausted to the atmosphere without taking full advantage of the energy used to condition the air to obtain the preferred psychometric condition in each of the various areas. Therefore, it would be desirable to provide a coating process having reduced energy requirements by taking advantage of more efficient flow of energy, particularly during an era of increasing energy costs.
SUMMARY OF THE INVENTION
[0009] The present invention is directed toward a method of conditioning the air supply to a paint application booth disposed within a paint application building. A booth psychometric condition preferred to apply paint inside the paint application booth is determined based upon specifications set forth by the paint or coating supplier. Air is removed from the paint application building and is conditioned to obtain the preferred booth psychometric condition. The air is conditioned while maintaining a generally constant enthalpy and is transferred into the paint booth at the preferred booth psychometric condition.
[0010] The inventive method of conditioning the air supply to the paint application booth takes advantage of the psychometric condition of the air disposed in the paint building exterior to the paint booth. Generally, air makeup supplied to the paint application building is conditioned by either heating and humidifying and cooling and dehumidifying depending on the seasonal condition and the regional location of the building. Therefore, energy is used to condition the air received from the atmosphere to provide a building environment that is more conducive to processing articles through a paint booth than is the atmosphere. Furthermore, the mechanical operations and machinery generally provide heat energy to the air disposed inside the application building that results in an increase in temperature of the air. Prior art buildings partly vent this air to the atmosphere when circulating fresh air through the paint application building resulting in the loss of the heat energy provided to the air by virtue of the work functions performed inside the building and the energy associated with conditioning the air to make the building interior more conducive to processing the articles through the paint booth than is the atmosphere outside the building.
[0011] By taking advantage of the energy associated with the air inside the building and making use of the psychometric condition of the air disposed inside the building, a significant energy reduction is achieved by routing the building air through the paint application booth as opposed to exhausting the air from the building back to the atmosphere. Specifically, the preferred psychometric condition inside the paint application booth is obtained by merely converting the sensible heat of the air being transferred from the building to the application booth to latent heat. The preferred psychometric condition is obtained when converting sensible heat to latent heat by merely adding humidity to the flow of air from the application building through the paint application booth. This provides the opportunity to either eliminate cooling and heating systems associated with the paint application booth or significantly downsizing heating and cooling apparatus because the heat energy already disposed in the building air is being recycled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a cross sectional view of a prior art paint application building;
[0013] FIG. 2 illustrates a cross sectional view of a paint application building of the present invention;
[0014] FIG. 3 is a psychometric table representing an application booth of the present invention being operated at a target psychometric condition;
[0015] FIG. 4 is another psychometric chart representing a range of temperature and humidity known to produce equivalent paint quality; and
[0016] FIG. 5 illustrates an alternative embodiment of the paint application building.
DETAILED DESCRIPTION OF THE INVENTION
[0017] Referring to FIG. 2 , a paint building of the present invention is generally shown at 110 . The inventive paint building 110 generally includes a non-working or general building area 112 , a work space 114 and an application booth 116 . As is known to those of skill in the art, the general building area 112 includes aisle ways, office space, transfer conveyors, accumulators, and storage areas. The work spaces 114 are areas where additional work is performed on articles, such as, for example, vehicle bodies 117 being processed through the paint application building 110 .
[0018] Many of the functions performed in the application building 110 and the work spaces 114 produce heat resulting in an increase in the air temperature within the work spaces 114 . For example, unpainted vehicle bodies generally referred to as body in white are first treated with the application of a phosphate coating, which is applied at about 130° F. and is subsequently coated with an electrodeposition primer and baked at a temperature approaching 400° F. Each of these operations result in an increase in air temperature resulting in an altering of the psychometric condition of the air disposed in the work space 114 . Further operations include sanding and cleaning the primered surface to remove particulate matter known to result in paint defects and also increase the temperature of the air in the work space 114 .
[0019] The application booth 116 is maintained in the most precise psychometric condition out of any area in the paint application building 110 . The type of paint being applied to the vehicle body 117 dictates a temperature and humidity range required to optimize the finished paint quality on the paint vehicle. For example, applying paint at an unrecommended high temperature or humidity may result in paint defects known as sags or orange peel on the vehicle body 117 . Therefore, the paint supplier generally sets a humidity and temperature range known to reduce the potential for finish paint defects. Generally, the paint supplier recommends a target temperature and humidity known to produce optimum paint finish on the vehicle body 117 . While a narrow range is also generally identified by a given paint supplier, it is recommended by that paint supplier that the target temperature and humidity be maintained at all times. It is contemplated by the inventors that the target temperature and humidity actually define a desirable range that provides an optimum paint application performance. It has also been contemplated by the inventors that the temperature and humidity target can be broadened along a line on a psychometric chart plotting dry bulb temperature against absolute humidity of air. The advantages of the present inventive paint building 110 are explained further below.
[0020] Ambient air is drawn through a building air inlet 118 from the atmosphere into a building air supply house 120 by fans sized and powered to produce the desirable amount of fresh air to the general building area 112 . The building area supply house 120 includes air conditioning assemblies (not shown) that heat, cool, humidify, or dehumidify the air being drawn through the air inlet 118 from the atmosphere to the preferred temperature and humidity of the general building area 112 .
[0021] Ambient air is also drawn from the atmosphere through a work booth air inlet 124 into a work booth air supply house 126 by fans (not shown) sized to provide the desired amount of fresh air to the various work booths 114 disposed within the paint application building 110 . Like the building air supply house 120 , the work booth air supply house 126 also includes air conditioning equipment to heat, cool, humidify, or dehumidify the air being drawn from the atmosphere 124 to the preferred temperature and humidity inside the various work booths 114 . As represented in FIG. 2 , the air from the work booth 114 is optionally vented through a work booth exhaust 128 to the atmosphere after appropriate abatement procedures are performed.
[0022] Air is drawn through a transfer 136 from the general building area 112 into a paint application booth air supply house 132 via fans sized to provide the desired amount of make up air to the application booth 116 . The booth air supply house includes an air conditioner 133 to adjust the psychometric condition of the air entering the paint application booth 116 , 216 . The air conditioner 133 either increases the humidity, decreases the humidity, increases the temperature, or decreases the temperature of the air entering the paint application booth 116 . As is known to those of skill in the art, this requires air conditioner to include a heater, chiller, humidifier, or dehumidifier. It is expected that the concepts of the present invention eliminates the need for a heat, or, in the alternative, enables the heater to be reduced in size. Air is exhausted from the application booth 116 through application booth exhaust 139 after the appropriate abatement is conducted in a known manner.
[0023] The method by which the advantages of the inventive paint building 110 is derived is best explained referring to a psychometric table set forth in FIG. 3 . FIG. 3 represents the application booth 116 being operated at a target psychometric condition 138 (spray booth requirement). In this example, ambient air delivered through one of the general building air inlet 118 or the work space air inlet 124 is identified at dry bulb temperature and humidity at 140 (building delivery). It should be understood by those of skill in the art that the temperature and humidity of the ambient air 140 changes depending on seasonal and regional factors.
[0024] The first line on the psychometric chart in FIG. 3 represents heat added to the air in the general building area 112 and through operation of necessary equipment in the paint building 110 . In this example, the ambient air temperature is increased from generally 65° F. to around 95° F. Converting the sensible heat disposed in the general building area 112 air to latent heat by merely increasing humidity of the air transfer from the general building area 112 to the application booth 116 , the psychometric condition of the transferred air becomes closer to the desired spray booth psychometric condition 138 . This reduces the amount of the heating required in the booth air supply house 132 as represented by line 144 of the psychometric chart shown in FIG. 3 .
[0025] A second example is represented in the psychometric chart of FIG. 3 where the temperature of the air in the building is increased from point 140 along line 146 to approximately 115° F. As set forth above, the sensible heat is converted to latent heat by merely adding humidity to the air transferred through transfer 136 from the building 112 , or more likely in this example, from the work area 114 to the application booth 116 . At generally constant enthalpies, the air temperature remains higher than its required psychometric condition 138 in the application booth 116 requiring additional cooling in the booth air supply house 132 as represented by line 148 of the psychometric chart in FIG. 3 .
[0026] It has been determined by the inventors that the booth requirement 138 shown in the psychometric table in FIG. 3 is achievable through a range of temperature and humidity known to produce equivalent paint quality. The range is represented in the psychometric chart shown in FIG. 4 by the spray booth control line 150 . By adopting the spray booth control line 150 as a process control parameter, the necessity for adding heat or removing heat from the air being transferred into the application booth 116 through transfer 136 from the general building 112 or the work booth 114 is eliminated further reducing the cost associated with conditioning the air inside the application booth 116 . The point identified in the psychometric chart of FIG. 4 as 140 increases in temperature along lines 142 and 146 depending upon the various processes being performed in the paint application building 110 . In each case, humidity is added converting sensible heat to latent heat in the continuous flow of air flowing from the paint application building 110 to the application booth 116 . As the spray booth control line 115 is adopted providing a range of enthalpies neither heat needs to be added nor removed further reducing the cost associated with conditioning the air being delivered to the application booth 150 .
[0027] A further alternative embodiment of the paint application building as shown in FIG. 5 as 210 . In this embodiment, a work space air inlet 224 provides air to the application building 210 . Air is drawn through the work space air inlet 224 by fans disposed in a work space air supply house 226 for use in a work space area 214 . As set forth above, heat is added to the air by virtue of the work being performed on the vehicle body 17 inside the work space 214 . A work space transfer line 252 exhausts air from the work space 214 and may pass the air through a filtration system 254 before the air is introduced through the non-work area 212 of the application building 210 . In this embodiment, air passes through transfer 236 after being exhausted from the non-work space 212 to the booth air supply house 232 via air supply fans (not shown). The psychometric condition of the air passing through the transfer 236 is determined prior to transferring the air into the application booth 216 . As set forth above, the air is humidified in the booth air supply house 232 prior to transferring the air into the application booth 216 . Air is continuously exhausted from the application booth through the application booth exhaust 239 where abatement is performed prior to releasing the booth air to the atmosphere. In this embodiment, costs are further reduced through the use of only a single exhaust 239 for the entire application building 210 . It should be understood by those of skill in the art that fresh air may be added to the transfer 236 at a predetermined ratio for this and the previous embodiments if necessary.
[0028] The paint application booth 116 , 216 of each of the embodiments set forth above include a sensor 119 , 219 that signals a controller 121 , 221 the temperature and humidity of the air inside the paint application booth 116 , 216 to establish a feed back control loop. Preferably, the controller 121 , 221 is a proportional integral derivative controller providing a level of control known to those of skill in the art to limit the amount of variability of the temperature and humidity in the paint application booth 116 , 216 . Therefore, the controller 121 , 221 maintains the temperature and humidity inside the booth 116 , 216 with the predetermined psychometric control range 150 .
[0029] The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation.
[0030] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described. | A method of conditioning the air supplied to a paint application booth having a separate air supply from a paint application building housing the paint application booth includes determining a booth psychometric condition preferred to apply paint inside the paint application booth. Air is removed from the paint application building and conditioned obtaining the preferred booth psychometric condition of the air removed while maintaining a generally constant enthalpy. The air removed from the paint application building is transferred into the paint booth at the booth psychometric condition preferred to apply paint inside the paint application booth. | 1 |
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application Ser. No. 61/119,094 filed on Dec. 2, 2008, the contents of which are incorporated herein in their entirety.
FIELD OF THE INVENTION
The present invention relates to the field of compact fluorescent bulbs and, more specifically, to the field of cleanup and disposal of compact fluorescent light bulbs.
BACKGROUND OF THE INVENTION
Compact fluorescent light bulbs (CFL) are becoming increasingly more common as they are a great way to conserve energy. More specifically, CFLs provide a substantial amount of illumination while using substantially less energy than traditional light bulbs. In fact, it has been found that CFLs may use up to about 75% less energy than traditional light bulbs. CFLs, however, contain metal contaminant material, i.e., Mercury. Accordingly, in the case of a breakage, there exists a danger of inhalation of Mercury vapor. Inhalation of Mercury vapor may lead to brain damage, birth defects, or any other number of dangerous illnesses. Statistics show that 1 in 6 children every year have been exposed to Mercury levels so high that they are at potentially at risk for learning disabilities, motor skills impairment and short-term memory loss. Further, the Mercury in one CFL can pollute 6,000 gallons of water beyond safe levels from drinking. Accordingly, there exists a need for a kit to be used to clean up and dispose of broken CFLs to minimize risks associated with the Mercury in a CFL.
Proposed solutions to the problem of spreading metal contaminants, which are found in CFLs, involve disposing of a CFL using an apparatus that may capture escaping contaminants. See, e.g., U.S. patent application Ser. No. 11/278,516 by Domanico. However, such solutions are inadequate for dealing with CFLs that may be unintentionally broken. Other proposed solutions to this problem involve using, for example, a complicated apparatus that submerges the CFL into a chemical bath. See, e.g., U.S. Pat. No. 5,360,169 to Köher. Such solutions are not practical for a residential or commercial setting. Other examples provide ways to safely store a CFL, containing contaminant metals when a CFL breaks inside of the proposed containment device, but these solutions fail to address the problem of cleaning up CFL debris when breakage occurs outside of a controlled environment. See, e.g., U.S. Pat. No. 7,410,054 to Shatford et al.; or U.S. patent application Ser. No. 12/151,408 by Ludtke, JR. et al.
SUMMARY OF THE INVENTION
As indicated above, there exists a need for an efficient cleanup kit to clean up damaged CFLs. The cleanup kit, according to an embodiment of the present invention, advantageously provides the tools necessary to easily capture and properly dispose of the debris that can result from damaged CFLs, without exposing the user to dangerous metal contaminants. According to a preferred embodiment of the present invention, a compact fluorescent cleanup kit is disclosed, which includes a plurality of member elements. The member elements comprise printed instructions, at least one glove, at least one mask, at least one eye protection member, at least one sealable container, at least one cleanup scoop, at least one single-sided adhesive member, and at least one towelette. The at least one glove, at least one mask, and at least one eye protection member may be donned to protect a user from exposure to metal contaminants that may be released when a compact fluorescent bulb is damaged. The at least one cleanup scoop, at least one single-sided adhesive member, and at least one towelette may be used to collect all debris from a damaged compact fluorescent bulb into the at least one sealable container.
Use of a cleanup kit, according to an embodiment of the present invention, should advantageously decrease the risk of exposure to metal contaminants, such as Mercury, contained in CFLs. Use of a cleanup kit, according to an embodiment of the present invention, for other broken light bulbs such as halogen light bulbs and incandescent light bulbs may also be advantageous and should decrease the risk of a user being injured by any broken glass.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a CFL cleanup kit according to an embodiment of the present invention.
FIG. 2 is a perspective view of the CFL cleanup kit illustrated in FIG. 1 showing the components of the CFL cleanup kit positioned within a container or packaging.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
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. Like numbers refer to like elements throughout.
The CFL cleanup kit 10 , according to an embodiment of the present invention, may illustratively include a main container 12 and a plurality of components carried therein. The plurality of components stored within a main container 12 of a CFL cleanup kit 10 may advantageously provide users with a convenient compilation of necessary supplies, to be used to clean up and properly dispose of broken CFLs. The number of CFLs in homes and businesses will greatly increase in the coming years, as CFLs will likely replace traditional light bulbs. Accordingly, it is advantageous for homeowners and businesses to have a CFL cleanup kit 10 , according to an embodiment of the present invention, readily available to assist in properly cleaning up and disposing of broken CFLs.
A CFL cleanup kit 10 may preferably include printed instructions 14 , at least one glove 16 , at least one mask 18 , at least one protective shoe-covering member 31 , at least one eye protection member 20 , at least one sealable container 22 , at least one light source 24 , at least one pipette 33 , at least one cleanup scoop 26 , at least one towelette 28 , and at least one single-sided adhesive member 30 . The main container 12 of a cleanup kit 10 may preferably be provided by a convenient quick and easy opening package, so that a user may advantageously and readily access the contents of the kit.
In a preferred embodiment, a typical cleanup kit 10 may include one set of printed instructions 14 , at least one glove 16 , which may be provided as two pairs of disposable gloves, at least one mask 18 , which may be provided as one disposable mask, at least one protective shoe-covering member 31 , which may be provided as a pair of polypropylene shoe covers, at least one eye protection member 20 , which may be provided as one pair of eye protection, i.e., safety glasses, at least one sealable container 22 , which may be provided as a biohazard bag, at least one light source 24 , which may be provided as a flashlight, at least one cleanup scoop 26 , which may be provided as two disposable cleanup scoops, at least one towelette 28 , which may be provided as one pre-moistened towelette and one dry towelette, and at least one single-sided adhesive member 30 , which may be provided as two pieces of single-sided adhesive strips.
Those skilled in the art will appreciate, after having the benefit of this disclosure, however, that any number of the components may be included within the main container 12 of a cleanup kit 10 . Further, those skilled in the art, after having the benefit of this disclosure, will appreciate that the components of a cleanup kit 10 , according to an embodiment of the present invention, may be provided in various sizes. In other words, it may be desirable for cleanup kits to be purchased and used for commercial applications as well as residential applications. Those skilled in the art will appreciate, after having the benefit of this disclosure, that commercial applications may require greater capacity than typical residential applications. Similarly, skilled artisans, after having the benefit of this disclosure, would recognize that various cleanup kits could be marketed and sold at different price points, depending on which components are provided with each. As a non-limiting example, a premium or deluxe version of a cleanup kit 10 could include more components than a basic or economy version of a cleanup kit 10 .
Those skilled in the art, after having the benefit of this disclosure, will appreciate that a cleanup kit 10 , according to an embodiment of the present invention, may also be used for cleaning up halogen-type light bulbs and incandescent light bulbs, which do not contain Mercury, as well as other products containing metal contaminants, e.g., switches, relays, thermometers, and other products that may include Mercury as understood by those skilled in the art.
The detailed instructions 14 in a cleanup kit 10 , according to an embodiment of the present invention, may be printed on card-type material, or any other type of strong material that may withstand the test of time. It may be preferred that the indicia of the printed instructions 14 is in large, bold type, but after having the benefit of this disclosure, those skilled in the art will appreciate that any type is sufficient for the printed instructions. The printed instructions 14 preferably may include the following directions:
1. In case of breakage, immediately remove all children and pets from vicinity. If you are pregnant, stay away from area and have another person do the cleanup. DO NOT walk through the area of the breakage. 2. Make sure to open all exterior windows and turn off any ventilation such as air conditioning or heat. 3. Immediately leave the room for at least 15 minutes. 4. Retrieve your emergency cleanup kit. Pull quick release tab and lay contents out on a clean surface. 5. Prior to re-entering the room, carefully put on disposable gloves, included in kit, being careful not to rip or tear any area of the glove. Place mask, included, on your face, covering your nose and mouth. Place protective shoe covers, included, over your shoes. Put on your safety eyewear, included. 6. You are now ready to approach the debris area where the breakage occurred. Pick up any Mercury beads with eyedropper and place eyedropper into the sealable biohazard bag (included) or glass jar with metal lid (not included). 7. Very carefully use the pickup cards or disposable scoops provided to gather and pick up all broken glass, powder, and other debris in the area. Place the debris into the sealable biohazard bag (included) or glass jar with metal lid (not included). 8. After the area seems to be generally clean, pat the area with the sticky side of tape provided to remove any remaining fine particles or small residue. 9. Scan the area with the flashlight, included, to look for glittering residue, broken glass, and other missed debris. 10. Now open the moist towelette to wipe the area of any residue spotted with your flashlight, and then do a final wipe of the area with a dry towelette. 11. Then VERY CAREFULLY place wipes, pickup cards/scoops, adhesive tape, and mask into the sealable bag. 12. Remove the protective shoe covers, pulling from the ankle down. They must now be inside out. Place in sealable bag. 13. Lastly, remove your disposable gloves, pulling from the wrist down. They must now be inside out. Place in sealable bag and seal. 14. Immediately place the sealable bag in an outdoor container for disposal. DO NOT place with normal household garbage. 15. Finally, BE SURE to wash your hands and face after waste has been removed from the area. 16. Continue to ventilate the area for as long as possible, and contact your local recycling center for disposal instructions, or visit www.epa.gov or www.osha.gov.
The foregoing instructions are provided merely for illustrative purposes and are not intended as a limitation on the type, number, or content of printed instructions 14 that may be included with a cleanup kit 10 , according to an embodiment of the present invention. More specifically, it would be apparent to those having skill in the art, after having the benefit of this disclosure, that additional instructions may be required where additional components are provided with a cleanup kit 10 . It would be equally apparent to those skilled artisans, who have had the benefit of this disclosure, that there may be fewer instructions, where fewer components are provided with a cleanup kit 10 . Optionally, printed instructions 14 , according to an embodiment of the present invention, may list each state's website that contains instructions for proper disposal and recycling of hazardous materials.
A cleanup kit 10 , according to an embodiment of the present invention, may also include printed instructions 14 that have been written in multiple languages, to allow for use in regions where more than a single language is prevalent amongst potential users. After having the benefit of this disclosure, it would be apparent to a person having skill in the art that printed instruction 14 may be provided on a sheet, which may be adapted to be carried by a main container 12 . It would be equally apparent to such a skilled artisan who has had the benefit of this disclosure that printed instructions 14 may also be provided on the exterior or interior surface of a main container 12 .
At least one glove 16 , according to an embodiment of the present invention, may be provided as any type of glove. For example, but not intended as a limitation, at least one glove 16 may be nitrile or latex free gloves, as understood by those skilled in the art, or any other type of glove suitable for protecting the hands of a user. At least one mask 18 , according to an embodiment of the present invention, may be provided as a surgical mask, for example, but not intended as a limitation, or any other type of mask suitable for reducing the chance of inhaling any portion of a broken CFL, as understood by those skilled in the art. At least one eye protection member 20 , according to an embodiment of the present invention, may be preferably provided by safety glasses or any similar type of eye protection suitable for protecting the eyes of a user when cleaning up a broken CFL.
At least one sealable container 22 , according to an embodiment of the present invention, may, for example, but not intended as a limitation, be provided by a sealable plastic bag, a biohazard bag, or a sealable rigid/semi-rigid container as understood by those skilled in the art. Optionally, at least one sealable container 22 may be provided by, for example, but not intended as a limitation, a laboratory bag, as understood by those having skill in the art. At least one light source 24 , according to an embodiment of the present invention, may advantageously be provided as a mini-flashlight, and preferably a mini-flashlight having an included battery.
At least one cleanup scoop 26 , according to an embodiment of the present invention, may be provided as cleanup cups, or cups having side wall and rear wall portions. Optionally, at least one cleanup scoop 26 , according to an embodiment of the present invention, may be provided by, for example, but not intended as a limitation, a pickup card or scraper, which could be used to push debris into cleanup cups. At least one cleanup scoop 26 may be intended as a single-use scoop. When provided as such, a cleanup scoop 26 should not be reused after being used to clean up a broken CFL.
At least one towelette 28 , according to an embodiment of the present invention, may be an anti-bacterial towelette, but those skilled in the art, after having the benefit of this disclosure, will appreciate that the purpose of a towelette is to clean up a broken CFL area, and accordingly may be provided by any moistened or dry cloth type of material. At least single-sided adhesive member 30 , according to an embodiment of the present invention, may be provided by high-strength tape, such as duct tape, as a non-limiting example. Those skilled in the art, after having the benefit of this disclosure, will appreciate that any single-sided adhesive may be used to accomplish the goals and features of the present invention. For convenience, a single-sided adhesive member 30 may be provided by fixing one side of a double-sided adhesive tape to a rigid surface, which has a handle grip attached to its opposite surface. As a non-limiting example, a rectangular plastic card may provide an appropriate rigid surface. Further, one having skill in the art, after having the benefit of this disclosure, would recognize that a plastic card may be manufactured, such that a point at its center is distended, forming a handle that is suitable for gripping, while still providing an adequate opposite surface for fixing one side of a double-sided adhesive tape.
At least one pipette 33 , according to an embodiment of the present invention, may be provided for capturing droplets of Mercury, which may be deposited on surfaces and pieces of debris, when a CFL has broken. It would be apparent, after having the benefit of this disclosure, to a person having skill in the art, that at least one pipette 33 may be provided as, for example, but not intended as a limitation, an eyedropper. At least one protective shoe-covering member 31 , according to an embodiment of the present invention, may be provided for preventing the spread of metal contaminants that would otherwise come into contact with the soles of a user's footwear. It would be apparent, after having the benefit of this disclosure, to a person having skill in the art, that at least one protective shoe-covering member 31 may be provided as, for example, but not intended as a limitation, a polypropylene shoe cover, which is typically used in clean room environments, as understood by those skilled in the art.
It might also be advantageous to include in a cleanup kit 10 , according to an embodiment of the present invention, a number of replacement CFLs 34 . A person having skill in the art would recognize, after having the benefit of this disclosure, that a user would be more likely to employ a replacement CFL 34 , in replacing a broken CFL, if that replacement CFL 34 was provided with a cleanup kit 10 . After having the benefit of this disclosure, it would be apparent to a skilled artisan that, where a user is more likely to employ a CFL, the potential for energy savings may be increased, as CFLs may consume as much as 75% less energy than comparable incandescent bulbs. Including replacement CFLs 34 in the cleanup kit 10 , according to an embodiment of the present invention, advantageously enhances the cleanup kit from a marketability perspective. In other words, the cleanup kit 10 , according to an embodiment of the present invention, which includes replacement CFLs therein, is advantageous to the perspective customer, as the customer need only purchase one item, instead of purchasing both a cleanup kit and a separate CFL. This also enhances use of shelf space in retail stores, thereby increasing profitability.
A cleanup kit 10 , according to an embodiment of the present invention, may preferably include a postage-paid package 32 , which has been addressed to an appropriate recycling and disposal facility. A skilled artisan would recognize, after having the benefit of this disclosure, that a sealable container 22 may be deposited into a postage-paid package 32 , after the sealable container 22 has been filled with debris from a broken CFL, and shipped to a facility that is equipped to properly dispose of or recycle spent CFLs. It would also be apparent to that skilled artisan, after having the benefit of this disclosure, that a number of shipping services provide pre-paid packages. Standard U.S. mail, FedEx, and United Parcel Service (UPS) are three non-limiting examples of such services. As another option, a shipping label may be provided in place of or in addition to a postage-paid package 32 . A skilled artisan, after having the benefit of this disclosure, would recognize that a shipping label may be adhered to a user-provided package, creating a suitable vessel for transporting a sealable container 22 , which has been filled with debris from a broken CFL, to a facility that is equipped to property dispose of or recycle spent CFLs.
Upon opening and using a cleanup kit 10 , according to an embodiment of the present invention, a user may properly dispose of all components of the cleanup kit. In other words, elements of a cleanup kit 10 , according to an embodiment of the present invention, may be single-use components. When so provided, all single-use elements of a cleanup kit 10 are intended to be disposable. Accordingly, all of the components of the cleanup kit 10 may preferably be inexpensive. The components of a cleanup kit 10 , according to an embodiment of the present invention, may also advantageously be easy to use, including easy-to-follow instructions that are provided within the main container 12 of a cleanup kit. Use of a cleanup kit 10 , according to an embodiment of the present invention, should advantageously decrease the risk of exposure to metal contaminants, such as Mercury, contained in CFLs. Use of a cleanup kit 10 , according to an embodiment of the present invention, for other broken light bulbs such as halogen light bulbs and incandescent light bulbs may also be advantageous and should decrease the risk of a user being injured by any broken glass.
Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims. | A compact fluorescent cleanup kit is disclosed, which comprises a plurality of member elements. The member elements comprise printed instructions, at least one glove, at least one mask, at least one eye protection member, at least one sealable container, at least one cleanup scoop, at least one single-sided adhesive member, and at least one towelette. The at least one glove, at least one mask, and at least one eye protection member may be donned to protect a user from exposure to metal contaminants that may be released when a compact fluorescent bulb is damaged. The at least one cleanup scoop, at least one single-sided adhesive member, and at least one towelette may be used to collect all debris from a damaged compact fluorescent bulb into the at least one sealable container. | 0 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
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CROSS REFERENCE TO RELATED APPLICATION
Background of the Invention
The present invention relates to a system for the direct sequencing of polymers such as DNA and RNA by passing the polymer through a nanoscale pore and measuring an electrical signal modulated by the polymer passing through the pore.
Genetic information may be encoded in a molecule of deoxyribonucleic acid (DNA) as a sequence of nucleotides: (guanine, adenine, thymine, and cytosine). Discovering the sequence of these nucleotides in DNA and other similar molecules is a foundational technology in biological studies.
One promising method of sequencing is “nanopore sequencing” in which a single strand of DNA, forming half of the DNA helix, is passed through a nanoscale opening in a membrane between two reservoirs. This nanopore opening may, for example, be a protein channel held in a lipid bilayer. An electrical potential applied across the reservoirs produces an ion flow between the reservoirs pulling the strand of DNA through the nanopore. As the strand passes through the nanopore, it modulates the ion current though the nanopore as a function of the size of the nucleotide instantaneously obstructing the nanopore. This fluctuation in the ion current may then be analyzed to determine the nucleotide sequence. An example system of nanopore sequencing is described in PCT patent WO2008102120 entitled: Lipid Bilayer Sensor System, hereby incorporated by reference.
The electrical signals produced by changes in ion current through a nanopore with different nucleotides are very small in amplitude and short in time span. For this reason, it can be hard to obtain reliable measurements having sufficient resolution to distinguish between different molecules in the sequence.
SUMMARY OF THE INVENTION
The present invention provides a nanopore whose dimensions may be controlled by electric signal. The ability to adjust the nanopore dimensions, in turn, allows the speed of passage of a polymer through the nanopore to be controlled. By controlling and varying the speed of passage of the polymer, the trade-off between signal quality and processing speed may be better controlled, providing, for example, longer measurement time when a nucleotide is in position within the nanopore and faster transition time between nucleotides.
The nanopore size may be controlled through the use of a piezoelectric substrate experiencing mechanical strain in the presence of a controlled electrical field. In some embodiments, shear strain is used to change a diameter of the nanopore. In some embodiments, the substrate may be operated in a resonant mode or may be controlled based on the signal from the measured polymer.
Specifically, the present invention provides an apparatus for the study of biological molecules that provides a piezoelectric substrate positionable between reservoirs of conductive fluid and presenting a nanopore opening. At least one electrode pair is provided to apply an electrical field to the piezoelectric substrate to change the dimension of the piezoelectric substrate holding the nanopore and at least one electrical sensor measuring a change in the electrical environment of the nanopore.
It is thus a feature of one embodiment of the invention to provide an electrically controllable nanoscale pore useful, for example, for biological measurements related to the passage of materials through the pore.
The piezoelectric substrate may be quartz.
It is thus a feature of at least one embodiment of the invention to provide a piezoelectric substrate material amenable to accepting small holes, for example, possible by laser ablation, and further providing good electrical and mechanical characteristics.
The nanopore may be an ion channel in a membrane suspended across an opening in the piezoelectric substrate and wherein the change in the dimension of the piezoelectric substrate changes a dimension of the membrane holding the nanopore.
It is thus a feature of at least one embodiment of the invention to permit investigations using biological nanopores.
The electrode pair may be positioned on opposite sides of the substrate outside of the reservoirs.
It is thus a feature of at least one embodiment of the invention to permit piezoelectric stimulation of the substrate while removing possibly interfering electrical voltages used for that stimulation from a measurement region around the nanopore.
The nanopore may be provided by a non-piezoelectric material coating an inner surface of an opening in the piezoelectric substrate thus reducing the diameter.
It is thus a feature of at least one embodiment of the invention to provide a nanopore mechanically and directly attached to a piezoelectric substrate eliminating the need for substantial preparation of the substrate before use.
The non-piezoelectric material may include first and second electrically independent sensing electrodes across the nanopore communicating with the electrical sensor.
It is thus a feature of at least one embodiment of the invention to closely integrate sensing electrodes for inductive, capacitive or resistive sensing into the nanopore structure.
The electrodes may provide a change in dimension of the piezoelectric substrate to change at least one diameter of the nanopore.
It is thus a feature of at least one embodiment of the invention to permit a change in nanopore diameter such as may be used to moderate the passage of molecules through the nanopore or for size/charge discrimination of poly-disperse molecules, for example in the case of exonuclease incorporation with DNA.
The electrical field may produce a shear of the substrate along a plane of the substrate.
It is thus a feature of at least one embodiment of the invention to permit nanopore diameter control using electrodes positioned laterally away from the nanopore at readily accessible upper and lower positions.
The apparatus may include multiple electrode pairs positioned on opposite sides of the nanopore providing countervailing thickness shear on opposite sides of the nanopore.
It is thus a feature of at least one embodiment of the invention to enhance the diameter control of the nanopore through the use of opposed shear modes.
The electrodes may be electrically insulated from the piezoelectric material and from the reservoirs.
It is thus a feature of at least one embodiment of the invention to reduce electrical interference between the piezoelectric control electrodes and the sensitive measurements in the region of the nanopore.
The electrical sensor may be any one or combination of a current sensor measuring ion flow through the nanopore as obstructed by the molecules in the nanopore, a capacitance sensor measuring capacitive coupling across the nanopore as changed by different molecules in the nanopore, and a current sensor measuring a resistive flow across the nanopore changed by molecules in the nanopore.
It is thus a feature of at least one embodiment of the invention to provide a versatile system that may use one or more different sensing modalities.
The invention may include an electrical controller communicating with the electrodes on the substrate to operate the electrodes to excite the substrate in a mechanical resonant mode of the substrate to provide a periodic change in nanopore dimension.
It is thus a feature of at least one embodiment of the invention to make use of the high mechanical quality factor (Q) of quartz allowing resonant mode operation.
The electrical controller may control a change in dimension of the nanopore over a time period compatible to a time between passages of different molecules through the nanopore. In one embodiment, the electrical controller may communicate with the electrodes on the substrate to increase a measurement time of each molecule and decrease a time between measurements when molecules are passing through the nanopore.
It is thus a feature of at least one embodiment of the invention to make use of control of the nanopore dimensions to change the speed of passage of a polymeric molecule to increase measurement time for each molecule element while minimizing total measurement time for the entire polymer.
These particular features 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
FIG. 1 is a simplified diagram of a nanopore sequencing apparatus providing controllable nanopore dimensions by means of a piezoelectric substrate;
FIG. 2 is a fragmentary detail of the first embodiment of the nanopore employing a protein nanopore supported by the piezoelectric substrate;
FIG. 3 is a figure similar to FIG. 2 of the second embodiment of the nanopore employing inner measurement electrodes deposited directly on a piezoelectric substrate;
FIGS. 4 a and 4 b are fragmentary cross-sectional and perspective views respectively of one method of forming measurement electrodes on an opening in a piezoelectric substrate;
FIG. 5 is a simplified block diagram showing control of the nanopore opening as a function of electrical measurements of nucleotides passing through the nanopore to synchronize the two;
FIG. 6 is a fragmentary block diagram of a second embodiment controlling the nanopore opening as a function of electrical measurement of the nucleotides passing through the nanopore to equalize a sensed electrical signal; and
FIG. 7 is a flowchart of a third embodiment of controlling the nanopore opening according to satisfactory completion of the nucleotide measurement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1 , an apparatus 10 for characterizing molecules passing through a nanopore may comprise a generally planar piezoelectric substrate 12 extending along a plane 15 and having an opening 14 passing through the substrate 12 generally perpendicular to the plane 15 . A first and second reservoir 16 a and 16 b may be constructed on either side of the substrate 12 about the opening 14 using upwardly extending and downwardly extending walls so that the reservoirs walls 18 encircle the opening 14 on both sides of the substrate 12 . These reservoirs 16 a and 16 b may be filled with a conductive fluid 20 such as a buffer solution, for example, as held by capillary attraction. Reservoir 16 a may have an introduced source of polymer strands 22 (for example, single DNA strands or double strand DNA helices and the necessary proteins and enzymes to separate the helix into strands) suspended therein.
Each of the reservoirs 16 a and 16 b may provide electrodes 23 communicating with a voltage source 24 together to provide an electrical voltage across the opening 14 tending to produce an ionic flow from reservoir 16 a to reservoir 16 b . This flow may draw the polymer strands 22 along with it causing individual polymer strands 22 to thread through the opening 14 . As monomer units 26 of the polymer strand 22 pass through the opening 14 , they may modulate the ionic current through the opening 14 (by blocking ion flow) causing a change in current that may be measured by a sensitive ion current sensor circuit 28 . In one embodiment, the ion current sensor circuit 28 may be, for example, a patch clamp amplifier such as the HEKA EPC 10 Signal, commercially available from HEKA Elektronik of GmbH Lambrecht, Germany.
As will be discussed below, other methods of measuring the interaction between the monomer units 26 and the opening 14 may also be used to produce what will be generally termed a modulation signal representing a sensing of the monomer units 26 . Each type of monomer unit 26 , for example guanine, adenine, thymine, and cytosine in the case of DNA, produces a modulation signal represented as different characteristic current flows which may be analyzed as a time sequence 30 to deduce the sequencing of monomer units 26 in the polymer strand 22 .
In the present invention, the substrate 12 may be a single layer of piezoelectric material, for example a quartz material having a thickness of approximately 184 micrometers. The quartz material of substrate 12 may be, in one example, a single AT cut crystal having a resonant frequency of 10 megahertz providing a monolithic and substantially homogenous piezoelectric substrate. Alternatively the substrate 12 may be a laminate of different materials, for example, a silicon layer bonded to a quartz substrate, the latter as described above, using the techniques discussed in ‘Bonding Silicon-On-Insulator to Glass Wafers for Integrated Bio-Electronic Circuits’, H. S. Kim, R. H. Blick, D. M. Kim, C. B. Eom, Applied Physics Letters 85, 2370 (2004).
The opening 14 may be formed by a laser ablation system, for example, of the type described in U.S. patent application Ser. No. 12/614,237 filed Nov. 6, 2009, assigned to the same assignee as the present invention and hereby incorporated by reference in its entirety. Using this technique, an ultraviolet absorbent liquid is confined to the back side of a quartz substrate to absorb energy when pulsed by an excimer laser passing through the substrate. This increasing energy is accompanied by a jump in temperature and pressure at the liquid/substrate interface inducing pore formation through the quartz substrate. A region around the pore becomes de-crystallized and non-piezoelectric but nevertheless the bulk piezoelectric properties of the substrate generally are preserved. This technique may provide for an opening with a diameter as small as 200 nm, while resulting in an end-of-procedure surface roughness of merely tens of nanometers as measured from the respective surface(s) of the substrate 12 such as may provide a gigaohm seal against the cellular membrane. Such hole formation is a result of a simple manufacturing process. Multiple openings 14 and reservoir walls 18 may be placed on a single substrate 12 .
Outside of the reservoir walls 18 , electrode pairs 32 a and 32 b may be applied adjacent to the upper and lower surfaces of opposite sides of the substrate 12 about an opening 14 but insulated from the substrate by insulation layers 34 . The inventors have determined that displacing the electrode pairs 32 from the opening 14 reduces interference between electrical power applied to the electrode pairs 32 and the measurement of ion current sensor circuit 28 to an acceptable amount consistent with electrical measurements of the modulating effects of the polymer strand 22 . The insulation layers 34 may, for example, be provided by a portion of a block of polydimethylsiloxane (PDMS) into which the electrode pairs 32 are embedded.
Each of the electrode pairs 32 a and 32 b may be generally excited by separate waveform generators 38 a and 38 b each providing an electrical field that may reach in amplitude of, for example, 5.2×10 6 V/m. The signals produced by the waveform generators 38 a and 38 b (or the polarity of the electrode pairs 32 a and 32 b ) may have a phase difference of 180 degrees so as to provide electrical fields that cause a countervailing or opposing shearing distortion of the substrate 12 along plane 15 on opposite sides of the opening 14 . This countervailing distortion serves to increase change in a diameter of the opening 14 as a function of the electrical field applied and is shown schematically by means of dotted lines about opening 14 . As shown, application of the electrical field reduces the diameter of the opening 14 ; however, it will be appreciated that the reduction in diameter may occur during a relaxation state when no field is provided. It will be appreciated that other modes of piezoelectric distortion may also be used including face shear, extensional, or longitudinal modes. In particular, it should be noted that the waveform generators 38 a and 38 b may also operate in a DC mode to statically control the shape and size of the opening 14 and that any AC signal may have a DC offset also allowing static displacement control of the substrate on the sub Angstrom scale.
This change in the size of the opening 14 can be used to moderate the movement of the polymer strand 22 through the opening 14 thereby improving measurement of the monomer units 26 . This improvement may be had by delaying passage of the polymer strand 22 when the monomer units 26 are centered in the opening 14 (thereby allowing a longer measurement time and lower signal-to-noise ratio) or may be used in other ways, for example, to control the size of the opening 14 to comport with the size of the monomer unit 26 to enhance sensitivity and linearity of the measurement, or to phase adjust a resonance of the substrate 12 quasi-statically to simply provide fine tuning of a desired flow rate. These techniques will be described further below.
Generally, the electrical signals produced by each of the waveform generators 38 a and 38 b may be controlled in strength, periodicity, and wave shape by an electric controller such as a computer 40 . The electrical signals provided by the waveform generators 38 may be sinusoidal or square wave or other wave shapes controlled in phase, frequency, and power by the computer 40 . The computer may further communicate with the electrodes 23 or other sensors associated with the opening 14 , for example allowing it to monitor current flow through the opening 14 , allowing for a “trigger” to hold the molecule within the opening 14 once it is captured within the opening 14 as will be described below. The computer 40 may execute a stored program 42 held in a non-transitory state in a computer memory as may be executed by electronic processor 45 . The computer 40 may provide for standard input devices including a keyboard and the like (not shown) and standard output devices including a graphics display 47 which may provide a graphic depiction of the time sequence 30 , for example.
Referring now to FIG. 2 , in one embodiment, the opening 14 in the substrate 12 may support a protein nanopore 44 , the latter held in a lipid bilayer 46 such as a cellular membrane whose periphery is supported by a polymer reservoir 48 adhered to a rim of the opening 14 . In this way, the size of the opening 14 may be readily reduced from a larger size generated using laser ablation techniques as described above. Nevertheless, a change in diameter of the opening 14 , indicated by dotted lines, provides forces through the polymer reservoir 48 and lipid bilayer 46 received by the protein nanopore 44 to control the inner dimension of the nanopore 44 .
Methods of fabricating and assembling of the protein nanopore 44 , lipid bilayer 46 , and polymer reservoir 48 are described generally in U.S. Pat. No. 8,137,569 and WO/2009077734 hereby incorporated by reference. In this embodiment, opening in the polymer reservoir 48 may be, for example, in the range of one micrometer to 50 micrometers while the opening of the protein nanopore 44 may be on the order of one to 100 nanometers for Alamethicin, however typical nanopore diameters range from a few nanometers to fractions of nanometers, i.e., a few Angstroms. An example protein nanopore 44 may be an Alamethicin ion channel produced by conventional technique as described in the article: Mechanical Actuation of Ion Channels Using a Piezoelectric Planar Patch Clamp System by Eric Stava et al, Lab Chip, 2012, 12, 80 also hereby incorporated by reference. This article also describes an alternative technique suitable for this invention, in which the substrate 12 may be treated to make it hydrophilic and the lipid bilayer 46 attached directly thereto.
Referring now to FIG. 3 , in an alternative embodiment, opening 14 may be narrowed to a nanoscale dimension by the growth of inwardly extending constrictor elements 50 within the opening 14 . Referring momentarily to FIGS. 4 a and 4 b , the constrictor elements 50 may be, for example, deposited by a sputtering or vacuum evaporation process in which a sputtering material 52 such as gold is applied obliquely to the opening 14 to preferentially coat an inner surface of the opening 14 in a radially non-symmetrical way. The substrate 12 may then be rotated by 180 degrees about an axis of the opening 14 and this process repeated to produce two opposed noncontacting and electrically isolated C-shaped constrictor elements 50 together reducing an effective diameter of the opening 14 . Desirably, each constrictor element 50 on a given side of the opening 14 may be in electrical communication with a metallic trace 54 on that side of the opening 14 . The metallic trace 54 may be insulated from the piezoelectric substrate 12 by a thin insulation layer 55 if desired.
The constrictor elements 50 and traces 54 may be covered with a nonreactive coating 56 for example a thin film of polydimethylsiloxane (PDMS) or parylene (poly(p-xylylene) polymers, further reducing the effective diameter of the opening 14 but preserving a close proximity between the conductive constrictor elements 50 and the strand 22 passing through the opening 14 .
This structure of FIG. 3 may be used with the circuitry shown in FIG. 1 to characterize a polymer strand 22 passing through the opening 14 by monitoring ion flow 17 . Alternatively or in addition, measurements may be made between traces 54 on opposite sides of opening 14 of capacitive coupling between the constrictor elements 50 and the polymer strand 22 within the opening 14 to provide an alternative method of characterizing the monomer units 26 using a sensitive capacitance measurement circuit 58 . This capacitance measurement measures the capacitance between the constrictor elements 50 as modulated by dielectric or conductive properties of the monomer units 26 . Alternatively, the capacitance measurement circuit 58 may be replaced or used in addition with a resistance measuring circuit 60 measuring changes in resistance between constrictor elements 50 caused by the interposition of monomer units 26 and relative changes in conduction through the monomer units 26 as opposed to the conductive fluid 20 . The measurements provided by each or any of these circuits of the ion current sensor circuit 28 , capacitance measurement circuit 58 and resistance measuring circuit 60 may be provided to the computer 40 and used individually or combined for improved signal-to-noise ratio.
Referring now to FIG. 5 , a measurement signal 62 may be derived using any individual or combination of the techniques associated with ion current sensor circuit 28 , capacitance measurement circuit 58 , or resistance measuring circuit 60 and possibly including other sensor techniques such as optical sensing. This measurement signal 62 may then be analyzed to produce a time sequence 30 described above with respect to FIG. 1 from which a nucleotide sequence may be calculated.
Alternatively or in addition, the measurement signal 62 may be used to control the waveform generators 38 during the movement of the polymer strand 22 through the opening 14 .
In one embodiment, the waveform generators 38 may be operated to provide a resonant or periodic excitation to the substrate 12 in which the opening 14 rapidly changes diameter as the polymer strand 22 passes therethrough. This resonant operation may match a natural resonant frequency of the substrate 12 to provide increased diameter variation in the opening 14 . Efficient resonant excitation with varying amplitude may also be used with this approach and is facilitated by the single crystal structure of the substrate 12 which gives it a high Q value.
In a more general case, quasi-static or periodic changing of the diameter of the opening 14 may be produced by adjusting a frequency and/or duty cycle of the periodic excitation from the waveform generators 38 , and may be used to accurately control the speed of passage of the strand 22 independently or in addition to control of the voltage across the electrodes 23 (shown in FIG. 1 ).
In one mode of operation, the resonant or non-resonant frequency or amplitude of the output of the waveform generators 38 may be altered to control the dimension of the opening 14 to provide a “ratchet” like action allowing a single monomer unit 26 to pass through the opening 14 in a regular cycle, the opening 14 contracting more closely (on average) about the monomer unit 26 during measurement to prolong the dwell time of the monomer unit 26 within the opening 14 so that ionic current, capacitance or resistance may be stably acquired, and then expanding (on average) about the monomer unit 26 to allow rapid movement to the next monomer unit 26 promoting faster overall processing speed.
For this purpose, a frequency 64 of fluctuations of the time sequence 30 contained in the measurement signal 62 such as indicates a passage of the monomer unit 26 through the opening 14 , may be extracted and provided to a phase comparator 66 also receiving output of the waveform generators 38 . The phase comparator 66 may output a generator control signal 68 having a phase lock (possibly with different phase offsets) to the time sequence 30 thereby synchronizing opening and closing of the opening 14 with the alignment of monomer units 26 within that opening.
It is contemplated that the present invention in some embodiments may provide for other control techniques that link control of the dimensions of the opening 14 to the measurement signal 62 of the strand 22 . For example, as shown in FIG. 6 , the static or average diameter of the opening 14 may be controlled by the measurement signal 62 according to a function provided by function block 70 , for example a comparator comparing the measurement signal 62 to a reference 72 . In this way, for example, the opening 14 may be adjusted according to a size or electrical conductivity of the monomer unit 26 within the opening 14 to provide increased sensitivity or linearization of the measurement such as may be obtained by preserving a more uniform gap between walls of the opening 14 and the monomer units 26 .
More generally, and as indicated by FIG. 7 , the computer 40 may execute a program providing for a narrowing of the opening 14 as indicated by process block 74 during a measurement until such time that the measurement is complete. Thus, as indicated by decision block 76 , when sufficient time has elapsed to obtain a sufficiently low noise measurement of a monomer unit 26 within the opening 14 , the program may proceed to process block 78 and the opening 14 widened until a new monomer unit 26 has aligned with the opening, as indicated by decision block 80 detecting an abrupt transition in the time sequence 30 .
Certain terminology is used herein for purposes of reference only, and thus is not intended to be limiting. For example, terms such as “upper”, “lower”, “above”, and “below” refer to directions in the drawings to which reference is made. Terms such as “front”, “back”, “rear”, “bottom” and “side”, describe the orientation of portions of the component within a consistent but arbitrary frame of reference which is made clear by reference to the text and the associated drawings describing the component under discussion. Such terminology may include the words specifically mentioned above, derivatives thereof, and words of similar import. Similarly, the terms “first”, “second” and other such numerical terms referring to structures do not imply a sequence or order unless clearly indicated by the context.
When introducing elements or features of the present disclosure and the exemplary embodiments, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of such elements or features. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements or features other than those specifically noted. It is further to be understood that the method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
References to a “processor” or “processor unit” should generally be understood to refer broadly to general-purpose computer processing elements for executing stored programs (software) comprised of sequences of arithmetic and logical operations stored in the general-purpose memory. The term “circuit” as used herein should be considered to broadly include both analog and digital circuitry together with associated firmware. The term “program” generally refers to a sequence of operations executed by a processor or circuit. References to memory, unless otherwise specified, can combinations of different memory structures including solid-state and electromechanical memories and may describe a distributed system of main memory and multiple cache layers. The term page table should be understood generally relate to a table mapping predefined address blocks of memory between a virtual address space and a physical address space regardless of the exact size of those blocks or the particular name given to the blocks. In all these cases, the guest operating system or hypervisor establish or install the bypass mapping values and the actual bypass is handled by the processing circuitry.
It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein and the claims should be understood to 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. All of the publications described herein, including patents and non-patent publications, are hereby incorporated herein by reference in their entireties. | A piezoelectric substrate having a nanopore opening that separates two reservoirs of conductive fluid may provide for sensitive biological measurements by allowing control of the size of the nanopore according to piezoelectric stimulation of the substrate. Multiple embodiments are provided of monolithic piezoelectric substrates and nanopores for this purpose as well as a control system for controlling the nanopore dimensions electrically using AC or DC waveforms. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of Application PCT/JP02/10439 filed Oct. 7, 2002, which was published in Japanese under PCT Article 21(2).
[0002] This application is based on Japanese Patent Applications No. 2001 - 313547 filed Oct. 11 , 2001 , and No. 2002 - 203031 filed Jul. 11 , 2002 , the contents of which are incorporated hereinto by reference.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to techniques for determining the constitution of a human being.
[0005] 2. Description of Related Art
[0006] It has been widely said that there is a constitution for a human being. Originally, each one of individual human beings retains his or her constitution inherent to himself or herself, and therefore, more precisely, a plurality of human beings cannot share the same constitution. However, several existing theories that have been proposed allow classification of the constitutions of all human beings into a limited number of types.
[0007] Recently, there has been indicated the strong relationship between foods that human beings eat and illness that human beings face. Described particularly, by way of example, the national report presented by the Government of the United States of America in 1970s, called “McGovern's Report,” addressed that the diseases which form six major causes of death such as cancer are recognized as “food-caused diseases,” meaning that all diseases are by root caused by foods.
[0008] Additionally, as an example, in 1992, in collaboration with the Ministry of Health, Labor, and Welfare in the United States of America, the United States Department of Agriculture categorized the proper foods that human beings should eat into five groups, for the purpose of presenting the dietary and lifestyle guidelines toward the twenty-first century, resulting in the creation of the food pyramid indicating the quantities of the proper foods that human beings should eat, for each one of the above groups. The guidelines pointed out that a food is capable of functioning as a factor for causing diseases, and also as a factor for preventing diseases.
[0009] Although the prevention of a disease therefore requires human beings to eat the foods suitable for the purpose, it has been already pointed out, in addition to the above, that an issue of whether or not a food is suitable for each individual's eating depends on his or her constitution.
[0010] Thus, it has been said that it is important for each individual to learn his or her constitution, from the perspective of practicing a proper diet and lifestyle and preventing diseases, and that it is also important from the perspective of mentally and spiritually normalizing each individual.
[0011] Furthermore, it is also important for each individual to learn his or her constitution, from the perspective of quick recovery, maintenance, improvement, etc., of each individual's health, for example.
[0012] It is possible to basically classify the constitutions of human beings into three types. This will be described in more detail below.
[0013] In general, when a substance is heated to incandescence or to vaporization (or plasma), the substance emits light. The wavelength of the emitted light varies according to the kinds of elements constituting the substance. As one example of the approach to perform the qualitative and quantitative analysis of an element by taking advantage of the above-described property, there is known the spectroscopic analysis employing the spectrum of an element to be analyzed. In this spectroscopic analysis, the wavelength of light emitted from an element to be analyzed reflects the nature of the element.
[0014] An element can be categorized depending upon the magnitude of a centripetal force of a proton, i.e., a force permitting a proton to attract an electron in the element. That is, an element can be categorized into one having a strong centripetal property (i.e., a property to move toward the center) due to a large centripetal force of the proton; and one having a strong centrifugal property (i.e., a property to move away from the center) due to a large centrifugal force of the proton.
[0015] After an extremely high thermal energy is added to an element, when the amount and the strength of the thermal energy each exceed a threshold level, the thermal energy is converted into light energy, resulting in the emission of a photon from the element. The photon travels at a high speed in space in a spiral rotary motion. When the movement of the photon is observed perpendicular to the traveling direction of the photon, the track along which the photon moves forms a wave. The length of the repetition unit of the wave is referred to as wavelength.
[0016] On the other hand, in the case of a small centripetal force of a proton in an element, the orbit along which an electron revolves in the element is large in diameter, and also the revolution speed is high.
[0017] At the emission of a photon from one element, a high revolution speed of its electron is accompanied by a high revolution speed of the photon. Due to the speed of light being constant, a high revolution speed of the photon is accompanied by both a large number of revolutions thereof, and a high density of the wave thereof. The high density is accompanied by both a large number of the repetition units of the wave of the photon, and a short wavelength thereof. The shorter the wavelength is, the higher the frequency of the wave is, and therefore, the amount of vibration energy of the photon is larger, resulting in a large force of the photon acting on other substances.
[0018] Therefore, in general, the stronger the centrifugal property of a proton is, the higher the revolution speed of an electron is, and the larger the acting force of the photon is.
[0019] Now, while an element which is shorter in the wavelength of light emitted from the element, and which is stronger in the centrifugal property is referred to as “yin-natured element,” an element which is longer in the wavelength of light emitted from the element, and which is stronger in the centripetal property is referred to as “yang-natured element.”
[0020] An element emitting light whose wavelength ranges from 3, 500 to 5,000 angstrom, i.e., an element whose wavelength is shorter, is classified as the above yin-natured element with its strong centrifugal property. The examples are such as potassium, oxygen, phosphorus, nitrogen, sulfur, calcium, etc. Alternatively, an element emitting light whose wavelength ranges from 5,000 to 8,000 angstrom, i.e., an element whose wavelength is longer, is classified as the above yang-natured element with its strong centripetal property. The examples are such as sodium, hydrogen, carbon, magnesium, etc.
[0021] It is added that the values of the above-mentioned wavelengths have been deprived from data disclosed in the atlas appearing typical photographs of spectrum, titled “ATLAS TIPISCHEN SPECTREN,” co-authorized by Dr. J. M. Adair and Prof. Y. E. Valenta; and the literature titled “Table of Spectrum,” authorized by Keisel. These values are addressed in the literature titled “MUSOGENRI•EKI (MONISM•DIVINATION),” authored by SAKURAZAWA Yukikazu, published by Japan CI Association.
[0022] As widely known, fundamental elements constituting a human body begin with oxygen, carbon, hydrogen, nitrogen, calcium, phosphorus, sulfur, potassium, sodium, chlorine, magnesium, etc., eventually consisting of approximately fifty kinds of elements. As described above, each element retains, with regard to its proton, both the centripetal property, i.e., yang-nature, and the centrifugal property, i.e., yin-nature, which are considered as two properties (or tendencies) contrary to each other. However, each element is biased toward either of the yang- or the yin-nature. Accordingly, it follows that each element apparently represents the more dominant of the yang- and the yin-nature. That is, the nature of each element depends on the difference in strength between the yang- and the yin-nature included in the each element.
[0023] A human body is constructed by combining an immense number of elements and by highly organizing them. Accordingly, both whether the whole of the elements constituting a human body is biased to either the yin- or the yang-nature, and how strong the bias is determine the nature of the entire of the above organization, namely, the constitution which the human being bears.
[0024] As will be readily understood from the above that, eventually, the constitution of a human being can be basically classified into the yin- and the yang-nature, and a medium-nature meaning the intermediate nature between the yin- and the yang-nature.
[0025] The major roles which the blood of a human being plays include: the conveyance of necessary substances into various pieces of the tissue of the human body; and the conveyance of waste substances into the excretion organ of the human body. The major roles further include: the removal of substances harmful to the human body, germ, etc.; the protection of the mode of life of the human body; the maintenance of the homeostasis of the inside environment of the human body; an even maintenance of the body temperature over the entire human body; and so on.
[0026] The blood consists of a liquid component, i.e., blood plasma; and a cell component floating in the blood plasma. The blood plasma occupies approximately 55 percent of the total blood, which is made up of water, protein, blood sugar, lipid, inorganic salt and the like, nitrogen combination, and so on. Alternatively, the above cell component occupies approximately 45 percent of the total blood, which is made up of the red blood cell, the white blood cell, the blood platelet, and so on.
[0027] The red blood cell is formed as a flat blood cell with a diameter of approximately 8 μm. The major component of the red blood cell is the hemoglobin contributing to the conveyance of oxygen and carbon dioxide, and to the maintenance of the acid-base equilibrium. The red blood cell contains various kinds of the blood group substances, thereby determining the blood group or blood type of each human being.
[0028] There is known the term “blood image or blood picture.” This term, meaning the nature and condition of the cell component of the blood, is used when collectively indicating: the number, shapes, and sizes of the red blood cells; the number of the white blood cells; the abundance ratio per kind; whether or not a morphological abnormality is present; etc. It has been said that the above blood image is useful in performing diagnosis of a human being, because of the nature of the blood image that it changes depending upon the kind of sickness that a human being suffers.
[0029] The technique for automatically analyzing the shape of a red blood cell using the image or picture of the red blood cell has been already proposed. One conventional approach of the technique is described in Japanese Publication No. Hei 8-304390.
[0030] According to the above conventional approach, the image of a plurality of red blood cells distributed two-dimensionally is picked up as a still image or picture. The digital data of the picked-up image undergoes a Fourier transform, thereby to calculate a Fourier spectrum. Based on the calculated Fourier spectrum, parameters relating to the number and/or the shapes of the red blood cells are analyzed.
[0031] In the above-mentioned Japanese Publication, the “parameter relating to the number of red blood cells” is, for example, the density of red blood cells, and the “parameter relating to the shapes of red blood cells” is, for example, a mean corpuscular diameter (MCD), a mean corpuscular volume (MCV), or the like.
[0032] Japanese Publication No. Hei 10-48120 discloses one conventional technique for correctly distinguishing red blood cells and white blood cells from each other based on a picked-up image of the red and the white blood cells in urine. This conventional technique utilizes, for each image picked up of a particle, both a parameter R representing the ratio of the concentration of the center part of the particle to the concentration of the peripheral part of the particle, and a parameter S representing the dispersion of the concentration between light and shade inside of the particle.
BRIEF SUMMARY OF THE INVENTION
[0033] The present inventors have conducted a study on techniques for determining the constitution of a human being using the nature and condition of red blood cells in the blood of the human being. As a result, the present inventors have obtained the finding that the classification of red blood cells is correlated with the classification of constitutions. The experimental data demonstrating the results of the above study will be described in more detail later.
[0034] Further, the present inventors have also obtained the finding that it is important to pay attention to both the size, i.e., the diameter of a red blood cell, and the thickness of a cell membrane of the red blood cell, in order to properly classify the red blood cell for determining the constitution of a human being.
[0035] In contrast with the above findings, none of the aforementioned two Japanese Publications teaches utilizing the classification results of red blood cells for determination of the constitution of a human being. Further, none of the two Japanese Publications teaches that it is important to pay attention to both the diameter of a red blood cell and the thickness of a cell membrane of the red blood cell in order to properly classify the red blood cell for determination of the constitution of a human being.
[0036] Based on the above-mentioned findings obtained by the present inventors, the present invention has been made to achieve an object of properly classifying a red blood cell for determination of the constitution of a human being.
[0037] The following modes are provided according to the present invention. These modes will be stated below such that these modes are sectioned and numbered, and such that these modes refer to the number(s) of other mode(s), where appropriate. This is for a better understanding of some of a plurality of technical features and a plurality of combinations thereof disclosed in this description, and does not mean that the scope of these features and combinations is interpreted to be limited to the scope of the following modes:
[0038] (1) An apparatus for determining a constitution of a human being, comprising:
[0039] a feature extraction means for extracting an outer diameter of a ring-shaped figure corresponding to a diameter of the red blood cell, and a width of the ring-shaped figure corresponding to a thickness of a cell membrane of the red blood cell, as features of a red blood cell in blood of the human being, on the basis of red-blood-cell image data representing a two-dimensional image of the red blood cell which is flat-shaped on a plane and which is enclosed by the cell membrane having the thickness, wherein the red-blood-cell image data is produced for allowing a portion of a cross section of the red blood cell to be obtained by cutting the red blood cell in a direction of the plane, to be visualized as the ring-shaped figure, wherein the portion corresponds to the cell membrane;
[0040] a red-blood-cell classification means for classifying the red blood cell as one of a predetermined plurality of types of red blood cells, on the basis of the extracted features, wherein the plurality of types includes an expansion type where a red blood cell exhibits an expansion tendency, a contraction type where a red blood cell exhibits a contraction tendency, and a medium type which is intermediate between the expansion and the contraction type, as three basic types of red blood cells; and
[0041] a constitution determination means for determining the constitution of the human being as one of a predetermined plurality of types of constitutions of human beings, on the basis of one of the plurality of types of red blood cells as which the red blood cell has been classified.
[0042] FIGS. 16 to 27 show respective images of red blood cells in blood samples collected from the bodies of a plurality of human beings, in the form of a micrograph taken, upon observation, under a phase-contrast microscope.
[0043] These micrographs have been taken by observing the red blood cells in dark field. The dark field observation is performed under the condition where, other than an illuminating light from a light source of the microscope, a scattered light from the red blood cells, i.e., the samples, enters the object lens of the microscope. As a result, a red blood cell is photographed such that, while a cell membrane portion of the red blood cell (a solid portion) is lightened up in the dark background, an inner portion of the red blood cell (a liquid portion, i.e., blood plasma) is darkened. Each micrograph has been obtained by photographing each real red-blood-cell at a magnification of approximately ×10,000.
[0044] The above dark field observation enables a technique of sharply photographing an outer and an inner circumferential plane of a cell membrane within a cross section of a red blood cell obtained by conceptually cutting the red blood cell parallel to a direction in which the red blood cell is flat-shaped, resulting in improvement of a technical easiness in precisely measuring of a thickness of the cell membrane.
[0045] [0045]FIGS. 16, 20, and 24 show the respective micrographs that were taken of the respective blood samples, immediately after being collected from the bodies of respective human beings, while FIGS. 17, 18, 19 , 21 , 23 , 25 , and 27 show the respective micrographs that were taken of the respective blood samples after being cultured under a predetermined condition. Apparently from these micrographs, red blood cells have a plurality of types in size and shape.
[0046] It is added that the micrographs of the red blood cells taken immediately after collection of the blood samples were taken under the following conditions:
[0047] Immediately after the blood (i.e., the whole blood) has been collected as a sample from the fingertip of the subject human being, the collected blood is put on a slide glass as expeditiously as possible, and subsequently, the collected blood is covered with a cover glass. Besides that, the periphery of the cover glass is sealed with oil for a microscope to perform an oil immersion, whereby the above micrographs were taken under the anaerobic condition where the collected blood is isolated from oxygen.
[0048] For culturing the red blood cells, the thus prepared blood samples are stored within an incubator (a device to culture) at a temperature of 38 degrees centigrade. The blood samples are stored within the incubator for a predetermined period of time (e.g., three days, several days, one week, two weeks).
[0049] A red blood cell can be generally classified depending upon its size and shape, into the following three basic types:
[0050] an expansion type where a red blood cell exhibits an expansion tendency (the blood cell is larger in diameter, and its cell membrane is thinner);
[0051] a contraction type where a red blood cell exhibits a contraction tendency (the blood cell is smaller in diameter, and its cell membrane is thicker); and
[0052] a medium type situated between the above two types.
[0053] When FIGS. 16, 20, and 24 showing the respective micrographs taken immediately after collection of red blood samples are attempted to be classified as one of the expansion, the contraction, and the medium type according to the above-mentioned classification rule, the micrographs of FIGS. 16, 20, and 24 are classified as the expansion, the medium, and the contraction type, respectively.
[0054] Thus, it is observed that the nature and condition of the red blood cell immediately after collected from a human body would allow classification of the red blood cell as one of three basic types consisting of the expansion, the contraction, and the medium type. In addition, it is also observed that the nature and condition of the red blood cell whose property has been enhanced by culturing the collected red blood cell would allow classification of the red blood cell as a type other than the three basic types. This will be described in greater detail below.
[0055] In the case of a red blood cell which has been determined to be the expansion type in view of a micrograph of the red blood cell taken immediately after collected from a human body, as shown in FIG. 16, there may arise, after culturing the collected blood cell: the instance where the red blood cell shows a strong-expansion tendency, as shown in FIG. 17; the instance where the red blood cell shows a normal-expansion tendency, as shown in FIG. 18; and the instance where the red blood cell shows not only an expansion tendency but also a contraction tendency, as shown in FIG. 19.
[0056] The finding that the red blood cell shows a strong-expansion tendency in FIG. 17 has been derived from the fact that it is observed from FIG. 17 that the red blood cell has been expanded, resulting in a large number of red blood cells with thinner cell membranes during the course of the hemolysis. Moreover, the finding that the red blood cell shows a normal-expansion tendency in FIG. 18 has been derived from the fact that it is observed that, unlike in FIG. 17, there are few red blood cells during the course of the hemolysis. Furthermore, the finding that the red blood cell shows not only an expansion tendency but also a contraction tendency in FIG. 19 has been derived from the fact that it is observed that the red blood cell has a large number of dents on its cell membrane, demonstrating the presence of a contraction tendency of the red blood cells.
[0057] In addition, as shown in FIG. 20, in the case of a red blood cell which has been determined to be the medium-type in view of the micrograph of the red blood cell taken just after collected from a human body, there may arise, after culturing the red blood cell: the instance where the red blood cell shows not only a medium tendency but also an expansion tendency, as shown in FIG. 21; the instance where the red blood cell shows a normal-medium tendency, as shown in FIG. 22; and the instance where the red blood cell shows not only a medium tendency but also a contraction tendency, as shown in FIG. 23.
[0058] The finding that the red blood cell shows not only a medium tendency but also an expansion tendency in FIG. 21 has been derived from the fact that it is observed from FIG. 21 that the red blood cell has been dilated, demonstrating the presence of a expansion tendency of the red blood cell. Moreover, the finding that it is observed that the red blood cell normally shows a normal-medium tendency in FIG. 22 has been derived from the fact that, unlike in FIG. 21, there are red blood cells having neither an expansion tendency nor a contraction tendency. Furthermore, the finding that the red blood cell shows not only a medium tendency but also a contraction tendency in FIG. 23 has been derived from the fact that it is observed that the red blood cell has a large number of dents on its cell membrane, demonstrating the presence of a contraction tendency of the red blood cell.
[0059] In addition, as shown in FIG. 24, in the case of a red blood cell which has been determined to be the contraction type in view of the micrograph of the red blood cell taken immediately after collected from a human body, there may arise, after culturing the red blood cell: the instance where the red blood cell shows a strong-contraction tendency, as shown in FIG. 25; the instance where the red blood cell shows a normal-contraction tendency, as shown in FIG. 26; and the instance where the red blood cell shows not only a contraction tendency but also an expansion tendency, as shown in FIG. 27.
[0060] The finding that the red blood cell shows a strong-contraction tendency in FIG. 25 has been derived from the fact that it is observed from FIG. 25 that, as a result of the red blood cell having a strong-contraction tendency and its cell membrane being thicker, there are a large number of red blood cells whose cell membranes have been reduced in transparency. Moreover, the finding that the red blood cell shows a normal-contraction tendency in FIG. 26 has been derived from the fact that it is observed that there are few red blood cells each having a strong-contraction tendency. Furthermore, the finding that the red blood cell shows not only a contraction tendency but also an expansion tendency in FIG. 27 has been derived from the fact that it is observed that, due to the occurrence of an expansion tendency of the red blood cell, the diameter of the red blood cell has been increased.
[0061] As will be apparent from the foregoing explanation, the consideration of the nature and condition of a cultured red blood cell reveals that the types of red blood cells include three basic types: a normal-expansion type, a normal-medium type, and a normal-contraction type; and a plurality of combination types obtained by combining some of these basic types.
[0062] The present inventors conducted experiments of 23 subject human-beings, including an experiment of determining the constitution of each subject human-being according to the theory for determining constitution described in the section of “Background Art,” and an experiment of determining (classifying) red blood cells in view of the findings of the present inventors described above by reference to the above-mentioned micrographs.
[0063] The more the constitution of a human being shows yin-nature, the more strongly the cells and the tissues of the human being show a centrifugal property expressed as expansibility in a cell named red blood cell. To the contrary, the more the constitution of a human being shows yang-nature, the more strongly the cells and the tissues of the human being show a centripetal property expressed as contractibility in a cell named red blood cell.
[0064] Then, there will be explained below the matching between the determination results of red blood cells and the determination results of constitutions for the 23 subject human-beings (the identification numbers “1” through “23” have been assigned to, respectively). In the explanation, for the simplicity of the matching, it will be presupposed that, in view of the fact that an expansion, a contraction, and a medium type of a red blood cell correspond to yin-, yang-, and medium-nature of a constitution, respectively, an expansion, a contraction, and a medium type of a red blood cell are to be classified as yin-, yang-, and medium-nature of the red blood cell, for convenience's sake.
[0065] While the determinations of constitutions of human beings were made in accordance with three separate kinds of rules, the determinations of red blood cell were made in accordance with a common rule. FIGS. 28 through 30 show three kinds of determination results of constitutions in a table in association with the determination results of red blood cells, respectively.
[0066] The determination results of constitutions shown in FIG. 28 were obtained under both the condition where the more the constitution is yin-natured, the more the elements with centrifugal properties exist within the human body, and therefore, the physical constitution (i.e., physique) of a human body bears expansibility, and the condition where, conversely, the more the constitution is yang-natured, the more the elements with centripetal properties exist within the human body, and therefore, the physical constitution of a human being has expandability.
[0067] Under these conditions, when one of the subjects corresponded to “MIZUBUTORI” meaning a fat and water-swelled human-being (the subcutaneous tissue is less elastic), the constitution of the subject was determined to be yin-nature. Conversely, when one of the subjects corresponded to “KATABUTORI” meaning a fat and stiff human-being (the subcutaneous tissue is elastic), the constitution of the subject was determined to be yang-nature. In the table of FIG. 28, the physique of each subject becomes stronger in “MIZUBUTORI” tendency when going leftward, and conversely, becomes stronger in “KATABUTORI” tendency when going rightward.
[0068] Besides that, in the table of FIG. 28, the red blood cell of one of the subjects becomes stronger in yin-nature (expansibility) when going upward, and conversely, becomes stronger in yang-nature (contractibility) when going downward. This directional arrangement applies also to FIGS. 29 and 30.
[0069] In the table of FIG. 28, per each subject, the determination result of a red blood cell is indicated in letters, and also one of a plurality of types of constitutions (indicated in letters in parenthesis) that the each subject belongs to is indicated by circle. This notation applies also to FIGS. 29 and 30. In the table of FIG. 28, a plurality of circles associated with a plurality of subjects is generally distributed along a line sloping downward when going from left to right.
[0070] The determination results of constitutions shown in FIG. 29 were obtained under both the condition where the more the constitution shows yin-nature, the more the elements with the centrifugal properties exist within the human body, and therefore, the surfaces of the cells of the human being have expansibility and are easier to radiate heat, leading to a low body-temperature, and the condition where the more the constitution shows yang-nature, the more the elements with centripetal properties exist within the human body, and therefore, the surfaces of the cells of the human being have contractibility and are hard to radiate heat, leading to a high body-temperature.
[0071] Under these conditions, when the body temperature of one of the subjects was low, the constitution was determined to be yin-nature, and conversely, when the body temperature was high, the constitution was determined to be yang-nature. In the table of FIG. 29, the body temperature of each subject becomes lower when going leftward, and conversely, becomes higher when going rightward.
[0072] Also in the table of FIG. 29, a plurality of circles associated with a plurality of subjects is generally distributed along a line sloping downward when going from left to right.
[0073] The determination results of constitutions shown in FIG. 30 were obtained under both the condition where the more the constitution shows yin-nature, the more the elements with the centrifugal properties exist within the human body, and therefore, the surfaces of the cells of the human being have expansibility and are easier to radiate heat, leading to a low blood-pressure, and the condition where the more the constitution shows yang-nature, the more the elements with the centripetal properties exist within the human body, and therefore, the surfaces of the cells of the human being have contractibility and are harder to radiate heat, leading to a high blood-pressure.
[0074] Under these conditions, when the blood pressure of one of the subjects was high, the constitution was determined to be yin-nature, and conversely, when the blood pressure of the subject was low, the constitution was determined to be yang-nature. In the table of FIG. 30, the blood pressure of each subject becomes lower when going leftward, and conversely, becomes higher when going rightward.
[0075] Also in the table of FIG. 30, a plurality of circles associated with a plurality of subjects is generally distributed along a line sloping downward when going from left to right.
[0076] As is evident from the above explanation, the results of the experiments shown in FIGS. 28 through 30 demonstrate that there is established a relationship between the determination results of constitutions and the determination results of red blood cells, wherein the relationship is represented with a line sloping downward when going from left to right. This means the validity of determining the constitution of a human being on the basis of the classification of a red blood cell of the human being.
[0077] As is apparent from the above explanation, giving attention to both the diameter of a red blood cell of a human being, and the thickness of its cell membrane would make is possible to property classify the red blood cell for determining the constitution of the human being.
[0078] Based on the findings described above, in the apparatus according to the present mode (1), red-blood-cell image data representing an image of a red blood cell of a human being is produced for allowing a portion of a cross section of the red blood cell to be visualized as a ring-shaped figure, wherein the portion corresponds to a cell membrane of the red blood cell, and wherein the cross section is to be obtained by cutting the red blood cell in a direction in which the red blood cell is flat-shaped.
[0079] Therefore, this apparatus would allow classification of a red blood cell using the red-blood-cell image sharply which has been picked up of an outer and an inner surface of a cell membrane, and which therefore permits precise measurement of the thickness of the cell membrane.
[0080] Moreover, in this apparatus, based on the thus produced red-blood-cell image data, both an outer diameter of the ring-shaped figure corresponding to a diameter of the red blood cell, and a width of the ring-shaped figure corresponding to a thickness of the cell membrane of the red blood cell are extracted as features of the red blood cell.
[0081] Accordingly, this apparatus would make it possible to classify a red blood cell by considering both the diameter thereof and the thickness of the cell membrane, and therefore, this apparatus would allow, based on the findings of the present inventors described above by reference to the previously-mentioned micrographs, correct classification of a red blood cell for the use of determining the constitution of a human being.
[0082] Further, in this apparatus, based on the extracted features, a red blood cell is classified as one of a predetermined plurality of types of red blood cell types. The plurality of red blood cell types include, in accordance with the aforementioned findings of the present inventors: an expansion type where a red blood cell shows an expansion tendency; a contraction type where a red blood shows a contraction tendency; and a medium type which is situated between the expansion and the contraction type, as three basic types of red blood cells.
[0083] Therefore, this apparatus would allow classification of a red blood cell as one of a plurality of types of red blood cells, as a result of focus on both the diameter of the red blood cell and the thickness of a cell membrane of the red blood cell.
[0084] The “red-blood-cell image data” in the present mode (1) may be produced by, for example, picking up an image of blood which has been collected from the body of a human being, using a microscope, by picking up an image of blood which is flowing within the capillary in the close proximity of the skin, or the arteriole or the venule of a human being, using a microscope, etc.
[0085] The diameter of a red blood cell and the thickness of its cell membrane tend to retain the relationship therebetween that the larger the diameter of the red blood cell, the thinner the cell membrane. Therefore, it is thought that focusing attention only on either the diameter or the thickness would be adequate. However, it is considered that there arise both a case in which the classification of a red blood cell performed by focusing attention only on the diameter is inadequate, and a case in which the classification of a red blood cell made by focusing attention only on the thickness is inadequate.
[0086] By contrast, the apparatus according to the present mode (1) would allow classification of a red blood cell in light of both the diameter thereof and the thickness of its cell membrane, and therefore, this apparatus would make it easier to ensure the accuracy of classification of a red blood cell.
[0087] However, this apparatus may be practiced in an arrangement to additionally incorporate a function to classify a red blood cell by focusing only on the diameter thereof, in an arrangement to additionally incorporate a function to classify a red blood cell by focusing only on the thickness of its cell membrane.
[0088] (2) The apparatus according to mode (1), wherein the red-blood-cell classification means classifies the red blood cell as a selected one of the contraction, the medium, and the expansion type, such that the selected one changes in a description order of the contraction, the medium, and the expansion type with increase in the diameter, and such that the selected one changes in a description order of the expansion, the medium, and the contraction type with increase in the thickness.
[0089] (3) The apparatus according to mode (1) or (2), wherein the plurality of types of red blood cells further includes at least one combination type combining at least two of the three basic types.
[0090] As is evident from the above-described explanation of mode (1), when the classifications of pre-cultured red blood cells and those of post-cultured red blood cells are considered in combination, it is understood that types of red blood cells include: three basic types consisting of an expansion, a medium, and a contraction type; and at least one combination type which is a composition of at least two of the basic types.
[0091] Based on these findings, in the apparatus according to the present mode (3), the plurality types of red blood cells in the above mode (1) includes, in addition to three basic types of red blood cells, at least one combination type which is a composition of two of the three basic types of red blood cells.
[0092] Here, one example of the “combination type of red blood cell” is a type combining an expansion and a contraction type which both belong to the basic types of red blood cells. Another example is a type combining an expansion and a medium type which both belong to the basic types of red blood cells. Still another example is a type combining a contraction and a medium type which both belong to the basic types of red blood cells.
[0093] (4) The apparatus according to any one of modes (1) through (3), wherein the red-blood-cell image data includes at least one of first and second red-blood-cell image data, wherein the first red-blood-cell image data represents an image which is picked up, using a microscope, of a pre-cultured red-blood-cell, after the blood containing the red blood cell is collected from a body of the human being, and without culturing the red blood cell in the collected blood, and wherein the second red-blood-cell image data represents an image which is picked up, using a microscope, of a post-cultured red-blood-cell in the collected blood, after culturing the red blood cell.
[0094] By reference to the explanation on the above mode (1), it is possible to classify a red blood cell on the basis of an image of a pre-cultured red-blood-cell which is picked up, using amicroscope, after the blood containing the red blood cell is collected from a body of the human being, and without culturing the red blood cell in the collected blood. Further, it is also possible to classify a red blood cell on the basis of an image of a post-cultured red-blood-cell which is picked up, using a microscope, after culturing the red blood cell.
[0095] Based on these findings, in the apparatus according to the present mode (4), the red-blood-cell image data set forth in any one of modes (1) through (3) includes at least one of the first red-blood-cell image data representative of an image of the pre-cultured red-blood-cell, and the second red-blood-cell image data representative of an image of the post-cultured red-blood-cell.
[0096] (5) The apparatus according to any one of modes (1) through (4), wherein the plurality of types of red blood cells further includes at least one combination type of a red blood cell combining at least two of the three basic types;
[0097] wherein the red-blood-cell image data includes:
[0098] first red-blood-cell image data representing an image of a pre-cultured red blood cell, which is picked up using a microscope, after the blood is collected from a body of the human being, and without culturing the red blood cell in the collected blood; and
[0099] second red-blood-cell image data representing an image of a post-cultured red blood cell, which is picked up using a microscope, after culturing the red blood cell in the collected blood;
[0100] wherein the red-blood-cell classification means includes:
[0101] (a) a provisional classification portion for provisionally classifying the red blood cell as one of the three basic types, on the basis of the first red-blood-cell image data, and depending on the outer diameter and the width of the ring-shaped figure indicating the image of the pre-cultured red blood cell; and
[0102] (b) a final classification portion for finally classifying the red blood cell as the same one of the basic types as which the red blood cell has been provisionally classified, or one of the at least one combination type, on the premise of one of the basic types as which the red blood cell has been provisionally classified, on the basis of the second red-blood-cell image data, and depending on the outer diameter and the width of the ring-shaped figure indicating the image of the post-cultured red blood cell.
[0103] By reference to the explanation on the above mode (1), when a red blood cell is provisionally classified on the basis of the pre-cultured red-blood-cell image, and when the same red blood cell is finally classified based on the result of the provisional classification, the accuracy of classification of a red blood cell will be improved more easily than when a red blood cell is classified based only on the pre-cultured red-blood-cell image.
[0104] Based on these findings, in the apparatus according to the present mode (5), a red blood cell is provisionally classified as one of the three basic types of red blood cells, depending on an outer diameter and a width of the ring-shaped figure representative of the pre-cultured red-blood cell, namely, a diameter of a pre-cultured red-blood-cell and a thickness of its cell membrane. Then, the red blood cell is finally classified as the same one of the basic types as which the red blood cell has been provisionally classified, or one of the at least one combination type, on the premise of one of the basic types as which the red blood cell has been provisionally classified, and depending on an outer diameter and a width of the ring-shaped figure indicating the image of the post-cultured red blood cell, namely, a diameter of the post-cultured red-blood-cell and a thickness of its cell membrane.
[0105] (6) The apparatus according to any one of modes (1) through (5), wherein the feature extraction means includes a pattern-recognition means for effecting a pattern recognition for the image of the red blood cell, thereby to extract the diameter of the image of the red blood cell and the thickness of the cell membrane as the features.
[0106] This apparatus would allow, by employing a pattern-recognition technique for images, extraction of a diameter of a red blood cell and a thickness of its cell membrane as features of the red blood cell.
[0107] (7) The apparatus according to mode (6), wherein the pattern-recognition means makes, with the image of the red blood cell being handled as an input pattern, and with a presupposed plurality of types of images of red blood cells being handled as a plurality of standard patterns, respectively, a match between the input pattern and the plurality of standard patterns, thereby to select one of the plurality of standard patterns which is the most similar to the input pattern as a similar standard-pattern, whereby the diameter of the red blood cell and the thickness of the cell membrane are extracted as the features.
[0108] (8) The apparatus according to any one of modes (1) through (7), wherein the image of the red blood cell represents the blood of the human being before food intake.
[0109] The shape of a red blood cell of a human being whose blood is collected changes between before and after food intake by the human being. Meanwhile, it is more suitable for an improved accuracy, to identify the true shape of the red blood cell of the same human being by the blood collected before food intake, than to identify it by the blood collected after food intake.
[0110] Depending on these findings, in the apparatus in accordance with the present mode (8), the image of the red blood cell set forth in any one of modes (1) through (7) is defined to represent the blood of a human being before food intake.
[0111] (9) The apparatus according to any one of modes (1) through (8), wherein the plurality of constitutions comprises a yin-nature, a yang-nature, and a medium-nature as three basic types of constitutions, and wherein the constitution determination means determines the constitution as the yin-nature, the yang-nature, or the medium-nature, when the red blood cell has been classified as the expansion type, the contraction type, or the medium type, respectively.
[0112] (10) The apparatus according to mode (9), wherein the plurality of types of red blood cells further comprises at least one combination type of a red blood cell combining two of the three basic types of red blood cells, wherein the plurality of types of constitutions further comprises at least one combination type of constitution combining two of the three basic types of constitutions, and wherein the constitution determination means determines the constitution as one of the at least one combination type of constitution, when one of the types of red blood cells as which the red blood cell has been classified corresponds to one of the at least one combination type of red blood cell.
[0113] (11) The apparatus according to any one of modes (1) through (10), further comprising:
[0114] a proper-diet-plan memory in which a predetermined plurality of kinds of proper-diet-plans have been stored directly or indirectly associated with the predetermined plurality of types of red blood cells, respectively; and
[0115] a proper-diet-plan displaying means for retrieving, in the proper-diet-plan memory, a proper-diet-plan corresponding to one of the types of red blood cells as which the red blood cell has been classified, and for displaying a content of the retrieved proper-diet-plan on a screen of the computer.
[0116] As described in the above mode (1), a constitution of a human being, which is to say, the physical features (physiological or pathological features) of a human being, and the shape of a red blood cell of the human being are deeply involved in each other. On the other hand, it has been said that factors determining the constitution of a human being include an acquired factor as well as a congenital factor. The acquired factor includes foods that human beings take.
[0117] Therefore, when the actual constitution of a human being is deviated from an ideal one (i.e., a medium one), it is possible to idealize the actual constitution of the human being (i.e., to make it closer to the medium one) by improving the diet that the human being has.
[0118] Based on these findings, in the apparatus in accordance with the present mode (11), depending on one of the types of red blood cells which has been specified through classification performed based on the diameter of a red blood cell of a human being and the thickness of the cell membrane, a plan of a diet which is recommended as one that the human being should have is provided as a proper-diet-plan. To be more specific, in a proper-diet-plan memory in which a predetermined plurality of kinds of proper-diet-plans have been stored directly or indirectly associated with a predetermined plurality of types of red blood cells, respectively, there is retrieved a proper-diet-plan corresponding to one of the types of red blood cells as which the red blood cell has been classified, and the content of the retrieved proper-diet-plan is displayed on a screen.
[0119] The “proper-diet-plan” in the present mode (11) may be interpreted to include a proper plan for a human being's act to take general foods (including what is called health foods), may be interpreted to include a proper plan for a human being to take all kinds of substances including foods with health claims that foods with nutrient function claims and foods for specified health use belong to, supplements, etc.
[0120] The apparatus according to the present mode (11) may be constructed such that the proper-diet-plan memory has stored therein the relationship between a predetermined plurality of kinds of proper-diet-plans and a predetermined plurality of types of constitutions. Further, the apparatus according to the present mode (11) may be also constructed such that the proper-diet-plan memory has stored therein the relationship between a predetermined plurality of kinds of proper-diet-plans and a predetermined plurality of types of red blood cells.
[0121] (12) The apparatus according to mode (11), wherein the proper-diet-plan displaying means displays, on the screen, the proper-diet-plan in the form of a recipe of a diet recommended as one that the human being should have.
[0122] The apparatus according to the above mode (11) may be practiced in such an arrangement that the proper-diet-plan is displayed on the screen in the form of materials of a diet recommended as one that the human being should have. However, in this arrangement, when the human being has the recommended diet, the human being himself or herself or a party concerned has to choose appropriate ones from the displayed materials and cook or prepare the diet, which is troublesome.
[0123] Alternatively, in the apparatus according to the present mode (12), the proper-diet-plan is displayed on the screen in the form of a recipe of a diet recommended as one that the human being should have. Therefore, this apparatus would reduce a need of the human being himself or herself or a party concerned to choose materials for preparing the recommended diet, resulting in an easy reduction in time and labor.
[0124] (13) The apparatus according to mode (12), wherein the proper-diet-plan displaying means includes a first means for displaying the recipe of the diet such that the recipe is segmented into a staple food, a side dish, and drinkables or liquid foods.
[0125] (14) The apparatus according to mode (13), wherein the first means displays: a plurality of kinds of candidate foods which is recommended for the human being to take as staple foods; a plurality of kinds of candidate foods which is recommended for the human being to take as side dishes; and a plurality of kinds of drinkables and liquid foods which is recommended for the human being to take as drinkables and liquid foods.
[0126] (15) The apparatus according to any one of modes (12) through (14), wherein the proper-diet-plan displaying means comprises a second means for displaying the recipe of the diet, per each meal or per each set of means for each day, in the form of eatables and drinkables recommended for the human being to take.
[0127] (16) A program executed by a computer to implement a method for determining a constitution of a human being, the method comprising:
[0128] a feature extraction step of extracting an outer diameter of a ring-shaped figure corresponding to a diameter of the red blood cell, and a width of the ring-shaped figure corresponding to a thickness of a cell membrane of the red blood cell, as features of a red blood cell in blood of the human being, on the basis of red-blood-cell image data representing a two-dimensional image of the red blood cell which is flat-shaped on a plane and which is enclosed by the cell membrane having the thickness, wherein the red-blood-cell image data is produced for allowing a portion of a cross section of the red blood cell to be obtained by cutting the red blood cell in a direction of the plane, to be visualized as the ring-shaped figure, wherein the portion corresponds to the cell membrane;
[0129] a red-blood-cell classification step of classifying the red blood cell as one of a predetermined plurality of types of red blood cells, on the basis of the extracted features, wherein the plurality of types includes an expansion type where a red blood cell exhibits an expansion tendency, a contraction type where a red blood cell exhibits a contraction tendency, and a medium type which is intermediate between the expansion and the contraction type, as three basic types of red blood cells; and
[0130] a constitution determination step of determining the constitution of the human being as one of a predetermined plurality of types of constitutions of human beings, on the basis of one of the plurality of types of red blood cells as which the red blood cell has been classified.
[0131] Execution of this program by a computer would allow provision of the same functions and effects as the apparatus according to the above mode (1).
[0132] The “method for determining a constitution of a human being” may be practiced in such an arrangement as to employ the features as set forth in any one of modes (2) through (15).
[0133] The “program” in the present mode (16) may be interpreted to incorporate not only a combination of instructions implemented by a computer to perform the functions of the program, but also files, data, etc. processed depending on each of the instructions.
[0134] (17) A recording medium which has stored therein the program according to mode (16) in a computer-readable manner.
[0135] Execution of the program stored in this recording medium would allow provision of the same functions and effects as the apparatus according to the above mode (1).
[0136] The “recording medium” in the present mode (17) may accept various kinds of formats, for example, at least any one of a magnetic recording medium such as a flexible disc; an optical recording medium such as a CD, and a CD-ROM; an magnetic optical recording medium such as an MO; an un-removable storage such as a ROM; etc.
[0137] (18) An apparatus for processing red-blood-cell image data representing a two-dimensional image of a red blood cell in blood of a human being, wherein the red blood cell is flat-shaped on a plane and is enclosed by a cell membrane having a thickness, and wherein the red-blood-cell image data is produced for allowing a portion of a cross section of the red blood cell to be obtained by cutting the red blood cell in a direction of the plane, to be visualized as a ring-shaped figure, wherein the portion corresponds to the cell membrane, the apparatus comprising:
[0138] a feature extraction means for extracting an outer diameter of the ring-shaped figure corresponding to a diameter of the red blood cell, and a width of the ring-shaped figure corresponding to the thickness of the cell membrane of the red blood cell, as features of the red blood cell, on the basis of the red-blood-cell image data; and
[0139] a red-blood-cell classification means for classifying the red blood cell as one of a predetermined plurality of types of red blood cells, on the basis of the extracted features, wherein the plurality of types includes an expansion type where a red blood cell exhibits an expansion tendency, a contraction type where a red blood cell exhibits a contraction tendency, and a medium type which is intermediate between the expansion and the contraction type, as three basic types of red blood cells.
[0140] The apparatus according to the above mode (1) may be recognized such that the apparatus is separated into a portion of classifying a red blood cell, and a portion of determining a constitution of a human being, and it is the apparatus according to the present mode (18) that is constructed by focusing only on the portion of classifying a red blood cell.
[0141] Therefore, this apparatus according to the present mode (18) would permit provision of a corresponding part of the functions and effects to be provided by the apparatus according to the above mode (1).
[0142] (19) The apparatus according to mode (18), further comprising a constitution determination means for determining the constitution of the human being as one of a predetermined plurality of types of constitutions, wherein the plurality of types of constitutions includes a yin-nature, a yang-nature, and a medium-nature as three basic types of constitutions, and wherein the constitution determination means determines the constitution as the yin-nature, the yang-nature, or the medium-nature, when the red blood cell has been classified as the expansion type, the contraction type, or the medium type, respectively.
[0143] (20) A program executed by a computer to implement a method for processing red-blood-cell image data representing a two-dimensional image of a red blood cell in blood of a human being, wherein the red blood cell is flat-shaped on a plane and is enclosed by a cell membrane having a thickness, and wherein the red-blood-cell image data is produced for allowing a portion of a cross section of the red blood cell to be obtained by cutting the red blood cell in a direction of the plane, to be visualized as a ring-shaped figure, wherein the portion corresponds to the cell membrane, the method comprising:
[0144] a feature extraction step of extracting an outer diameter of the ring-shaped figure corresponding to a diameter of the red blood cell, and a width of the ring-shaped figure corresponding to the thickness of the cell membrane of the red blood cell, as features of the red blood cell, on the basis of the red-blood-cell image data; and
[0145] a red-blood-cell classification step of classifying the red blood cell as one of a predetermined plurality of types of red blood cells, on the basis of the extracted features, wherein the plurality of types includes an expansion type where a red blood cell exhibits an expansion tendency, a contraction type where a red blood cell exhibits a contraction tendency, and a medium type which is intermediate between the expansion and the contraction type, as three basic types of red blood cells.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0146] In the drawings:
[0147] [0147]FIG. 1 schematically illustrates a proper-diet-plan presentation system according to a first embodiment of the present invention;
[0148] [0148]FIG. 2 is a block diagram schematically illustrating several kinds of devices to be connected to an image capturing device 60 in FIG. 1;
[0149] [0149]FIG. 3 is a flow chart schematically illustrating a main program which has been stored in a program memory 36 in FIG. 1;
[0150] [0150]FIG. 4 is a flow chart schematically illustrating a program for processing image data of red blood cells, which has been stored in the program memory 36 in FIG. 1;
[0151] [0151]FIG. 5 is a flow chart schematically illustrating S 23 in FIG. 4 by the name of feature extraction routine, in more detail;
[0152] [0152]FIG. 6 is a front view illustrating features referring to a diameter of an image of a red blood cell and a thickness of a cell membrane in the feature extraction routine in FIG. 5;
[0153] [0153]FIG. 7 is a front view illustrating variations in the diameter d of the image of the red blood cell in the feature extraction routine in FIG. 5;
[0154] [0154]FIG. 8 is a front view illustrating variations in the thickness t of the image of the red blood cell in the feature extraction routine in FIG. 5;
[0155] [0155]FIG. 9 illustrates in a table a relationship represented by data of pre-culture relationship between features and types of red blood cells, wherein the data has been stored in a data memory 38 in FIG. 1;
[0156] [0156]FIG. 10 illustrates in a table a relationship represented by data of post-culture relationship between features and types of red blood cells, wherein the data has been stored in the data memory 38 in FIG. 1;
[0157] [0157]FIG. 11 illustrates in a table the fact that a part of a plurality of final types of red blood cells in FIG. 10 is constructed by combining a plurality of basic types of red blood cells;
[0158] [0158]FIG. 12 is a flow chart schematically illustrating a constitution determination program which has been stored in the program memory 36 in FIG. 1;
[0159] [0159]FIG. 13 illustrates in a table a relationship represented by data of a relationship between types of red blood cells and types of constitutions, wherein the data has been stored in the data memory 38 in FIG. 1;
[0160] [0160]FIG. 14 is a flow chart schematically illustrating a proper-diet-plan presentation program which has been stored in the program memory 36 in FIG. 1;
[0161] [0161]FIG. 15 is a front view illustrating an example of an image displayed on a screen as a result of execution of the proper-diet-plan presentation program in FIG. 14;
[0162] [0162]FIG. 16 is a micrograph of a pre-cultured blood in which a red blood cell shows an expansion type;
[0163] [0163]FIG. 17 is a micrograph of a post-cultured blood in which a red blood cell shows a strong-expansion type;
[0164] [0164]FIG. 18 is a micrograph of a post-cultured blood in which a red blood cell shows a normal-expansion type;
[0165] [0165]FIG. 19 is a macrograph of a post-cultured blood in which a red blood cell shows an expansion type with a contraction tendency;
[0166] [0166]FIG. 20 is a micrograph of a pre-cultured blood in which a red blood cell shows a medium type;
[0167] [0167]FIG. 21 is a micrograph of a post-cultured blood in which a red blood cell shows a medium type with an expansion tendency;
[0168] [0168]FIG. 22 is a micrograph of a post-cultured blood in which a red blood cell shows a normal-medium type;
[0169] [0169]FIG. 23 is a micrograph of a post-cultured blood in which a red blood cell shows a medium type with a contraction tendency;
[0170] [0170]FIG. 24 is a micrograph of a pre-cultured blood in which a red blood cell shows a contraction type;
[0171] [0171]FIG. 25 is a micrograph of a post-cultured blood in which a red blood cell shows a strong-contraction type;
[0172] [0172]FIG. 26 is a micrograph of a post-cultured blood in which a red blood cell shows a normal-contraction type;
[0173] [0173]FIG. 27 is a micrograph of a post-cultured blood in which a red blood cell shows a contraction type with an expansion tendency;
[0174] [0174]FIG. 28 is a diagram for explaining in a table a relationship obtained experimentally between determination results of constitutions and determination results of red blood cells;
[0175] [0175]FIG. 29 is another diagram for explaining in a table a relationship obtained experimentally between determination results of constitutions and determination results of red blood cells;
[0176] [0176]FIG. 30 is still another diagram for explaining in a table a relationship obtained experimentally between determination results of constitutions and determination results of red blood cells.
DETAILED DESCRIPTION OF THE INVENTION
[0177] There will be described below a more specific one of embodiments according to the present invention in more detail by reference to the drawings.
[0178] In FIG. 1, a hardware resource of a proper-diet-plan presentation system (hereinafter, referred to simply as “system”) according to one embodiment of one aspect of the present invention is schematically shown in a block diagram. The system includes; an apparatus for determining a human's constitution according to one embodiment of another aspect of the present invention; and a recording medium according to one embodiment of yet another aspect of the present invention.
[0179] The system is used by a plurality of users, each of who requests the system to provide a proper-diet-plan presentation service to the users. The system may be embodied using a combination of a personal computer personally used at home, and a server computer connected to the personal computer via the Internet functioning as a communication network, or may be embodied using a personal computer, without relying on a server computer.
[0180] As shown in FIG. 1, the system 10 is constructed to primarily have a computer 20 . The computer 20 is constructed such that a processing unit (hereinafter, abbreviated as “PU”) 30 and a memory 32 are connected with each other via a bus 34 .
[0181] The memory 32 is constructed to include recording medium, such as a ROM, a RAM, a magnetic disk, an optical disk, etc. In the memory 32 , a program memory 36 in which various programs have been stored, and a data memory 38 in which various sets of data have been stored or will be stored, where necessary.
[0182] With the system 10 , an input device 40 for inputting data to the system 10 , and a display device 46 for displaying data output from the system 10 on a screen (not shown), are connected. One example of the input device 40 is constructed to have a keyboard, a mouse functioning as a pointing device, etc. On the other hand, one example of the display device 46 is constructed to have at least one of an LCD, a CRT, etc.
[0183] The system 10 is further equipped with an image capturing device 60 . The image capturing device 60 is configured to capture an image of blood collected from the body of each user, in the form of a grayed image or variable density image (a multi-valued image within which concentration information of each picture element is multi-valued). While the present invention may be practiced in such an alternative embodiment that an image of a red blood cell is captured into the system 10 as a binary image, the concentration information of which is binarized, the present invention is practiced in the present embodiment, for the purpose of classifying a red blood cell by additionally considering levels of concentration of a cell membrane of a red blood cell within am image of the red blood cell, such that the image of the red blood cell is incorporated into the system 10 in the form of a multi-valued image.
[0184] The collection of blood from each user is preferably conducted before the each user's meal (for example, before breakfast).
[0185] As shown in FIG. 2, the image capturing device 60 is connected to an image pick-up device 62 such as a CCD camera. The image pick-up device 62 is mounted with a phase contrast microscope 64 functioning as a microscope.
[0186] The phase contrast microscope 64 is used for observing blood collected from each user's body at a given magnification. In the present embodiment, for the blood collected from the same user, both a micrograph of the blood immediately after the blood is collected from the user, and a micrograph of the cultured blood are picked up.
[0187] To be more specific, initially, blood (whole blood) is collected from the fingertip of a user's body. The collected blood is put on a slide glass 70 as soon as possible, and then, the collected blood is covered with a cover glass 72 , and the periphery of the cover glass 72 is sealed with oil for a microscope to perform an oil immersion, As a result, the collected blood is put under an anaerobic condition where the collected blood is isolated from oxygen.
[0188] The thus prepared blood sample is attached at a given position of the phase contrast microscope 64 , and as a result, an image of a pre-cultured red blood cell is picked up.
[0189] After being picked up, the same blood sample is cultured. More particularly, the blood sample is stored within an incubator at a temperature of 38 degrees centigrade for a predetermined period of time (e.g., three days, several days, one week, and two weeks).
[0190] Upon culturing, in the same manner as when an image of a pre-cultured blood cell is picked up, an image of the blood sample is again picked up with the blood sample being attached to the phase contrast microscope 64 , resulting in a picked-up image of a post-cultured red blood cell.
[0191] These images of the pre-cultured and the post-cultured red blood cell are both incorporated into the system 10 via the image capturing device 60 .
[0192] As shown in FIG. 1, the program memory 36 has stored therein various kinds of programs, originally including a main program, a program for processing image data of red blood cells, a constitution determination program, and a proper-diet-plan presentation program.
[0193] In FIG. 3, the main program is schematically illustrated in a flow chart. The main program is executed once for each user.
[0194] When each cycle of execution of this main program is initiated, in a step S 1 (hereinafter, referred to simply as “S 1 .” The same is true for all other steps.), the program for processing image data of red blood cells is implemented. Thereafter, in S 2 , the constitution determination program is implemented. Following that, in S 3 , the proper-diet-plan presentation program is implemented. Then, one cycle of execution of this main program is terminated.
[0195] In FIG. 4, the program for processing image data of red blood cells is schematically illustrated in a flow chart.
[0196] For this program for processing image data of red blood cells, first of all, in S 21 , data representing the image of the pre-cultured red blood cell is captured into the computer 20 , as a first red-blood-cell image data. The captured first red-blood-cell image data is stored into the data memory 38 , as shown in FIG. 1.
[0197] Then, in S 22 , like in S 21 , data representing the image of the post-cultured red blood cell is captured into the computer 20 , as a second red-blood-cell image data. Similarly, the captured second red-blood-cell image data is stored into the data memory 38 , as shown in FIG. 1.
[0198] Following that, in S 23 , on the basis of the captured first and second red-blood-cell image data, features of the red blood cell are extracted for each of the images of the pre-cultured and the post-cultured red-blood-cell.
[0199] In FIG. 5, the details of S 23 are schematically illustrated as the feature extraction routine in a flow chart.
[0200] For this feature extraction routine, first of all, in S 31 , the images of the pre-cultured and the post-cultured red blood cell are sequentially selected as a subject image, and along with that, for the subject image, preprocessing required for image processing such as later image segmentation is performed. The preprocessing may be performed such that edge enforcement process is implemented for separating a red-blood-cell image defined as each sub-image of and within the subject image, from the background of the subject image.
[0201] Following that, in S 32 , the image segmentation for the subject image is performed for segmenting the subject image into individual red-blood-cell images. For example, one subject image generates a plurality of red-blood-cell images as a result of the image segmentation.
[0202] After that, in S 33 , data representing each of the resulted red-blood-cell images is stored as an input-pattern data, as shown in FIG. 1, into the data memory 38 . This data memory 38 has stored therein a plurality of sets of standard-pattern data respectively indicating a plurality of standard patterns with which an input pattern represented by the input-pattern data is to be matched.
[0203] As shown in FIG. 6, an input pattern referring to a red-blood-cell image may be defined as a hollow or solid circle identified by the diameter d and the thickness t of the cell membrane.
[0204] Then, each of the standard patterns is defined as an image which is changed with parameters respectively referring to the diameter d and the thickness t, and the standard patterns are presupposed by variations in each parameter.
[0205] For the diameter d of the standard patterns, as shown in FIG. 7, five ranks respectively corresponding to “extremely small,” “small,” “medium,” “large,” and “extremely large” are provided. Alternatively, for the thickness t of the standard patterns, as shown in FIG. 8, five ranks respectively corresponding to “extremely small,” “small,” “medium,” “large,” and “extremely large” are provided, similarly.
[0206] When the thickness t of the input pattern is “extremely small”, the cell membrane of the input pattern is lighter or lower in concentration. Therefore, it is previously designed that, the standard pattern that rank “extremely small” has been assigned to is selected, on the condition that the cell membrane of the input pattern is lighter or lower in concentration, which is depicted in FIG. 8 in a broken line for the sake of convenience in explanation.
[0207] Alternatively, when the thickness t of the input pattern is “extremely large,” the cell membrane of the input pattern is darker or higher in concentration. As a result, it is previously designed that, the standard pattern that rank “extremely large” has been assigned to is selected, on the condition that the input pattern is entirely darker higher in concentration, which is depicted in FIG. 8 in a solid circle for the sake of convenience in explanation.
[0208] In S 33 of FIG. 5, further, the plurality of standard patterns is sequentially read out from the data memory 38 , and the read-out standard pattern is matched or collated with the current input pattern. Per each matching, the level of similarity (correlation) between the current standard pattern and the current input pattern is determined.
[0209] After that, in S 34 , based on the determined level of similarity, one of the plurality of standard patterns which is the most similar to the current input pattern with regard to the diameter d, and one of the plurality of standard patterns which is the most similar to the current input pattern with regard to the thickness t are selected. As a result of this selection, the diameter d of the red blood cell and the thickness t of the cell membrane are extracted as the features of the red blood cell from the current input pattern.
[0210] Then, one cycle of execution of this feature extraction routine is terminated.
[0211] Thereafter, in S 24 of FIG. 4, based on the image of the pre-cultured red blood cell, a provisional classification (sorting) of the red blood cell of the current user is performed.
[0212] As shown in FIG. 1, data of a pre-cultured relationship between features and types of red blood cells has been stored in the data memory 38 . In FIG. 9, the relationship represented by the data of the pre-cultured relationship is shown in a table.
[0213] According to the relationship represented by the data of the pre-cultured relationship between features and types of red blood cells, an expansion type is selected as a provisional type of the red blood cell, on the condition that the rank of the diameter d of the red blood cell is “large,” and that the rank of the thickness t is “small.” In addition, a contraction type is selected as a provisional type of the red blood cell, on the condition that the rank of the diameter d is “small,” and that the rank of the thickness t is “large.” Additionally, a medium type is selected as a provisional type of the red blood cell, on the condition that the rank of the diameter d is “medium,” and that the rank of the thickness t is also “medium.”
[0214] Then, in S 24 of FIG. 4, according to the relationship represented by the data of the pre-cultured relationship between features and types of red blood cells, the current provisional type of the red blood cell is classified as one of the expansion, the contraction, and the medium type.
[0215] Following that, in S 25 , on the basis of the image of the post-cultured red blood cell, a final classification of the red blood cell of the current user is performed.
[0216] As shown in FIG. 1, data of a post-cultured relationship between features and types of red blood cells has been also stored in the data memory 38 . In FIG. 10, the relationship represented by the data of the post-cultured relationship is shown in a table.
[0217] According to the relationship represented by the data of the post-cultured relationship between features and types of red blood cells, when the provisional type of the red blood cell is “expansion type,” (a) a strong-expansion type is selected as a final type of the red blood cell, on the condition that there exist not less than a predetermined number of red blood cells in which the rank of the diameter d is “extremely large,” and in which the rank of the thickness t is “extremely small;” (b) a normal-expansion type is selected as a final type of the red blood cell, on the condition that there exist not less than a predetermined number of red blood cells in which the rank of the diameter d is “large,” and in which the rank of the thickness t is “small;” and (c) an expansion type with contraction tendency is selected as a final type of the red blood cell, on the condition that the rank of the diameter d of each red blood cell is “small.”
[0218] Here, the “expansion type with contraction tendency” refers to, as shown in FIG. 11, a combination type of a red blood cell consisting by combining or binding the expansion and the contraction type which both belong to the basic types of red blood cells.
[0219] Alternatively, as shown in FIG. 10, when the provisional type of the red blood cell is “medium type,” (a) a medium type with expansion tendency is selected as a final type of the red blood cell, on the condition that the rank of the diameter d of each red blood cell is “large,” (b) a normal-medium type is selected as a final type of the red blood cell, on the condition that the rank of the diameter d of each red blood cell is “medium,” and (c) an expansion type with contraction tendency is selected as a final type of the red blood cell, on the condition that the rank of the diameter d of each red blood cell is “small.”
[0220] Here, the “medium type with expansion tendency” refers to, as shown in FIG. 11, a combination type of a red blood cell consisting by combining or binding the expansion and the medium type which both belong to the basic types of red blood cells.
[0221] In addition, the “medium type with contraction tendency” refers to, as shown in FIG. 11, a combination type of a red blood cell consisting by combining or binding the medium and the contraction type which both belong to the basic types of red blood cells.
[0222] Additionally, as shown in FIG. 10, when the provisional type of the red blood cell is “contraction type,” (a) a strong-contraction type is selected as a final type of the red blood cell, on the condition that the rank of the diameter d of each red blood cell is “extremely small,” and that the rank of the thickness t is “extremely large,” (b) a normal-contraction type is selected as a final type of the red blood cell type, on the condition that the rank of the diameter d of each red blood cell is “small,” and that the rank of the thickness t is “large,” and (c) a contraction type with expansion tendency is selected as a final type of the red blood cell, on condition that the rank of the diameter d of each red blood cell is “medium,” and that the rank of the thickness t is also “medium.”
[0223] Here, the “contraction type with expansion tendency” refers to, as shown in FIG. 11, a combination type of a red blood cell consisting by combining or binding the expansion and the contraction type which both belong to the basic types of red blood cells.
[0224] Then, in S 25 of FIG. 4, according to the relationship represented by the data of post-cultured relationship between features and types of red blood cells, the current final type of the red blood cell is classified as the same one of the basic types of red blood cells that corresponds to the provisional type of the red blood cell, or as one of a plurality of combination types of red blood cells. The thus determined final type of the red blood cell is stored in the data memory 38 .
[0225] Then, one cycle of execution of this program for processing image data of red blood cells is terminated.
[0226] In FIG. 12, the constitution determination program in FIG. 1 is schematically illustrated in a flow chart.
[0227] For this constitution determination program, first of all, in S 41 , the final type of the red blood cell which has been determined as a result of the execution of the program for processing image data of red blood cells is read out from the data memory 38 . Next, in S 42 , depending on the read-out final type of the red blood cell, the constitution of the current user is determined.
[0228] As shown in FIG. 1, the data of relationship between types of red blood cells and types of constitutions has been previously stored in the data memory 38 . In FIG. 13, the relationship represented by the data of relationship between types of red blood cells and types of constitutions is illustrated in a table.
[0229] According to this relationship, when the final type of the red blood cell is the “strong-expansion type,” the “normal-expansion type,” and the “expansion type with contraction tendency,” respectively, the type of constitution is determined as the “strong yin-nature,” the “normal yin-nature,” and the “yin-nature with yang-nature.”
[0230] Here, while the “strong yin-nature” and the “normal yin-nature” both belong to basic types of constitutions, the “yin-nature with yang-nature” belongs to a combination type of constitution consisting by combining the “yin-nature” and the “yang-nature” which both belong to the basic types of constitutions.
[0231] Additionally, when the final type of the red blood cell is the “medium type with expansion tendency,” the “normal-medium type,” and the “medium type with contraction tendency,” respectively, the type of constitution is determined as “medium-nature with yin-nature,” the “normal medium-nature,” and the “medium-nature with yang-nature.”
[0232] Here, while the “normal medium-nature” belongs to the basic types of constitutions, the “medium-nature with yin-nature” is a combination type of constitution consisting by combining the “yin-nature” and the “medium-nature” which both belong to the basic types of constitutions, and the “medium-nature with yang-nature” is a combination type of constitution consisting by combining the “yang-nature” and the “medium nature” which both belong to the basic types of constitutions.
[0233] In addition, when the final type of the red blood cell is the “contraction type with expansion tendency,” the “normal-contraction type,” and the “strong-contraction type,” respectively, the type of constitution is determined as the “yang-nature with yin-nature,” the “normal yang-nature,” and the “strong yang-nature.”
[0234] Here, while the “normal yang-nature” and the “strong yang-nature” both belong to the basic types of constitutions, the “yang-nature with yin-nature” is a combination type of constitution consisting by combining the “yin-nature” and the “yang-nature” which both belong to the basic types of constitutions.
[0235] Then, in S 42 of FIG. 12, according to the relationship represented by the data of relationship between types of red blood cells and types of constitutions, the constitution of the current user is determined as the type of constitution corresponding to the final type of the red blood cell. The thus determined type of constitution is stored in the data memory 38 .
[0236] Following that, in S 43 , the thus determined type of constitution is displayed on the screen of the display device 46 , and upon request, the final type of the red blood cell is also displayed together.
[0237] Then, one cycle of execution of this constitution determination program is terminated.
[0238] In FIG. 14, the proper-diet-plan presentation program in FIG. 1 is schematically illustrated in a flow chart.
[0239] For this proper-diet-plan presentation program, first of all, in S 51 , the type of constitution which has been determined as a result of the execution of the constitution determination program is read our from the data memory 38 .
[0240] After that, in S 52 , a proper-diet-plan that suits the read-out type of constitution is retrieved in the data memory 38 .
[0241] As shown in FIG. 1, a proper-diet-plan memory 80 is provided with the data memory 38 . In the proper-diet-plan memory 80 , proper-diet-plan data indicative of a plurality of kinds of proper-diet-plans has been previously stored in association with a plurality of presupposed types of constitutions for an arbitrary user, respectively. The proper-diet-plan data indicative of each kind of proper-diet-plan has been made as data for presenting a diet in the form of a recipe such that it is divided into a staple food, a side dish, and drinkables and liquid foods (including miso-soup, western soup, for example) to the user, wherein the diet suits the user's constitution and contributes to the improvement of the user's constitution toward the medium nature.
[0242] Following that, in S 52 , the thus retrieved proper-diet-plan data is read out from the proper-diet-plan memory 80 , and on the basis of the retrieved proper-diet-plan data, the proper-diet-plan that suits the current user's constitution is displayed on the screen of the display device 46 .
[0243] In FIG. 15, one example of the display is illustrated so as to reflect the image on the screen. In this example, the recipe of the diet suitable to the current user's constitution is displayed, together with the constitution, in the form of a combination of a plurality of kinds of candidates of staple foods; a plurality of kinds of candidates of side dishes; and a plurality of kinds of candidates of drinkables and liquid foods.
[0244] Then, one cycle of the execution of this proper-diet-plan presentation program is terminated, and as a result, one cycle of the execution of the main program in FIG. 3 is also terminated.
[0245] As is evident from the above, in the present embodiment, a portion of the proper-diet-plan presentation system which executes S 21 through S 23 in FIG. 4 constitutes one example of the “feature extraction means” set forth in the above mode (1), a portion of the proper-diet-plan presentation system which executes S 24 and S 25 constitutes one example of the “red-blood-cell classification means” set forth in the same mode, and a portion of the proper-diet-plan presentation system which executes S 2 in FIG. 3 constitutes one example of the “constitution determination means” set forth in the same mode.
[0246] Further, in the present embodiment, the method implemented by the execution of the program for processing image data of red blood cells in FIG. 4 constitutes one example of the “method” set forth in the above mode (16), S 21 through S 23 in FIG. 4 together constitute one example of the “feature extraction step” set forth in the same mode, S 24 and S 25 in FIG. 4 together constitute one example of the “red-blood-cell classification step” set forth in the same mode, and S 2 in FIG. 3 constitutes one example of the “constitution determination step” set forth in the same mode.
[0247] Furthermore, in the present embodiment, a portion of the proper-diet-plan presentation system which executes S 24 in FIG. 4 constitutes one example of the “provisional classification portion” set forth in the above mode (5), and S 25 in FIG. 4 constitutes one example of the “final classification portion” set forth in the same mode.
[0248] Still further, in the present embodiment, a portion of the proper-diet-plan presentation system which executes S 32 through S 34 in FIG. 5 constitutes one example of the “pattern recognition means” set forth in the above mode (6).
[0249] Yet still further, in the present embodiment, a portion of the proper-diet-plan presentation system which executes S 52 and S 53 in FIG. 14 constitutes one example of the “proper-diet-plan displaying means” set forth in the above mode (11).
[0250] Furthermore, in the present embodiment, the program for processing image data of red blood cells in FIG. 4 and the constitution determination program in FIG. 12 together constitute one example of the “program” of the above mode (16).
[0251] Still further, in the present embodiment, a portion of the memory 32 in which the program for processing the image data of red blood cells in FIG. 4 has been previously stored, and a portion of the memory 32 in which the constitution determination program in FIG. 12 has been previously stored together constitute one example of the “recording medium” of the above mode (17).
[0252] While one embodiment of the present invention has been described above by reference to the drawings, such description is for illustrative purposes, and the present invention may be carried out in alternative embodiments in which various modifications or improvements may be made of the present invention in light of the teachings of those skilled in the art without departing from the sprit of the present invention. | With the object of properly classifying a flat-shaped red blood cell in the blood of a human being to thereby determine the constitution of the human being, an outer diameter of a ring-shaped figure corresponding to a diameter d of the red blood cell, and a width of the ring-shaped figure corresponding to a thickness t of a cell membrane of the red blood cell are extracted as the features of the red blood cell, on the basis of red-blood-cell image data produced for allowing a portion of a cross section of the red blood cell to be obtained by cutting the red blood cell in a direction of the plane of the red blood cell, to be visualized as the ring-shaped figure, wherein the portion corresponds to the cell membrane, and the red blood cell is classified as one of a predetermined plurality of types of red blood cells including an expansion, a contraction, and a medium type, on the basis of the extracted features. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an acceleration measuring apparatus that is used in automobiles, airplanes, industrial machines, cameras, portable terminals, medical equipment, watches, toys, game machines or the like for measuring vibrations, inclinations, travel distances and travel directions.
2. Description of the Related Art
Acceleration sensors have been widely used to measure vibrations, inclinations, travel distances and travel directions. Such acceleration sensors measure an electrical value, such as voltage, converted from a force produced due to an acceleration. However, since the sensitive section thereof has a variable characteristic because of production variation, the measured value cannot be used for any purpose as it is. Thus, the acceleration sensors have to be calibrated, by subjecting them to a known acceleration, so as to provide an output proportional to an acceleration.
The acceleration sensors have an x-axis directional sensor, a y-axis directional sensor and a z-axis directional sensor to measure respective accelerations in directions of three axes of orthogonal coordinates, that is, an x-axis, a y-axis and a z-axis. In calibration of sensitivity of such an acceleration sensor, each of the directional sensors has to be calibrated by sequentially aligning the x-, y- and z-axes with the gravitational acceleration direction. Japanese Patent No. 3,111,017 discloses a calibration method that reduces the inconvenience of such calibration involving calibrating each of the directional sensors by sequentially aligning the acceleration sensor with the three directions. According to the calibration method disclosed in the Japanese Patent, the acceleration sensor is mounted on a jig that allows components of a same magnitude of the gravitational acceleration to be applied to the x-axis, y-axis and z-axis directional sensors, so that sensitivities of the x-axis, y-axis and z-axis directional sensors can be calibrated simultaneously. According to this method, although the sensitivities, that is, outputs provided when an acceleration of 1G is applied to the sensor, can be calibrated simultaneously, a zero gravity state, that is, a zero-point cannot be calibrated.
In recent years, with the development of micromachine manufacture technology, highly sensitive acceleration sensors of the capacitance type and semiconductor piezo-resistor type that can detect an acceleration of 1G or lower have become popular. Such highly sensitive acceleration sensors are often used to detect not only vibrations but also inclinations, travel distances or travel directions, and thus, it is essential for such sensors to calibrate a zero-point output level.
Furthermore, since the acceleration sensors provide a weak output, the output is necessarily amplified by means of an amplifier. It is required to calibrate the sensitivity and zero point of the amplified output. In addition, an acceleration measuring apparatus incorporates a processing device that stores calibration parameters and calibration formulas and performs data processing using the parameters and calibration formulas. Thus, it is required to calibrate not only the output of the acceleration sensor but also the amplified output and the output of the processing device.
SUMMARY OF THE INVENTION
The invention, therefore, has an object to provide an acceleration measuring apparatus that is able to calibrate its output with a zero-point in the state that no acceleration is applied as well as sensitivity.
Another object of the invention is to provide an acceleration measuring apparatus comprising an acceleration sensor and a data processing device for dealing with the sensor output from the data processing device.
Further object of the invention is to provide an acceleration measuring apparatus that calculates the output with calibration including output variations by ambient temperature.
It would be apparent from the description of the invention below that the invention has further objects to provide a calibration method of the acceleration measured by the acceleration measuring apparatus.
An acceleration measuring apparatus according to the invention comprises an acceleration sensor that detects each component of an acceleration and produces an output based on each of the detected components in each axis direction of at least two mutually perpendicular axes of orthogonal coordinates for the acceleration sensor, a holding means that holds the acceleration sensor at at least two different positions, in which the acceleration sensor axes at one position each is at an angle, with the gravitational acceleration direction, different from that at the other position, and a processing circuit. The processing circuit develops calibration parameters based on the output by each component in the at least two axis directions of the gravitational acceleration measured by the acceleration sensor positioned at each of the at least two different positions and calibrates the output created by the acceleration sensor based on each of the detected components of the acceleration in each of the at least two axis directions by using the calibration parameters to provide a calibrated output.
It is preferable that the acceleration sensor detects each component of the acceleration in each direction of three mutually perpendicular axes of orthogonal coordinates for the acceleration sensor and creates the output based on each of the detected components, and that the holding means holds the acceleration sensor at two different positions in which each of the acceleration sensor axes at one position is at a angle, with the gravitational acceleration direction different, from that at the other position.
In the acceleration measuring apparatus as described above, it is desirable that the processing circuit further comprises a memory, stores the obtained calibration parameters in the memory, and calibrates the output created by the acceleration sensor based on each of the detected components of the acceleration in each of the three axis directions by using the stored calibration parameters to provide the calibrated output.
The processing circuit preferably calibrates the output created by the acceleration sensor based on each of the detected components of the acceleration in each of the three axis directions by using the sensitivity and the zero-point output in each of the three axis directions, according to the following equation:
Calibrated output=(the output based on each of the detected components of the acceleration−the zero-point output)/the sensitivity.
The acceleration measuring apparatus may further comprise a means for measuring an ambient temperature, and the processing circuit may develop temperature functions of calibration parameter, based on the output by each component in the three axis directions of the gravitational acceleration measured by the acceleration sensor positioned at each of the two different positions and calibrate the output created by the acceleration sensor based on each of the detected components of the acceleration by using the calibration parameters obtained with the ambient temperature by the temperature functions of calibration parameter to provide the calibrated output.
The temperature functions of calibration parameter preferably include a temperature function of output per unit magnitude of acceleration (hereinafter called “temperature function of sensitivity”) in each of the three axis directions of the acceleration sensor and a temperature function of output of the acceleration sensor in each of the three axis directions without applied acceleration (hereinafter called “temperature function of zero-point output”).
In the acceleration measuring apparatus as described above, it is desirable that the processing circuit further comprises a memory, stores the obtained temperature functions of calibration parameter in the memory, and calibrates the output created by the acceleration sensor based on each of the detected components of the acceleration in each of the three axis directions by using calibration parameters at the ambient temperature obtained with the ambient temperature by the stored temperature functions of calibration parameter to provide the calibrated output.
The processing circuit preferably calibrates the output created by the acceleration sensor based on each of the detected components of the acceleration in each of the three axis directions by using the sensitivity and the zero-point output at the ambient temperature calculated with the ambient temperature by the temperature functions of sensitivity and the temperature functions of zero-point output, respectively, according to the following equation:
Calibration output=(the output based on each of the detected components of the acceleration−the zero-point output)/the sensitivity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an explanatory perspective view of an acceleration measuring apparatus according to the invention;
FIG. 2 is a block diagram showing a processing circuit installed in the acceleration measuring apparatus shown in FIG. 1;
FIGS. 3 (A)- 3 (B). shows examples of a semiconductor piezo-resistor type three-dimensional acceleration sensor used in the acceleration measuring apparatus of the invention, in which FIG. 3A is its perspective view and FIG. 3B is its plan view;
FIG. 4 shows an explanatory relationship of the perpendicular coordinate axes of the acceleration sensor and an applied acceleration;
FIG. 5A is an explanatory diagram showing the position relationship θ: 0 degree between the acceleration sensor and the gravitational acceleration and FIG. 5B shows the position relationship θ: 30 degrees and φ: 45 degrees between them; and
FIG. 6A is a graph showing a relationship between the sensitivity of the acceleration sensor used in the invention and ambient temperature and FIG. 6B is a graph showing a relationship between the zero-point output of the apparatus and ambient temperature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
An acceleration measuring apparatus according to the invention will be described in detail below with reference to the drawings. FIG. 1 is a perspective view of an acceleration measuring apparatus 1 according to the invention, and FIG. 2 is a block diagram of a processing circuit installed in the acceleration measuring apparatus 1 according to the invention. The acceleration measuring apparatus 1 comprises a printed wiring board 20 , an acceleration sensor 10 , an amplifier 3 for amplifying an output of the acceleration sensor 10 , an A/D converter 4 for converting an analog signal to a digital signal, a memory for storing a calibration parameter, a microprocessor 5 for performing a calibration calculation, and a temperature sensor 6 for measuring an ambient temperature. Referring to FIG. 2, the microprocessor 5 includes a memory 5 a . For the sake of clarity, identical components or parts are assigned the same reference numerals.
The acceleration sensor 10 is a semiconductor piezo-resistor type three-directional acceleration sensor sealed in a ceramic package. FIG. 3 is a schematic view of the semiconductor piezo-resistor type threedimensional acceleration sensor 10 implemented in the package. FIG. 3A is a perspective view of the sensor, and FIG. 3B is a plan view of the acceleration sensor 10 showing an arrangement of piezo-resistance elements (the wiring pattern and terminals are not shown). The sensor 10 is made of silicon and comprises a weight 11 at the center thereof, a frame 12 formed around the weight, and beams 16 , 17 , 18 and 19 that interconnect the weight 11 and the frame 12 in four directions.
In response to an external force, the weight 11 is displaced, whereby the beams 16 , 17 , 18 and 19 are deformed to generate a stress therein. Orthogonal coordinates are defined in such a manner that the beams 16 and 17 extend along the x-axis of the orthogonal coordinates, the beams 18 and 19 extend along the y-axis, and the z-axis extends perpendicular to and upward from the upper surface of the sensor. Piezo-resistance elements 31 and 32 for detecting an acceleration in the x-axis direction are mounted on the beam 16 , and piezo-resistance elements 33 and 34 for detecting an acceleration in the x-axis direction are mounted on the beam 17 . Piezo-resistance elements 41 and 42 for detecting an acceleration in the y-axis direction are mounted on the beam 18 , and piezo-resistance elements 43 and 44 for detecting an acceleration in the y-axis direction are mounted on the beam 19 . In addition, piezo-resistance elements 51 and 52 for detecting an acceleration in the z-axis direction are mounted on the beam 16 , and piezo-resistance elements 53 and 54 for detecting an acceleration in the z-axis direction are mounted on the beam 17 . Four piezo-resistance elements that detect accelerations in the respective axis directions constitute a bridge circuit. For example, if an acceleration in the x-axis direction is applied to the weight 11 , the piezo-resistance elements 31 and 33 are subjected to a compressive stress, and the piezo-resistance elements 32 and 34 are subjected to a tensile stress. By applying a certain voltage of DC 5V, for example, to the bridge circuit, the bridge circuit can provide an output when an acceleration is applied to the weight.
Measurements of output sensitivity and zero-point output of the acceleration sensor 10 are shown in TABLE 1. As can be seen from the sensitivity in TABLE 1, the sensor outputs have small values, and therefore, are amplified about 100-fold by the amplifier for measurement. Thus, the sensitivity and zero-point output after amplification are both about 100 times larger in value than those before amplification. Thus, in the invention, the outputs after amplification, that is, the outputs of the acceleration measuring apparatus 1 , are calibrated as described later.
TABLE 1
x-axis sensor
y-axis sensor
z-axis sensor
Sensitivity (mV/G)
3.5
3.6
4.0
Zero-point output (mV)
1.2
−1.0
2.5
FIG. 4 shows the orthogonal coordinates for the acceleration sensor 10 and an acceleration vector a applied to the acceleration sensor 10 . The angle which the acceleration vector a forms with the z-axis of the orthogonal coordinates is θ′, and the angle which a plane including the z-axis and the acceleration vector a forms with the x-axis is φ. The acceleration vector a is assumed to point downward for convenience in considering the gravitational acceleration. Assuming that the angle which the extension of the acceleration vector a in the +z direction forms with the z axis is θ, there is established a relation expressed by θ=180°−θ′. Thus, provided that the magnitude of the acceleration vector a is denoted by “a”, the axis-directional components of the orthogonal coordinates of the acceleration vector a are expressed as follows.
ax=a ·sin θ′·cos φ= a ·sin θ·cos φ (1)
ay=a ·sin θ′·sin φ= a ·sin θ·sin φ (2)
az=a ·cos θ′=− a ·cos θ (3)
On the other hand, the output of the acceleration measuring apparatus 1 having the acceleration sensor 10 can be expressed by the following formula.
Output=applied acceleration×sensitivity of acceleration measuring apparatus+zero-acceleration output (4)
In this formula, the sensitivity of the acceleration measuring apparatus refers to the magnitude of an output thereof provided when an acceleration of unit magnitude is applied to the acceleration sensor, and the zero-acceleration output refers to an output of the acceleration measuring apparatus 1 provided when no acceleration is applied to the acceleration sensor 10 .
Provided that an output voltage V of the acceleration measuring apparatus 1 when the acceleration vector a is applied to the acceleration sensor 10 is expressed as (Vx, Vy, Vz), where Vx, Vy and Vz denote the, axis-directional components of the orthogonal coordinates, each of the components can be expressed as follows based on the formula (4).
Vx=Vxs·ax+Vx 0 =Vxs·a ·sin θ·cos φ+ Vx 0 (5)
Vy=Vys·ay+Vy 0 =Vys·a ·sin θ·sin φ+ Vy 0 (6)
Vz=Vzs·az+Vz 0 =−Vzs·a· cos θ+ Vz 0 (7)
In these formulas, Vxs, Vys and Vzs denote the axis-directional components of the sensitivity, and Vx 0 , Vy 0 and Vz 0 denote the axis-directional components of the zero-point acceleration output voltage.
The acceleration measuring apparatus 1 of the invention has holding means that holds the acceleration sensor 10 in two different positions with respect to the gravitational acceleration direction. In this EXAMPLE, the two different positions are those shown in FIGS. 5A and 5B. When the acceleration sensor 10 is in the position shown in FIG. 5A, the gravitational acceleration direction corresponds with the -z axis direction of the orthogonal coordinates. Thus, applying a relation of θ=0° to the formulas (5) to (7) results in the following formulas. Here, the output voltage (Vx, Vy, Vz) of the acceleration measuring apparatus 1 when in the first position, that is, the position shown in FIG. 5A is expressed by (Vx 1 , Vy 1 , Vz 1 ).
Vx 1 = Vx 0 (8)
Vy 1 = Vy 0 (9)
Vz 1 =− Vzs·a+Vz 0 (10)
Since the magnitude a of the gravitational acceleration is 1G, the formula (10) results in the following formula.
Vz 1 =− Vzs+Vz 0 (10′)
In the position shown in FIG. 5B, the gravitational acceleration direction is expressed by θ=30° and φ=45°. Thus, the formulas (5) to (7) are further expressed as follows. Here, the output voltage (Vx, Vy, Vz) of the acceleration measuring apparatus 1 when in the second position, that is, the position shown in FIG. 5B is expressed by (Vx 2 , Vy 2 , Vz 2 ).
Vx 2 = Vxs /22 +Vx 0 (11)
Vy 2 = Vys /22 +Vy 0 (12)
Vz 2 =−3 ·Vzs /2 +Vz 0 (13)
Since the output voltages (Vx 1 , Vy 1 , Vz 1 ) and (Vx 2 , Vy 2 , Vz 2 ) of the acceleration measuring apparatus are measured, the zero-point output component Vx 0 and the sensitivity component Vxs can be determined from the formulas (8) and (11), the zero-point output component Vy 0 and the sensitivity component Vys can be determined from the formulas (9) and (12), and the zero-point output component Vz 0 and the sensitivity component Vzs can be determined from the formulas (10′) and (13).
The output voltage components (Vx 1 , Vy 1 , Vz 1 ) of the acceleration measuring apparatus measured in the position shown in FIG. 5A were 123 mV, −101 mV and −151 mV, respectively. Furthermore, the output voltage components (Vx 2 , Vy 2 , Vz 2 ) of the acceleration measuring apparatus measured in the position shown in FIG. 5B were 247 mV, 26 mV and −97 mV, respectively. The sensitivity (Vxs, Vys, Vzs) and the zero-point output (Vx 0 , Vy 0 , Vz 0 ), which serve as calibration parameters, determined using the measurements are shown in TABLE 2.
TABLE 2
x-axis sensor
y-axis sensor
z-axis sensor
Sensitivity (mV/G)
351
359
403
Zero-point output (mV)
123
−101
252
The calibration parameters shown in TABLE 2 were stored in the memory 5 a . When an applied acceleration is measured, the microprocessor 5 can perform a calibration calculation to determine the applied acceleration by substituting the calibration parameters determined based on the output voltages of the acceleration measuring apparatus 1 and stored in the memory 5 a in the following formula (14), which is derived from the formula (4).
Acceleration (calibrated output)=(detected output−zero-point output)/sensitivity (14)
Theoretically, the resulting calibrated output is 0 when the applied acceleration is 0G, 1 when the applied acceleration is 1G, or 2 when the applied acceleration is 2G. Actual measurement in which a known acceleration was applied thereto resulted in a detection error of 1% or lower.
EXAMPLE 2
The acceleration sensor 10 was held by the holding means in-two different positions with respect to the orthogonal coordinates for the acceleration sensor 10 of the acceleration measuring apparatus 1 described with reference to EXAMPLE 1. In one of the positions, the gravitational acceleration direction was expressed by θ=10° and φ=20°, and in the other position, the gravitational acceleration direction was expressed by θ=20° and φ=45°. In each of the positions, the output voltages (Vx 1 , Vy 1 , Vz 1 ) and (Vx 2 , Vy 2 , Vz 2 ) of the acceleration measuring apparatus 1 were measured. Measurements (Vx 1 , Vy 1 , Vz 1 ) for the position of θ=10° and φ=20° and measurements (Vx 2 , Vy 2 , Vz 2 ) for the position of θ=20° and φ=45° were substituted in the formulas (5) to (7) to calculate the calibration parameters, that is, the sensitivity (Vxs, Vys, Vzs) and the zero-point output (Vx 0 , Vy 0 , Vz 0 ). The calculated calibration parameters of sensitivity and zero-point output were stored in the memory 5 a . Using calibration parameters determined based on output voltages for an applied acceleration measured by the acceleration measuring apparatus 1 and stored in the memory 5 a , the microprocessor 5 can perform a calibration calculation based on the formula (14) to determine the applied acceleration. A known acceleration was applied to the acceleration sensor 10 , output voltages for the acceleration components were each measured by the acceleration measuring apparatus, and then the magnitude of the applied acceleration was determined from the formula (14) using the measurements. The error between the magnitude of the acceleration determined from the formula (14) and the true magnitude of the known acceleration was 1% or lower.
EXAMPLE 3
FIGS. 6A and 6B are graphs showing variations of the sensitivity and zero-point output of the acceleration sensor 10 , respectively, depending on ambient temperatures. The acceleration measuring apparatus has a temperature sensor 6 to compensate the ambient temperature variations.
Sensitivities and zero-point outputs of the acceleration measuring apparatus at ambient temperatures of −20° C., 25° C., and 50° C. are shown in TABLE 3.
TABLE 3
Temperature
Sensitivity (mV/G)
Zero-point output (mV)
T° C.
Vxs(T)
Vys(T)
Vzs(T)
Vx0(T)
Vy0(T)
Vz0(T)
−20° C.
367
378
404
122
−96
204
25° C.
350
360
400
120
−100
250
50° C.
344
354
403
119
−102
266
To determine a temperature function of sensitivity and a temperature function of zero-point output, quadratic approximation was performed for the values of sensitivity and zero-point output shown in TABLE 3. Then, the following formulas were obtained.
Temperature function of x-axis sensitivity: 0.0020 T 2 −0.388 T +358.5
Temperature function of y-axis sensitivity: 0.0023 T 2 −0.411 T +368.9
Temperature function of z-axis sensitivity: 0.0030 T 2 −0.104 T +400.7
Temperature function of x-axis zero-point output: 0.00006 T 2 −0.045 T +121.1
Temperature function of y-axis zero-point output: 0.0001 T 2 −0.090 T − 97 . 8
Temperature function of z-axis zero-point output: −0.0055 T 2 +1.050 T +227.2
These temperature functions were stored in the memory 5 a . A sensitivity (T) and a zero-point output (T) for an ambient temperature measured by the temperature sensor 6 were determined, and the microprocessor 5 performed a calibration calculation expressed by the following formula using the measured output to determine the acceleration.
Calibrated acceleration output=(output of each detected acceleration component−zero-point output ( T ))/sensitivity ( T )
Varying the ambient temperature from −40° C. to 85° C., measurement was made by applying a known acceleration. Then, a detection error of 3% or lower was provided.
As described above, since the acceleration sensor is set in two different positions in which the gravitational acceleration direction is slightly inclined with respect to any of the orthogonal coordinate axes, the acceleration measuring apparatus of the invention can calibrate the sensitivity (1G output) and the zero-point output, and since the output is corrected by the calibrated values, the acceleration measuring apparatus of the invention can provide an output portional to the acceleration applied to the sensor even if it has a charecteristic variation due to production variation of the sensor or measuring circuit. Furthermore, any temperature drift of the sensor can be corrected because the calibrated values of sensitivity and zero-point output, which depend on temperature, are obtained.
Furthermore, since the angle of inclination is small and two-step calibration is possible, the calibration apparatus is simplified, and an inexpensive and highly precise acceleration measuring apparatus is provided. | An acceleration measuring apparatus capable of calibrating its output with a zero-point in the state of no acceleration applied as well as sensitivity. An acceleration sensor detects each component of an acceleration and creates an output based on each of the detected components in each direction of at least two mutually perpendicular axes of orthogonal coordinates for the acceleration sensor. The acceleration sensor is held at at least two different positions; each of the acceleration sensor axes at one position is at a angle, with the gravitational acceleration direction, that is different from the angle at the other position. A processing circuit develops calibration parameters based on output by each component in the at least two axis directions of the gravitational acceleration measured by the acceleration sensor positioned at each of the at least two different positions and calibrates the output of the acceleration measured by using the calibration parameters to provide a calibrated output. | 6 |
TECHNICAL FIELD
The present invention is directed to the field of carbon black production using hydrogen and carbon monoxide containing synthesis gas to provide heat for the carbon black formation. More specifically, the heat and/or fuel value of the tail gas from carbon black production is utilized to convert methane fuel to a synthesis gas used in turn as fuel in the carbon black production process.
BACKGROUND OF THE PRIOR ART
In the manufacture of carbon black, natural gas is combusted with a stoichiometric excess of oxidant, typically air, to provide a hot combustion gas. Oil feedstock is sprayed into the hot gas causing it to pyrolyze into elemental carbon product. This product is carried in the reactor tail gas through various quench steps and heat recovery before it is separated in a filter device. Residual, low pressure tail gas from the filters contains large quantities of nitrogen, water, carbon dioxide, hydrogen and carbon monoxide yielding a low BTU(50-150 British Thermal Unit/standard cubic foot BTU/SCF) fuel. Some tail gas is used to fuel carbon dryer furnaces and boilers, but excess gas is incinerated.
Effective utilization of the low BTU excess tail gas can result in an overall energy efficiency improvement for the carbon black process. Efficiency improvements can also result from effectively integrating waste heat recovery into the carbon black process and limiting quench requirements. Increased efficiency can translate into reduced natural gas requirements or increased carbon black production.
Better utilization of carbon black reactor tail gas has been proposed by several patents in the prior art.
In U.S. Pat. No. 4,261,964, Scott, IV et al. proposed extracting the combustible components (hydrogen and/or carbon monoxide) from the tail gas and replacing 33% to 100% of the natural gas fuel with these components. The method for CO extraction described was a liquid adsorbent process known as COSORB. Hydrogen was recovered from the resultant CO--free tail gas with a cryogenic process.
There are several disadvantages to this process. The solvent CO absorption process (COSORB) is very sensitive to oxygen and water content in the tail gas. Water must be removed from the tail gas with dryers; failure to remove water results in severe corrosion problems in the COSORB equipment due to HCl formation. Oxygen will result in solid precipitates that foul and plug equipment.
The low pressure tail gas (near atmospheric) will require a large absorber column and high solvent circulation rates due to low separation driving force for CO removal. The COSORB solvent requires about 100,000-150,000 BTU/lb mole CO for regeneration. The combination of high energy requirements and high capital makes this recovery method uneconomical.
U.S. Pat. Nos. 4,460,558 and 4,393,034 utilize oxygen enriched air for the carbon black reactor oxidant gas. This minimizes the nitrogen content of the tail gas, upgrading its heating value, and making it suitable for reactor fuel.
Oxygen enrichment also has several disadvantages especially when retrofitting an existing carbon black process. Oxygen enrichment increases combustion chamber temperatures and requires a refractory changeout or the advantages of oxygen enrichment are limited. Oxygen is costly--its cost is about equivalent to the natural gas fuel cost that is replaced. Equipment must be installed to cool and condense water from the tail gas to improve its heating value. The integrated SMR process can retrofit existing carbon black processes without requiring equipment changeout in the carbon black process.
Chen cites in U.S. Pat. No. 4,490,346 a method for using the low BTU content tail gas by combusting with with near stoichiometric amounts of air and then tempering the combustion mixture with diluent tail gas or air before oil injection. A special compact reactor configuration with means for diluent introduction is needed to carry out this process.
The disadvantages of the prior art set forth above have been overcome by the present invention which will be described in greater detail below.
BRIEF SUMMARY OF THE INVENTION
The present invention is a process for the production of carbon black from a hydrocarbon feedstock comprising: reforming a hydrocarbon fuel into a predominantly hydrogen and carbon monoxide containing synthesis gas with steam in a catalytic elevated temperature reformation reaction, pyrolyzing said hydrocarbon feedstock to produce a carbon black containing tail gas wherein the heat of the pyrolysis is provided by the combustion of said synthesis gas, quenching the tail gas and recovering the carbon black from the tail gas, utilizing said tail gas either before or after carbon black recovery to provide the elevated temperature for the reforming of the hydrocarbon fuel.
Preferably, at least a portion of the tail gas after carbon black recovery is combusted with an oxidant gas to produce the elevated temperature for the reformation of the hydrocarbon fuel.
Alternatively, the tail gas after quench provides the elevated temperature for the reformation of the hydrocarbon fuel by indirect heat exchange.
Optionally, carbon dioxide is added to the elevated temperature reformation reaction.
DETAILED DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a first preferred embodiment of the present invention.
FIG. 2 is a schematic illustration of a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The proposed invention in FIG. 1 integrates a steam-methane reformer (SMR) 10 with the carbon black process 12 to improve overall energy efficiency. The SMR utilizes waste energy from the carbon black process by producing synthesis gas 14, containing H 2 and CO, from natural gas 16 and steam 22 (CH 4 +H 2 O→3H 2 +CO). The synthesis gas replaces natural gas fuel for the carbon black reactor 12 and its upgraded heating value allows for overall reduction of natural gas consumption or an increase in carbon black production.
FIG. 1 illustrates one embodiment of the SMR/Carbon Black integrated process. Natural gas 16, as a hydrocarbon fuel containing mostly methane and some N 2 , CO 2 , C +2 , is heated 18 to about 750° F., and trace H 2 S is removed using a solid adsorbent of typically ZnO in vessel 20. Process steam 22 is mixed with the natural gas 24 resulting in a mixed feed 26 with a steam/carbon ratio of 1.0-3.5 (typically 1.5). Carbon dioxide 28, if available, can also be mixed into the feed from 0.1 to 2.0 CO 2 /C ratios. The mixed feed (steam and natural gas) is heated in the convection section coil 30 to 900°-1050° F. and enters a steam-methane reformer (SMR) 10. In the SMR, the mixed feed passes through tubes 32 with a Ni containing catalyst. such as 5-30% Ni on an alumina support, which promotes the reaction of methane and steam to produce hydrogen and carbon monoxide (reforming reaction). The water gas reaction (CO+H 2 O→CO 2 +H 2 ) also occurs to yield a synthesis gas containing hydrogen, carbon monoxide, carbon dioxide, water and small amounts of unreacted methane. The synthesis gas 14 exits the SMR at 1300°-1700° F. and is sent to the carbon black reactor 12 for fuel.
The heat input for the reforming reactions is provided by burning the hot (about 500°-1100° F.) carbon black process excess tail gas 34 (50-150 BTU/SCF) Higher Heating Value (HHV) in the furnace 10 containing the reformer tubes 32. Optionally, the tail gas can be cooled, separating condensed water, and improving its heating value to the SMR furnace. Hot flue gas 36 (about 1700°-2000° F.) from the furnace section is used to preheat reformer mix feed 30, optionally preheat fuel 40 and combustion air 38 to 500°-1500° F., preheat natural gas feed 18 and raise sufficient steam 42 for the reforming reaction and excess steam for export, if economical.
The carbon black process combusts the synthesis gas 14 with preheated air or other oxidant gas 44 (800°-1400° F.) in the furnace section of the reactor 12. Combustion air or other oxidant gas from stoichiometric to a large excess (100-200%) is used to produce a hot combustion gas (2300°-3400° F.). Oil feed 46, as a hydrocarbon feedstock, is sprayed into the hot gas and pyrolyzed to carbon black product. Excess oxygen in the combustion gas partially oxidizes the oil feedstock producing a tail gas containing principally N 2 , H 2 , CO, CO 2 and H 2 O. The tail gas is quenched and cooled. The carbon black product 48 is then filtered from the tail gas, and a portion is sent to the SMR for fuel. Excess tail gas 52 can be removed from the process.
FIG. 2 is another embodiment of the proposed invention. Natural gas 54 is preheated 56 to about 750° F. against hot carbon black reactor effluent gas 66 and desulfurized 58. Steam 60 is added and the mixed feed 62 is, optionally, preheated 64, also against hot effluent gas 66. Steam is either provided external from the process or also raised 68 from the effluent gas. The mixed feed 70 enters tubes 72 containing a Ni catalyst where steam-methane reforming is accomplished. The resulting synthesis gas 74 is used to fuel the carbon black reactor 76 along with air or oxidant gas 78 which may be preheated 80 against effluent gas 66. The heat for the reforming reaction 72 is provided by convective heat transfer from the carbon black pyrolysis hot reactor effluent, post primary quench at about 2000° F.
Carbon black containing tail gas 82 is passed through a filter 84 to recover carbon black 86 and an effluent tailgas 88.
The integrated SMR/Carbon black process utilizes waste energy from the carbon black process to reform natural gas into synthesis gas with an upgraded heating valve. This synthesis gas fuels the carbon black reactor and effectively transfers that waste energy back to the carbon black reactor. This integrated effect improves overall process efficiency and can reduce natural gas consumption or improve carbon black production. The waste energy used for reforming is either from the excess low BTU value tail gas or the hot reactor effluent gas, post primary quench.
Several advantages are offered over conventional carbon black production:
1. Natural gas savings or increased carbon production are achieved cost effectively. Capital investment for the SMR has an expected attractive payback. No retrofit changes are required to the carbon black process.
2. Carbon black fuel containing CO and CO 2 can improve carbon black yield, further improving the overall economics. A carbon production increase of 40% can be achieved with 1:1 H 2 /CO fuel.
3. Excess steam generated by the SMR process (embodiment #1) can further reduce natural gas consumption for steam furnaces or be used to cogenerate electricity.
4. Reactor effluent waste heat (embodiment #2) used for reforming reduces direct quench requirements. Limiting water addition to the reactor effluent improves carbon yields.
The conventional carbon black process requires about 47 thousand standard cubic feet per hour (MSCFH) natural gas fuel to produce 154 thousand pounds per day (MLB/DAY) carbon. The integrated SMF process of the present invention requires only 32 MSCFH natural gas which constitutes a 32.5% energy savings. Alternatively, plant production can be increased to about 190 MLB/DAY. If a 10% carbon yield increase is realized, production can increase to 258 MLB/DAY.
The present invention has been set forth with regard to several preferred embodiments, however, the full scope of the present invention should be ascertained from the claims which follow. | Carbon black is produced from a pyrolyzed hydrocarbon wherein pyrolysis is effected by combusting a synthesis gas containing hydrogen and carbon monoxide. The synthesis gas is produced from reforming a hydrocarbon fuel, wherein the reformation is heated by combusting carbon black effluent tail gas or indirect heat exchange of the hot tail gas. | 8 |
[0001] This application claims priority from PCT/US99/05365, filed Mar. 11, 1999 and U.S. Ser. No. 09/040,485 filed Mar. 17, 1998.
[0002] The invention relates to a gene encoding a protein and peptides therefrom that includes an epitope, a cancer associated antigen, useful as a marker that is not restricted to previously defined histological classes of cancer. Antigenic peptides are useful as a vaccine for treatment and prevention of cnacer. Antigenic peptided are useful as a vaccine for treatment and prevention of cancer, and for the preparation of new, specific, monoclonal antibodies. Antisense molecules are useful in pharmaceutical compositions and are useful for diagnosis and treatment.
BACKGROUND OF THE INVENTION
[0003] Cancer is a leading cause of death in men and women throughout the world. In the United States alone, over 1 million new cases are diagnosed each year, and over 0.5 million deaths are reported annually (Landis et al., 1998). Historically, tumors are grouped and treated, based in part by the tissues in which they arise, e.g.—breast cancer, colon cancer, and lung cancer, and the like. Yet, within lung cancer, for example, it is well recognized that these tumors are a very heterogeneous group of neoplasms. This is also true for tumors arising in other tissues. In part, because of this heterogeneity, there are complex and inconsistent classification schemes which are used for human tumors. Previous attempts to treat cancer have been hampered by: 1) the arbitrary classification of tumors arising within given tissues, and 2) by using microscopic methods based on how these tumors look (histological classification). Although existing classifications for Terminology used herein is as follows, “cancer is a malignant tumor, wherein a “tumor” is an abnormal mass of tissue, that need not be malignant. “Neoplasm” us a form f new growth.”
[0004] various tumor types have some prognostic value, almost all of the classifications fail to predict responsiveness to treatments and likelihood of cure or disease course. Improved classification schemes based on the biological constitution of these neoplasms is required to significantly alter the survival statistics of humans who have cancer. One approach to solving these problems is to locate molecules specific to tumors, preferably antigens in molecules that are markers for cancer cells. (A “marker” is defined herein as any property which can be used to distinguish cancer from normal tissues and from other disease states.) The markers' presence is then a basis for classification.
[0005] Monoclonal antibodies (MCAs) prepared by somatic cell hybridization techniques, usually in mice, are useful molecular probes for the detection and discrimination of cellular antigens, and therefore have great potential for detecting cancer associated antigens. These antibodies bind to specific antigens and the binding is detectable by well known methods. When binding occurs, the inference is made that a specific antigen is present. Those cancer associated antigens which are exposed to the cell surface or found in the cancer mass, are molecular targets for the immune systems (including host antibodies) of the host. Recent findings suggest that cancer patients who have antibodies against their tumors, do better than those who do not mount this type of immune response (Livingston, et al., 1994). Therefore, natural, induced, or administered antibodies are a promising therapeutic approach.
[0006] The humanization of non-human MCAs (the process by which non-human MCA reactive sites are shuttled into cloned human antibodies and expressed) results in reduced immunogenicity of the foreign antibodies without the loss of their specific binding in in vivo and in ex vivo applications. MCAs can be used as in vivo imaging agents diagnostic tests, and for therapy (Research, et al. 1988 , 1990 ; Rosen, et al. 1988).
[0007] Vaccine therapy is a well established approach directed at inducing an immune response without exposure to the causative agent of a disease or condition. Many vaccines are available, for example, to stimulate a response in a host to bacterial and viral agents. The use of tumor associated antigens (markers) in a vaccine could prevent primary cancer occurrence, and could also provide a means to prevent recurrence of the disease.
[0008] Gene therapy is a means by which the genetic make-up of cells is modified to express the gene of interest. There are many forms of gene therapy including: gene replacement, antisense suppression therapy, and surrogate gene expression. Discovering genes encoding cancer-associated, preferably cancer-specific antigens (markers) opens the door to genetic intervention against cancer cell proliferation. The accurate and consistent use of a cancer marker to differentiate cancerous from normal tissue, not only has diagnostic potential, but is also desirable for treatment and prognosis. Therefore, such markers have been sought.
[0009] Recent studies have shown that the enzyme encoding human aspartyl beta-hydroxylase (HAAH) is overexpressed in some human adenocarcinoma cell lines, and in primary hepatocellular cancers, therefore could be a marker. The gene said to encode HAAH has been cloned and sequenced (Gronke, et al., 1989, 1990; Wang, et al, 1991; Jia, et al., 1992, 1994; Korioth, et al., 1994; Lavaissiere, et al., 1996). However, little is known about HAAH expression in human tumors in general (Lavaissiere, et al., 1996).
[0010] The study of the HAAH enzyme grew out of the study of its bovine counterpart (Gronke, et al., 1989, 1990; Wang, et al., 1991; Jia, et al., 1992). Bovine aspartyl beta-hydroxylase is an intracellular, glycosylated protein, localized in the rough endoolasmic reticuium. The protein has been reported to have three major species of molecules; a 85 kilodalton form, and two active forms with molecular weights of 56 and 52 kilodaltons respectively (Lavaissiere, et al., 1996).
[0011] Using standard biochemical methods, bovine aspartyl beta-hydroxylase (bAAH) has been purified and characterized (Gronke, et al. 1990; Wang, et al., 1991). The activity of the enzyme has been shown to be correlated with the 52 and 56 kilodalton species which were purified. Immunologically, a related higher molecular weight form (85-90 kilodalton) was also observed. As part of the purification, bAAH is bound to Con A sepharose, which is consistent with the conclusion that the enzyme is glycosylated. (Subsequent reports on the DNA sequence show three possible glycosylation sites, with one site being very close to the known active enzyme domain.) The protein is very acidic in nature, and a detergent is not required to solubilize the active fraction. The active enzyme site is dependent from the biochemically isolated bovine protein (bAAH) on the presence of histidine at position 675 (Jia, et al., 1994).
[0012] A partial amino acid sequence was obtained for HAAH. DNA probes (a DNA probe is a molecule having a nucleotide sequence that is capable of binding to a specified nucleotide sequence under certain conditions) deduced from this amino acid sequence was used to screen a bovine cDNA library (Jia, et al., 1992). (A cDNA library contains the sections of DNA that encode for gene products, e.g. peptides as opposed to genomic DNA). Several overlapping cDNA sequences in the library contained a 764 amino acid open reading frame (ORF) sequence which will be expected to encode an 85 kilodalton protein. Also present in this ORF sequence were two other possible start codons, that is, locations at which encoding begins. The most 3′ start codon was preceded by a ribosome binding site. Translation of the clone having this sequence resulted in a protein that was about 85 kilodaltons. Antiserum was raised to the membrane fraction of human MG-63 calls and was used to immunoscreen a cDNA library made from MG-63 cells. Data on one clone was reported which could encode a 757 amino acid protein, and, by sequence analysis, was found to have strong N-terminal homology with bAAH (Korioth, et al., 1994). When this clone was used in an in vitro translation system (an artificial cocktail of normal cell cytoplasm used to convert mRNA into protein), a 56 kilodalton protein was produced. It was suggested that this was due to posttranslational cleavage.
[0013] The HAAH enzyme is responsible for the modification of specific aspartic acid residues within the epidermal growth factor-like domains of proteins. It has been hypothesized that these modified aspartic acid residues allow the epidermal growth factor-like domains to become calcium binding domains. (Gronke, et al., 1989, 1990; Wang, et al., 1991; Jia, et al., 1992, 1994; Korioth, et al., 1994; Lavaissiere, et al., 1996).
[0014] An enzyme related to HAAH, aspartyl beta-hydroxylase (AAH), was first studied because it specifically modified select aspartic acid or asparagine residues in a group of biologically important proteins including the vitamin K-dependent coagulation factors VII, IX, and X. Other proteins like C, S, and Z also have this modification (Gronke, et al, 1989, 1990; Wang, et al., 1991; Jia, et al., 1992, 1994; Korioth, et al., 1994; Lavaissiere, et al., 1996). Aspartic acid and asparagine residues have been shown to be modified by HAAH in proteins containing epidermal growth factor-like domains. The function of the beta-hydroxyaspartic and beta-hydroxyasparagine residues is unknown, however, it has been speculated that this modification is required for calcium binding in the epidermal growth factor EGF-like domains of selected proteins.
[0015] Antibodies were raised to human hepatocellular carcinoma FOCUS cells (Lavaissiere, et al., 1990). One MCA reacted with an antigen that was highly expressed in hepatocellular carcinomas (Lavaissiere, et al., 1996). Immunoscreening using this antibody and a lambda gt11 HepG2 library resulted in the isolation of a partial cDNA, which was subsequently used to isolate a larger clone.
[0016] A human adenocarcinoma cell line designated A549 was reported as having very high levels of HAAH activity (Lavaissiere, et al., 1996). A mouse monoclonal antibody designated MCA 44-3A6 (U.S. Pat. No. 4,816,402) was produced against the human adenocarcinoma cell line A549 (ATCC accession number CCL 185) (Radosevich, et al., 1985). The antibody recognized a cell surface, non-glycosylated antigenic protein having an estimated apparent molecular weight of 40 kDa).
[0017] The antigen was expressed by A549 cells, and was found to be a good adenocarcinoma marker; that is, it was frequently expressed by cancers which looked like adenocarcinomas when examined histologically (Radosevich, et al., 1990a; Lee, at al., 1985). MCA 44-3A6 is unique in that it is the first monoclonal antibody which has this binding specificity. The results from an International Workshop for Lung cancer confirmed other related published findings on MCA 44-3A6 (Stahel, 1994).
[0018] The antibody designated MCA 44-3A6 has clinical utility because it differentiates antigens associated with adenocarcinomas. The normal and fetal tissue distribution of the antigen is restricted to some glandular tissues (Radosevich, et al., 1991). Detection can occur on formalin fixed-paraffin embedded tissue (Radosevich, et al., 1985, 1988, 1990a, 1990b; Lee, et al., 1985, 1986; Piehl, et a. 1988; Combs, et al., 1988b, 1988c; Banner, et al., 1985). The antibody has a restricted binding pattern within human pulmonary tumors (Lee, et al., 1985; Banner, et al., 1985; Radosevich, et al., 1990a, 1990b).
[0019] In a study of over two hundred pulmonary cancers, MCA 44-3A6 was found to react with all of the adenocarcinomas tested, many of the large cell carcinomas, as well as with subsets of intermediate neuroendocrine small cell lung cancers, well-differentiated neuroendocrine small cell carcinomas, carcinoids, but not mesotheliomas. MCA 44-3A6 does not react with squamous cell carcinoma, bronchioloalveolar carcinoma, or small cell carcinoma (Lee, et al., 1985). MCA 44-3A6 is useful in distinguishing adenocarcinomas that are metastatic to the pleura from mesothelioma (Lee, et al., 1986). The antibody has selected reactivity among adenocarcinomas and in large cell carcinomas (Piehl, et al., 1988; Radosevich, et al., 1990b).
[0020] In a study of over 40 cases of lung cancer comparing cytological and histological findings, MCA 44-3A6 was found to be useful in cytological diagnosis and was consistent with the histological finding (Banner, et al., 1985). Histology is the study of tissues (which are made of cells). Cytology is the sturdy of cells which have been removed from the organizational context which is commonly referred to as tissue. Cells removed from tissues do not always behave the same as if they were in the tissue from which they were derived. Fortunately, the antigen detected by MCA 44-3A6 expressed in adenocarcinoma cells in tissue behaves in the same ways as adenocarcinoma cells removed from tissues. This is a very diagnostically important characteristic. Similar correlations using cytologically prepared cell blocks of pulmonary carcinomas, as well as ACs presenting in body fluids from other sites throughout the body were demonstrated (Lee, et al., 1985; Spagnolo, et al., 1991; Combs, et al:, 1988c). Also, MCA 44-3A6 binds to adenocarcinomas from sites other than lung cancer. The expression of the antigen in primary and metastatic lesions was also reported (Combs, et al., 1988a). The utility of the MCA antibody in differentiating cancer from benign lesions in human breast tissue was also noted (Duda, et al., 1991).
[0021] The cellular localization of the antigen detected by MCA 44-3A6 W2s determined. By using live cell radioimmunoassays (a radioactive antibody test directed at determining binding of the antibody to live cells), immunofluorescence, and live cell fluorescence activated cell sorter (FACS) analysis, the antigen detected by MCA 44-3A6, was shown to be on the outside surface of the cell (Radosevich, et al., 1985). Additional studies using immunogold-electron microscopy and FACS analysis have demonstrated that this antigen is non-modulated (that is not internalized by the cancer cell when bound by an antibody), is expressed on the extracellular surface of the plasma membrane, and is not cell cycle specific that is, the cell makes protein all the time it is going through the process of cell replication, and also when it is not dividing (Radosevich, et al., 1991). The antigen is not found in the serum of normal or tumor bearing patients, and is not shed into the culture media by positive cell lines (that is, cancer cells are known to bleb off portions of their cell membranes and release them into the surrounding fluid.) (Radosevich, et al., 1985). Recently 3 of 27 randomly tested adenocarcinoma patients were found to have naturally occurring antibodies to the antigen. In addition, radiolabeled MCA 44-3A6 was used to localize A549 tumors growing in nude mice. A douxorubicin immunoconjugate MCA 44-3A6 is selectively toxic in vitro (Sinkule, et al., 1991).
[0022] Determination of the nucleotide and amino acid sequences of the antigen detected by MCA 44-3A6 would enhance the usefulness of this antigen in cancer diagnosis, treatment and prevention.
BRIEF SUMMARY OF THE INVENTION
[0023] The antigen detected by the antibody MCA 44-3A6 as described in the Background is now designated as “Labyrinthin.” A gene (designated labyrinthin; abbreviated lab) characterized by a unique nucleotide sequence that encodes the antigen detected by MCA 44-3A6 was isolated and characterized. (lab notation signifies the nucleic DNA/RNA forms; “Lab” notation refers to the protein which is encoded by the lab DNA/RNA).
[0024] The invention described herein used the antibody MCA 44-3A6 as a tool to clone the gene encoding Lab. In addition, an epitope (the necessary binding site for an antibody found on the antigen) for MCA 44-3A6 was identified on the Lab protein expressed by the clone to be PTGEPQ. 2 The epitope represents an important immunodominent sequence; that is, when injected into animals, the animals readily produce antibodies to this sequence. 2 Standard abbreviations for amino acids.
[0025] An aspect of the invention is the use of lab DNA in the sense 3 expression mode for: 1) the marking of human tumors by nucleotide probes; 2) the detection of DNA and mRNA expression of lab in cells and tissues; 3) the transformation of cells into a glandular-like cell type; 4) the production of Lab antigen in vivo for immunization; 5) the ex vivo expression of Lab for immunization to produce antibodies; and 6) production of Lab in vitro. Use of an antisense molecule, e.g. by production of a mRNA or DNA strand in the reverse orientation to a sense molecule, to suppress the growth of labyrinthin-expressing (cancerous) cells is another aspect of the invention. 3 The normal transcription of a DNA sequence which proceeds from the 3′ to the 5′ end to produce a mRNA strand from the sense strand of DNA, the mRNA being complementary to the DNA
[0026] An aspect of the invention is a vector comprising a DNA molecule with a nucleotide sequence encoding at least an epitope of the Lab antigen, and suitable regulatory sequences to allow expression in a host cell.
[0027] Another aspect of the invention is an amino acid sequence deduced from the protein coding region of the lab gene. Selected regions of the sequence were found via immunological methods, to produce effects corresponding to effects from both naturally occurring (from cancer cells), chemically produced (synthetically produced peptides), and expression products of the cloned lab gene.
[0028] Another aspect of the invention is the use of the entire deduced amino acid sequence of Lab, peptides derived from Lab, or chemically produced (synthetic) Lab peptides, or any combination of these molecules, for use in the preparation of vaccines to prevent human cancers and/or to treat humans with cancer. For purposes of the present invention, “humans with cancer” are those persons who have the Lab antigen detected in their cells. These preparations may also be used to prevent patients from ever having these tumors prior to their first occurrence.
[0029] Monoclonal antibodies directed to the Lab protein, or antigenic components or derivatives of Lab proteins, are useful for detection of Lab and for other purposes. Monoclonal antibodies which are made in species other than those which react with the Lab antigen can be modified by a number of molecular cloning methods such that they retain their binding with the Labyrinthin peptides, yet are not immunogenic in humans (Sastry, et al., 1989; Sambrook, et al., 1990). In brief, this is done by replacing the binding site sequence of a cloned human antibody gene, with the binding site sequence of the non-human monoclonal antibody of interest. These “humanized” MCAs are used as therapeutic and diagnostic reagents, in vivo, ex vivo, and in vitro.
[0030] The use of the Lab protein or antigenic peptides derived therefrom in diagnostic assays for cancer is a way to monitor patients for the presence and amount of antibody that they have in their blood or other body fluids or tissue. This detection is not limited to cancers of a class or classes previously defined, but is useful for cancer cells that have the Lab marker antigen. The degree of seroconversion, as measured by techniques known to those of skill in the art [e.g., ELISA (Engrall and Perimann, 1971)] may be used to monitor treatment effects.
[0031] Treatment with antisense molecules to lab or antibodies to Lab in a pharmaceutical composition is an approach to treat patients who have Lab in, or on, their cancer cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 is the nucleic acid sequence of the lab gene.
[0033] FIG. 2 is the amino acid sequence for Lab, deduced from the lab gene.
[0034] FIG. 3 is an illustration of the lab gene and how it is related to the HAAH enzyme.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Molecular Biology of Labyrinthin: To demonstrate that the epitope MCA 44-3A6 is encoded by a protein sequence, high molecular weight DNA from the cell line A549 was isolated. This DNA was co-precipitated (via calcium) with a plasmid (pSVneo), and used to transfect a mouse cell line designated B78H1 cells (Albino, et al., 1985). This mouse cell line is negative for the expression of the epitope and was reported to have a high frequency of incorporation and expression of any human DNA sequences. If a given B78H1 cell was in a state to take up DNA, it would be expected to have taken up both human DNA and the plasmid DNA. The plasmid DNA makes the cell resistant to G418 (a normally toxic drug). Therefore, if a cell normally sensitive to G418 growth inhibitor grows in G418, it had to have taken up the plasmid, and may also have taken up one or more A549 DNA sequences. After G418 selection (a way of choosing only cells which have resistance to growth in G418 by the uptake/expression of the Neo gene on pSVneo plasmid, and therefore representing cells that were in a state to uptake other DNA at the same time), approximately 15 of 1×10 5 clones were detected using immunoselection with MCA 44-3A6. This finding is consistent with a conclusion that human A549 cells have DNA that encodes Lab and possesses the regulatory sequences necessary for the expression of Lab.
[0036] Comparison of HAAH and Labyrinthin: Because the DNA sequence of lab was determined as an aspect of the present invention, HAAH and lab could be compared. HAAH and the lab nucleotide sequences have some internal fragment similarities, but are different on either side of the fragment, and are related to different products. This conclusion is based in part by the analysis and homology of the DNA sequences reported for these two genes. Specifically, the lab 5′ region has no homology with HAAH. The protein coding region of lab has about a 99.6% homology with an internal segment of the proposed protein coding region for HAAH. The 3′ region has no homology with the HAAH reported sequence. Virtually all of the other data comparing HAAH and labyrinthin are different, for example: 1) molecular weights of the proteins, 2) cellular localization, 3) chromosome localization, 4) histological presentation in normal tissues and tumors, 5) northern blot expression, 6) immunological findings.
[0037] Although the protein coding region of lab is identical to an internal region of the sequence reported for HAAH, the 5′ untranslated region of HAAH is different, and part of the 5′ translated protein coding region of HAAH is missing from that found in the lab clone. From both HAAH and lab clones, the deduced protein would be expected to be very acidic in nature, and therefore would run anomolously in SDS gels. As predicted, the Lab protein migrates anomolously in SDS gels. What was cloned and disclosed in the present invention migrates identically to the native protein found in several cell lines. Convincing evidence that the correct gene fragment encoding the antigen detected by MCA 44-3A6 has been cloned (mRNA) is that when the recombinant protein is made, that recombinant protein should act (in this case—have an apparent molecular weight) the same as independent biologically derived source of that protein. Lab provided from clones has the characteristics of Lab from cells.
[0038] The deduced amino acid sequence encoded by HAAH requires the use of an open reading frame which would produce a protein that is 85-90 kilodaltons, and does not take into account that there are several start codons and other shorter open reading frames. The deduced HAAH protein (biochemically) is glycosylated and the reported sequence has glycosylation sites (Korioth, et al., 1994; Lavaisslere, et al., 1996). To the contrary, Lab is not glycosylated, nor does it have predicted glycosylated sites.
[0039] The deduced HAAH amino acid sequence contains a region shared by the Lab amino acid sequence which is predicted to be very hydrophobic. Lab requires strong detergents in order to be soluble; HAAH does not. The increased expression of HAAH (by enzyme activity measurements) in the same cell line (A549) which was used to clone and study lab extensively, suggests that both of these gene products may be important to the AC phenotype and that at least A549 cells make both functional HAAH and Lab. Successful transfections of the antisense to lab into A549 resulted in a marked decrease in expression of lab and in the growth rate of the cells. The expression of a sense lab construct in NIH-3T3 cells (normal mouse fibroblasts) resulted in a marked change in phenotype, a phenotype consistent with that of ACs. Therefore, lab expression is associated with conversion of normal cells to cancerous cells. Lab and HAAH have potential calcium binding domains in common.
[0040] cDNA Library Contruction and Cloning: A cDNA lambda gt11 phage library was constructed using mRNA which was isolated from actively growing A549 cells (Sambrook, et al., 1990). This oligo(dT)-primed cDNA was cloned into the Eco RI site using Eco RI linkers. The library has about 83% clear (containing an insert) plaques with a titer of 1.2×10 10 /ml representing a minimum of 1.46×10 6 independent plaques which, by Polymerase Chain Reaction, have insert sizes ranging from 0.6 to 5 kilobases. Since Lab is a 40 kilodalton integral protein, (a protein which is embedded in the plasma membrane) the theoretical full length mRNA encoding this protein, including a potential leader sequence is estimated to be about 1.1 kilobases. This library was immunoscreened using the antibody MCA 44-3A6. Eight independently derived phage stocks (identical phage which are from the same plaque) were isolated. These have all been plaque purified by repeated cycles of immunoscreening/isolation. Upon Eco RI digestion of these eight isolates, inserts of about 2 kb were seen. The largest insert was isolated (2A1A1) and the Eco RI fragment was cloned into the pGEM-3Z plasmid.
[0041] Sequencing and Sequence Analysis: The DNA fragment designated 2A1A1 was found to have an insert of 2442 base pairs in length ( FIG. 1 ), containing a 5′ untranslated region, a ribosome binding site, and a start codon which would be expected to encode a 255 amino acid protein ( FIG. 2 ). The 3′ untranslated region is remarkable in that it contains only four instability sequences; ATTTA (Xu, et al., 1997). In addition there are sequences found in the very 3‘end of mRNA’s which result in adenylation of the mRNA (Sambrook, et al., 1990). The lab sequence contains both a sub-optimal (ATTAAA) and optimal (AATAAA) poly-adenylation site. These are sequences found in the very 3‘end of mRNA’s which result in adenylatlon of the mRNA. This finding provides molecular data which supports the cellular and biochemical data that has been outlined herein. (The HAAH clone has a poly A signal, but the whole 3′ region has not been sequenced.)
[0042] A calcium binding site motif is noted in the Lab amino and sequence ( FIG. 2 ), however, it is out of the known required structural context to be a binding site. In this case, the calcium limiting sequence is there, but it is not in a protein sequence context that is known to make it work as a binding site. Homology was noted with lab and an EST clone (designated #055501) which represented only a portion of the 3′ untranslated region and independently confirmed this portion of the sequence. Some internal fragment homology is also noted with HAAH, but the 5′ untranslated and part of the 5′ translated region is different (58 amino acids), as well as a major portion of the 3′ coding region is missing in lab FIG. 3 ).
[0043] Genomic DNA Cloning and Analysis: Using a PCR fragment representing the protein coding region of lab as a probe, a genomic lambda FIX II library made from the human pulmonary fibroblast cell line WI-38 was screened. Ten primary plaques were isolated out of approximately 1×10 6 screened plaques. Using seven of these as target DNA, Polymerase Chain Reaction conditions were established with primers for the protein coding region, producing a 765 base pair fragment, the expected protein coding region for lab. On Northern blots (a method used to qualitatively assess mRNA) lab only detects one band noted at 2.7 kilobases. The recombinant protein made from the lab clone, when tested on Western blots (a method used to qualitatively define proteins) using MCA 44-3A6, has the same relative mobility as the Lab protein when made by A549 cells.
[0044] Lab and HAAH genes give different results in the proteins they encode. HAAH consistently gives two bands on Northern blot analysis (2.6 and 4.3 kilobases) suggesting that the 2.6 kilobase band is due to alternative splicing, i.e. the cell cuts and splices the mRNA. Also, if lab and HAAH are the same gene, HAAH should be detected in all tissues and cancer cell lines in which Lab is found. However, Lab is not seen on Northern blots of cell lines EMT6 or QU-DB, nor is there immunoreactivity in these cells; indicating that Lab mRNA is not made, and that Lab protein is not produced in these cells. Lab protein is rarely expressed in normal cells, where both the HAAH mRNA and HAAH protein have been reported to be expressed in almost every tissue studied.
[0045] mRNA Analysis: Northern blot analysis of the DNA fragment from the A549 cell line using lab cDNA as a probe identified a single band of about 2.7 kilobases. This is expected based on the cDNA (2442 base pairs) and a poly-A tail of about 300 base pairs. Northern blot analysis of the mouse cell line, EMT6, and of the human large cell carcinoma cell line, QU-DB, confirm that no transcript for lab is produced by these cells. This is consistent with immunoassays which are negative for lab expression on these cells.
[0046] Antisense and Sense cDNA Expression. The plasmid (pBK-CMV) (Sambrook, et al., 1990) may carry either the sense or antisense full length cDNA lab into A549 and NIH 3T3 cells. An antisense molecule can be, for example, a complementary sequence to a sense molecule that hybridizes with the sense molecule, preventing its expression. Using the MTT assay (Siddique, et al., 1992) to assess the growth rate of A549 cells expressing antisense to lab, a marked reduction in growth rate was noted. The antisense transfected A549 cells appear to have a greater degree of contact inhibition. A detectable amount of Lab is reduced in these antisense transfected cells. NIH-3T3 cells convert from a fibroblast-like cell type morphology (large, thin spindle shaped) to a large, adenocarcinoma appearing cells (very round, plump) when sense expression occurs.
[0047] Chromosome Localization: The chromosome localization for lab, using full length cDNA as a probe via in situ hybridization (Sambrook, et al. 1990) is tentatively on chromosome 2q12-14, with possibly some reactivity to chromosomes 4 and 8. Using the same probe (the full length cDNA sequence of lab) and FACS sorted chromosomes (Lebo, et al. 1985) staining was also noted on chromosome 2, with weak staining on 4 and none on 8. The use of genomic clones will be of particular value in resolving these data because higher stringency hybridization conditions than that allowable for the cDNA, can be used, thereby reducing background signals. This is yet another proof that the correct gene was cloned and that the results are not due to a method artifact. There may be mutations in the genomic DNA of tumors and for the present invention, DNA was cloned from tumor cells (A549). Therefore, a mutated gene could have been cloned. However, that is not the case because the genomic DNA from a normal cell (DNA) produced the same sequence as what cloned as described herein. Therefore, a normal gene was cloned from A549 cells. The weak signals on chromosomes 4 and 8 are consistent with a pseudogene or a related gene. For example, HAAH has been reported to be on chromosome 8q12 by in situ hybridization, so this result on chromosome 8 could reflect the HAAH and lab sequence homology.
[0048] Protein Molecular Characterization of Labyrinthin: Previous work using Western blot analysis (a qualitative assay to assess antigens) has shown that the Lab antigen is a 40 kilodalton (by relative mobility) protein detectable in A549 cells (Radosevich, et al., 1985). The epitope does not appear to be modulated or blocked by lectins, and is selectively expressed on the cell surface, primarily localized to the plasma membrane. (Radosevich, et al., 1985, 1991). Lab is sensitive to proteases, but not lipid or carbohydrate altering reactions (Radosevich, et al., 1985). The biochemical properties of Lab are consistent with Lab being an integral membrane protein.
[0049] Having a deduced amino acid sequence from the lab gene of the present invention, allows further characterization of the Lab protein. Extensive computer analysis of Lab has identified a eukaryotic leader-like sequence and theoretical cleavage site, 3 myristylation sequence sites, a weak membrane anchoring domain (MAD I), and a strong membrane anchoring domain (MAD II) ( FIG. 2 ). [(In the HAAH sequence, there are 58 (theoretical) amino acids followed by a sequence homology in the Lab protein coding sequence and an additional 445 amino acid 3′ to the lab sequence.)]
[0050] When Lab is expressed as a fusion protein in a bacterial GST fusion expression system (pGEMEX-2T) (Amereham Pharmacia Biotech, Inc., Piscataway, N.J., 08854, USA), and subjected to Western blot analysis using the antibody MCA 44-3A6, the resulting blots demonstrate that the expressed cleaved fusion protein has the same relative mobility as the protein detected in A549 cells. The deduced molecular weight for Lab is 28.8 kilodaltons and on Western blots it has a relative mobility identical to the form expressed by A549 cells (apparent relative mobility=40 kilodaltons). The 55 glutamic and 27 aspartic acid residues a (82 residues combined) are almost uniformly distributed throughout the protein (255 amino acids total; 228 no leader sequence), except for the leader sequence and the strongest membrane anchoring domain (MAD II). These data suggest that Lab migrates anomelously in SDS gels. Cell lines other than A549 (e.g. adenocarcinomas DU-145, ATCC # HTB-81; ZR-75-1, ATCC # CRL-1504, and so forth) have an antigen detected with the same molecular weight antigen as Lab. Neither a 85-90 kilodalton molecular weight species, nor a 52 and 56 kilodalton molecular weight species is noted when probing Western blots for Lab.
[0051] Epitope Mapping Using the Antibody MCA 44-3A6 and Vaccine Feasibility of Lab: Using Polymerase Chain Reaction and the GST fusion protein system, subclones of the protein coding region were made, and epitopes mapped the binding of MCA 44-3AS to six amino acids (PTGEPQ) representing amino acids #117-122 of Lab (“P” peptide). In order to determine this epitope, the entire coding region was divided into regions, Polymerase Chain Reaction primers were designed to amplify each region, and the subsequent expression of Polymerase Chain Reaction products were cloned and tested by Western blot analysis using the antibody MCA 44-3A6.
[0052] The DNA fragment representing the positive Western blot result was then further subdivided. Polymerase Chain Reaction products were generated and cloned, expressed, and tested via Western blot. Constructs were made in this way both from the 5′ end and the 3′ end and the intervals of the number of amino acids were reduced upon each round. This resulted in the last round representing a one amino acid difference from the previous round (in both directions), such that one could deduce the exact binding site of the MCA 44-3A6. This demonstrates that at least these six amino acids are exposed to the external cell surface. To further prove the point, the DNA encoding only these six amino acids have been cloned and the fusion protein is positive by Western blot analysis. Synthetically prepared “P” peptide can be specifically detected by MCA 44-3A6, and the synthetic peptide was immunogenic in 5 of 5 mice tested. Computer analysis/modelling also predicted that this epitope would be very immunogenic using computer assisted analysis (GCG programs) (Genetics Computer Group, Madison, Wis. 53703).
[0053] Vaccine Preparation: A vaccine is a preparation of antigen(s), which when given to a host, results in the host producing antibodies against the antigen(s). The host response results in the host being immune to the disease to which the vaccine was directed. Vaccine treatment therefore, prevents the clinical presentation of a disease, without the host being exposed to the disease causing agents. Lab has all the characteristics of a preferred cancer vaccine. The lab gene is frequently expressed by tumors which look like adenocarcinomas, is expressed an the outside of the cells, is expressed by all of the cells within a given S cancer, is expressed at all times by these cancer cells, and is infrequently expressed by normal cells. Lab protein (peptides) can be produced by any number of methods using molecular cloning techniques, and can be produced in large quantities, thus making it a practical antigen to use as a vaccine. After the Lab protein has been purified so that it is suitable for injection into humans, it is administered to individuals intradermally, subcutaneously, or by other routes, so as to challenge the immune system to produce antibodies against this protein (peptides).
[0054] The use of molecular modeling and computer assisted analysis GCG programs (Genetics Crystal Group, Madison, Wis. 53703) allows the identification of small portions of a molecule, slightly larger than an epitope (six to seven amino acids for proteins), which are expected to be on the surface of a protein molecule. In addition, the degree of hydrophobicity or hydrophilicity of a given sequence, and how immunogenic the sequence would be in animals, can be determined (Genetics Crystal Group, Madison, Wis. 53703). After defining which sequences meet these criteria, the peptides are synthetically made, or produced by a number of standard methods. One or more of these peptides can then be formulated to be used as a vaccine, and administered to the host as outlined above, as a vaccine.
[0055] A vaccine comprising a molecule having an amino acid sequence selected from the group of sequences encoded by the cDNA of FIG. 1 , sequences of FIG. 2 , encoded by the cDNA, the peptides APPEDNPVED, EEQQEVPPDT, DGPTGEPQQE, and EQENPDSSEPV, and any fragments or combinations thereof.
[0056] A given vaccine may be administered once to a host, or may be administered many times. In order for some patients to recognize a given vaccine, an acjuvant may also need to be administered with the peptides. Adjuvants are nonspecific immune stimulators which heighten the immune readiness and aid in the conversion of the host from not having detectable serum antibodies to having very high titer serum antibodies. It is this high level (titer) of antibodies, which effectively protects the host from the diseases or conditions to which the antibodies are directed,
[0057] Functional Studies: Studies directed at understanding the cellular function(s) of Lab are extensions of cell localization/characterization studies (Siddique, et al., 1992). Changes in levels of Lab in response to extracellular exposure to various response to extracellular exposure to various cations (Ca++, Mg++, Cu++, and Fe++) were undertaken. Lab expression in A549 cells was only modulated by Ca++. Using the highly specific fluorescent Fura-2/AM Ca++ method of measuring cytosolic Ca++, (Molecular Probes Inc., Eugene, Oreg. 97402) it was demonstrated that; 1) the internal Ca++ concentration is higher in A549 cells than in QU-DB cells, and 2) that the A549 cell line responds to various external Ca++ levels (Siddique, et al., 1992). Since pH can modulate intracellular free Ca++ levels, external pH manipulations should result in changes in the expression levels of Lab. Extracellular pH changes (in the presence of normal Ca++ concentrations) result in 1) a parallel change in intracellular pH as measured by SNARF-1 AM/FACS, (Molecular Probes Inc., Eugene, Oreg. 97402) 2) transcript levels increase for Lab (when compared to GAPDH expression via Northern blot); and that 3) Lab protein also increases (using Western/Slot blot analysis). The intracellular changes in pH (due to external changes) for A549 cells are Identical to those reported for normal cells. The increased expression of lab is also not due to cell death (as measured by MTT assays) (Siddique, et al., 1992). In addition, incubation of recombinant Lab at various pH solutions does not alter immunoreactivity. Preliminary data suggests that when these experiments are conducted on A549 cells grown in reduced Ca++, the induced expression of lab is blunted.
[0058] Methods of Diagnosing Cancer Cells in a Sample of Cells: Biological samples from a subject are used to determine whether cancer cells are present in the subject. Examples of suitable samples include blood and biopsy material. One method of diagnosis is to expose DNA from cells in the sample to a labeled probe that is capable of hybridizing to the lab gene, or a fragment thereof, under stringent conditions, e.g. 6×ssc; 0.05×blotto; 50% formamide; 42° C. (Sambrook, et al., 1990). Of course, the hybridizing conditions are altered to achieve optimum sensitivity and specificity depending on the nature of the biological sample, type of cancer, method of probe preparation, and method of tissue preparation.
[0059] After contacting the sample with the probe, the next step is determining whether the probe has hybridized with nucleotide sequences of the DNA from the sample, from which the presence of the lab gene is inferred, said presence being diagnostic of cancer.
[0060] Another diagnostic method is to obtain monoclonal antibodies preferably labeled, either antibodies already existing, or new ones directed to the antigenic peptides that are aspects of the present invention, and contact a sample with these to detect the Lab antigen. These monoclonal antibodies are useful in the development of very specific assays for the detection of Lab antigen, and allow the tests to be carried out in many different formats; resulting in a broader application in science and medicine.
[0061] The current invention is useful in that it describes a new gene which is expressed on the surface of tumors, which was not previously reported. This gene is not tissue specific, and therefore will allow the detection of tumors regardless of the organ in which they arise. Likewise, the use of this gene to produce a vaccine for these tumors, will have a very broad application. Diagnostic tests will also have this broad tissue use, making the detection of Lab/lab a “pan-marker” for cancer, in particular for what have been designated previously, adenocarcinomas.
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BACKGROUND OF THE DISCLOSURE
1. Field of the Invention
The present invention relates to the field of manufacturing integrated circuits and, more particularly to an apparatus for controlling the flow of process material into a thin film deposition chamber.
2. Description of the Background Art
Chemical vapor deposition (CVD) processes are widely used to deposit material layers on semiconductor devices and integrated circuits. These CVD processes deposit material layers on semiconductor devices and integrated circuits by reacting gaseous precursors adjacent to the surfaces thereof. The reaction rate for CVD processes is controlled via temperature, pressure and precursor flow rates.
Some precursors are derived from low vapor pressure liquids. The low vapor pressure liquids are transported using a bubbler (or boiler). The bubbler includes an ampoule containing a source of the liquid precursor. A carrier gas provided to the ampoule saturates the liquid precursor and transports the vapor to a process chamber. The amount of vapor transported depends on the process chamber pressure, the carrier gas flow rate, as well as the vapor pressure in the ampoule containing the source of liquid precursor. As such, the flow rate of vaporized precursor is difficult to control, which decreases the quality of material layers produced therefrom.
Additionally, liquid precursor shut-off is problematic due to residual liquid precursor in the lines between the ampoule and the process chamber. This residual liquid precursor may be continuously leaked into the process chamber after shut-off resulting in chamber and/or substrate contamination.
Thus, there is a need to provide an apparatus for improved control of a liquid precursor to a process chamber.
SUMMARY OF THE INVENTION
An apparatus for controlling the flow of liquid material from a liquid material source to a process chamber is disclosed. The apparatus comprises an injector/vaporizer disposed proximate to the process chamber. The injector/vaporizer includes one or more piezoelectric grids located proximate to a vaporization chamber. The one or more piezoelectric grids function to control the flow of liquid material into the vaporization chamber. Each piezoelectric grid includes interlocking arrays of strips attached to a frame.
BRIEF DESCRIPTION OF THE DRAWINGS
The teachings of the present invention can be readily understood by considering the following detailed description with the accompanying drawings, in which:
FIG. 1 is a schematic illustration of an apparatus that can be used for the practice of embodiments described herein;
FIG. 2 is a schematic illustration of an injector/vaporizer used for the practice of embodiments described herein;
FIG. 3 is a top view of the vaporizing chamber of the injector/vaporizer shown in FIG. 2 ;
FIG. 4 is a cross-sectional view of a portion of the top view of the vaporizing chamber shown in FIG. 3 ;
FIG. 5 is an expanded view of a portion of the liquid material outlet passage shown in FIG. 4 ;
FIG. 6 illustrates a top view of a grid including interlocking arrays of strips attached to a frame;
FIG. 7A illustrates two or more grids stacked perpendicular to one another;
FIG. 7B is a top view of the grids depicted in FIG. 7A showing that the interlocking arrays of strips form a plurality of pores;
FIG. 8 is a flow diagram illustrating the operation of the injector/vaporizer; and
FIG. 9 depicts a timing diagram for operating the injector/vaporizer.
DETAILED DESCRIPTION
FIG. 1 is a schematic representation of a deposition system 10 that can be used to perform integrated circuit fabrication in accordance with embodiments described herein. The deposition system 10 typically includes a precursor delivery system 100 , a process chamber 110 , and a gas delivery system 120 , along with other hardware components such as power supplies (not shown) and vacuum pumps (not shown). Examples of such a deposition system include TxZ™ systems and DxZ™ systems, commercially available from Applied Materials, Inc., Santa Clara, Calif.
In the precursor delivery system 100 , a liquid precursor 112 is delivered to a gas delivery system 120 through conduction line 114 . A pressure regulator 116 is connected to the conduction line 114 between the precursor delivery system 110 and the gas delivery system 120 . The pressure regulator pressurizes the liquid precursor within a range of about 10 psi to about 100 psi.
In the gas delivery system 120 , a carrier gas, such as, for example, helium (He), is provided to an injector/vaporizer 122 via conduction line 124 . An optional liquid flow meter (LMF) 126 connected to conduction lines 121 , 123 monitors the flow rate of liquid precursor to the injector/vaporizer 122 .
The gas delivery system 120 communicates with a showerhead (not shown) in the process chamber 110 . Process gases such as vaporized liquid precursor and/or carrier gas flow from the injector/vaporizer 122 to the process chamber 110 through heated conduction line 132 .
Referring to FIG. 2 , the injector/vaporizer 122 comprises a body block 213 made of metallic materials superior in thermal conductivity, heat resistance and corrosion resistance such as, for example, stainless steel. The body block 213 includes at least one heater 214 .
A liquid material inlet passage 215 and a gas outlet passage 216 are formed within the body block 213 without crossing each other. A liquid material outlet opening 219 for the liquid material inlet passage 215 opens onto an upper surface 220 of the body block 213 , so as to introduce a liquid material (LM) into a vaporizing chamber 232 .
The gas outlet passage 216 opens onto the upper surface 220 of the body block 213 , such that a gas (G) generated in the vaporizing chamber 232 exits the body block 213 therethrough. A carrier gas inlet passage 217 also opens onto the upper surface 220 of the body block 213 . The carrier gas mixes with the vaporized liquid material in the vaporizing chamber and carries it out through the gas outlet passage 216 .
Referring to FIG. 3 , the liquid material outlet opening 219 on the upper surface 220 of the body block 213 opens at a central portion 226 thereof. A groove 227 that is concentric with the liquid material outlet opening 219 is formed around the central portion 226 . The gas outlet passage 216 and the carrier gas inlet passage 217 are also encompassed by the groove 227 .
Typically, the inside diameter of the liquid material outlet opening 219 has dimensions of about 0.5 mm (millimeters) to about 1.5 mm. The inside diameter of the gas outlet passage 216 and the carrier gas inlet passage 217 have dimensions of about 2 mm to about 4 mm. The distance from the liquid material outlet opening 219 to the groove 227 formed concentrically therewith is about 3 mm to about 6 mm. The dimensions of the liquid material outlet opening 219 , the gas outlet passage 216 , the carrier gas inlet passage, as well as the distance between the liquid material outlet opening 219 and the groove 227 may be variable depending on the volume of liquid material (LM) introduced through the liquid material inlet passage 215 .
Referring again to FIG. 2 , a diaphragm 234 and control valve plunger 236 is positioned on the upper surface 220 of the body block 213 over the groove 227 . The diaphragm 234 along with the control valve plunger 236 functions to shut-off the flow of the gas (G) generated in the vaporizing chamber 232 through the gas outlet passage 216 . The diaphragm 234 is pressed by the control valve plunger 236 against the central portion 226 to stop the flow of liquid material from the liquid material outlet opening 219 into the vaporization chamber 232 .
FIG. 4 shows a cross-section of the upper surface 220 of the body block 213 depicted in FIG. 3 , taken along line 1 - 1 ′. At least one grid 405 is positioned at the top of the liquid material inlet passage 215 near the liquid material outlet opening 219 . The one or more grids 405 function to control the flow rate of the liquid material into the vaporizer chamber 232 . The one or more grids 405 may optionally be positioned perpendicular to each other as shown in FIG. 5 .
FIG. 6 illustrates a top view of a grid 405 including interlocking arrays of strips 502 , 504 attached to a frame 500 . Each strip in the array of strips 502 is electrically connected to the others via contacts 508 . Each strip in the array of strips 504 is electrically connected to the others via contacts 506 .
The strips 502 , 504 are made of a piezoelectric material that expands uniformly in each direction and has a maximum material expansion of n. Thus, the distance between each of the strips 502 , 504 should be no more than 2n and the distance between the edges of each strips 502 , 504 , and the frame 500 should be no more than n.
When the maximum expansion for the grid 405 is reached, the aperture opening thereof is zero. This is because each of the interlocking arrays expands such that adjacent strips 502 , 504 touch one another as well as the edges of the frame.
Referring to FIGS. 7A-7B , the two or more grids 405 may be stacked perpendicular to one another such that the interlocking arrays of stripes 502 , 504 form a plurality of pores 702 . As the arrays of strips on each of the grids 405 expands to the maximum expansion of n, the diameter of each pore in the plurality of pores 702 is reduced to zero. The distance between each of the two or more grids 405 is variable. The distance between each of the grids is preferably less than about 1 cm.
The piezoelectric material should be formed of a material that is inert with respect to the liquid material to be vaporized. Additionally, the piezoelectric material should be inert with respect to pressure changes within the liquid material inlet passage 215 , as well as vaporization temperatures, magnetic noise and electrical noise.
A voltage is applied to each of the arrays of strips 502 , 504 through contacts 506 , 508 . The amount of expansion for each strip depends on the composition of the piezoelectric material as well as the magnitude of the applied voltage. As such, varying the voltage applied to the strips 502 , 504 adjusts the size of the opening between adjacent strips, thereby affecting the flow rate of liquid material into the vaporizer chamber 232 .
The piezoelectric materials should have a Young's modulus of less than about 250 GPa. Examples of suitable piezoelectric materials include barium titanate (BaTiO 3 ) and lead zirconate titanate (PZT), among others.
Typically, there is a pressure-drop across the one or more grids 405 between the liquid material inlet passage 215 and the vaporizing chamber 232 . The liquid material (LM) is vaporized due to the pressure-drop along with the heating thereof in the vaporizing chamber 232 . As a result a desired flow rate of gas (G) can be provided to the process chamber 110 (FIG. 1 ).
Referring to FIG. 3 , a flow of vaporized liquid material radiates from the liquid material outlet opening 219 across the center portion 226 toward the groove 227 . The carrier gas provided through carrier gas inlet passage 217 transports the vaporized liquid material out of the vaporizing chamber 232 through the gas outlet passage 216 . The carrier gas may be, for example, an inert gas (IG), such as nitrogen (N 2 ), argon (Ar), or helium (He).
Alternatively, the vaporizing chamber 232 may be formed within the body block 213 . Additionally, the heater 214 is not always positioned within the body block 213 , as shown in FIG. 2 . For example, a heater (not shown) may be wound around conduction lines 121 , 123 to preliminarily heat the liquid material (LM) supplied to the injector/vaporizer 122 , thereby providing the thermal energy required for the vaporization to the liquid material (LM) in the vaporizing chamber 232 . For such an embodiment, vaporization of the liquid material (LM) within the injector/vaporizer 122 provides a larger flow rate of gas (G) to the process chamber 110 than for a heater 214 positioned within the body block 213 .
A close proximity for the injector/vaporizer 122 to the process chamber 110 is preferred, so the vapor created does not have to travel over a large distance before dispersion into the process chamber 110 . As such, less plating or clogging of transfer lines, such as conduction line 132 , is likely. Moreover, the close proximity of the injector/vaporizer 122 to the chamber 110 significantly reduces the likelihood of pressure gradients that affect the deposition process.
For example, if the deposition system 10 is operating at a pressure of about 1.5 torr, a 0.5 torr drop in pressure is significant enough to degrade the properties of the film being deposited. Additionally, the close proximity of the injector/vaporizer 122 provides for faster processing of wafers by reducing the time lag associated with removing gaseous material from a conduction line after injector/vaporizer 122 shut-off. Byproducts of the deposition process can be pumped out of just the chamber instead of the extra volume of the delivery system also. Less excess process material is carried to the chamber which results in less extraneous deposition on chamber components and cross-contamination of neighboring chambers during wafer transfer.
The flow of liquid material (LM) through the injector/vaporizer 122 may be pulsed by alternately opening and closing the one or more grids 405 . FIG. 8 depicts a flow diagram of the method of the present invention. The method 800 begins at step 802 with the one or more grids 405 ( FIGS. 4-5 ) in the injector/vaporizer 122 at their maximum expansion, n, so the flow of liquid material (LM) into the vaporizing chamber 232 is shut-off.
In step 804 , the one or more grids 405 are opened for a first peirod of time T 1 . The one or more grids 405 are opened by contracting one or more of the interlocking arrays of strips 502 , 504 . The strips 502 , 504 may be contracted by varying the applied voltage provided through contacts 506 , 508 .
At step 806 , the one or more grids 405 are expanded again to their maximum expansion, n, for a second time period T 2 , so the flow of liquid material (LM) into the vaporizing chamber 232 is shut-off. The opening and closing steps are repeatedly cycled at step 808 until a third period of time T 3 has elapsed. After the third period of time has elapsed, the method ends at step 808 with the one or more grids 405 closed.
FIG. 9 depicts a timing diagram of a drive signal 900 produced by a controller (not shown) that controls the operation of the injector/vaporizer 122 . The drive signal 900 represents a voltage or current delivered to the one or more piezoelectric grids 405 . When the drive signal 900 is at first level 902 , the arrays of strips 502 , 504 are fully expanded to shut-off the flow of liquid material (LM). When the drive signal 900 is at a second level 904 , the arrays of strips 502 , 504 are not fully expanded to provide a flow of liquid material (LM) therethrough. The controller maintains the drive signal 900 at the first level 902 for a peirod of time T 1 . T 1 is typically between approximately 2 milliseconds and 30 milliseconds. The controller then changes the signal 900 to level 904 for a peirod of time T 2 . T 2 is typically between approximately 1 second and 10 seconds.
The one or more piezoelectric grids 405 expand or contract over a duty cycle of duration T 1 +T 2 . The flow rate can be adjusted between about 0.5 sccm to about 500 sccm by varying the parameters. For example, if the one or more piezoelectric grids 405 operate with about a 2 second duty cycle during which the piezoelectric grids 405 are open for approximately 5 milliseconds, the flow rate for the liquid material can be increased by decreasing time period T 2 , for fixed T 1 . Alternatively, decreasing time period T 1 , for fixed T 2 decreases the flow rate.
For a fixed flow rate, the volume of liquid material flowing through the piezoelectric grids 405 can be controlled by repeating the duty cycle for a time period T 3 . T 3 is typically between about 10 seconds to about 600 seconds. Additionally, T 1 and T 2 may be shifted up or down in the duty cycle so that the piezoelectric grids 405 are opened at any time during the duty cycle.
The injector/vaporizer 122 may be controlled by a processor based system controller 150 (FIG. 1 ). The system controller 150 includes a programmable central processing unit (CPU) (not shown) that is operable with a memory, a mass storage device, an input control unit, and a display unit. The system controller 150 further includes power supplies (not shown), clocks (not shown), cache (not shown), input/output (I/O) circuits (not shown) and the like. The system controller 150 also includes hardware for monitoring wafer processing through sensors (not shown) in the deposition chamber 110 . Such sensors measure system parameters such as wafer temperature, chamber atmosphere pressure and the like. All of the above elements are coupled to a control system bus (not shown).
The memory contains instructions that the central processing unit (CPU) executes to facilitate the performance of the deposition system 110 . The instructions in the memory are in the form of program code. The program code may conform to any one of a number of different programming languages. For example, the program code can be written in C, C++, BASIC, Pascal, as well as a number of other languages.
The mass storage device stores data and instructions and retrieves data and program code instructions from a processor readable storage medium, such as a magnetic disk or magnetic tape. For example, the mass storage device can be a hard disk drive, floppy disk drive, tape drive, or optical disk drive. The mass storage device stores and retrieves the instructions in response to directions that it receives from the central processing unit. Data and program code instructions that are stored and retrieved by the mass storage device are employed by the central processing unit for operating the deposition system 110 . The data and program code instructions are first retrieved by the mass storage device from a medium and then transferred to the memory for use by the central processing unit.
The input control unit couples a data input device, such as a keyboard, mouse, or light pen, to the central processing unit to provide for the receipt of a chamber operator's inputs. The display unit provides information to a chamber operator in the form of graphical displays and alphanumeric characters under control of the central processing unit.
The control system bus provides for the transfer of data and control signals between all of the devices that are coupled to the control system bus. Although the control system bus is described as a single bus that directly connects the devices in the central processing unit, the control system bus can also be a collection of busses. For example, the display unit, input control unit and mass storage device can be coupled to an input-output peripheral bus, while the central processing unit and memory are coupled to a local processor bus. The local processor bus and input-output peripheral bus may be coupled together to form the control system bus.
The system controller 150 is coupled to various elements of the deposition system 110 , via the control system bus and the I/O circuits. These elements may include the injector/controller 122 and the liquid flow meter 126 . The system controller 150 provides signals to the chamber elements that cause these elements to perform operations for depositing a layer of material therein.
Although various embodiments which incorporate the teachings of the present invention have been shown and described in detail herein, those skilled in the art can readily devise many other varied embodiments that still incorporate these teachings. | An apparatus for controlling the flow of liquid material from a liquid material source to a process chamber is disclosed. The apparatus comprises an injector/vaporizer disposed proximate to the process chamber. The injector/vaporizer includes one or more piezoelectric grids located proximate to a vaporization chamber. The one or more piezoelectric grids function to control the flow of liquid material into the vaporization chamber. Each piezoelectric grid includes interlocking arrays of stripes attached to a frame. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a carbon preform and a carbon/carbon composite material.
2. Prior Art
A carbon/carbon composite material is light in weight and has excellent thermal resistance and, further, is superior in sliding movability, strength properties, fracture toughness, and thermal conductivity, etc., so that it has been used as industrial materials such as heat resistant materials, slidable materials, e.g., brake materials, and furnace materials.
In the manufacture of the carbon/carbon composite material, generally, a method for manufacturing a carbon preform and densifying it has been employed in order to obtain sufficiently high strength and sliding movability.
A method for manufacturing a carbon preform is disclosed in, e.g., Japanese Pat. Appln. Laid-Open Gazette No. Sho 49-62768. According to this method, a nonwoven fabric sheet obtained by needle-punching a carbon fiber aggregate is cut into an annular shape, and a plurality of annular nonwoven fabric sheets each obtained in this manner are stacked to a predetermined thickness, thereby preparing a carbon preform.
According to this method, however, large amounts of waste nonwoven fabric sheets remain after cutting. Although in the above gazette No. Sho 49-62768 this waste material is made into fibers by fibrillation and blending so that it can be recycled, since the fibers obtained in this manner have low quality, they cannot be used to form a carbon preform. Accordingly, the method disclosed in said gazette has a disadvantage that the yield becomes very low.
A method for manufacturing a carbon preform with an increased yield is disclosed in, e.g., Japanese Pat. Appln. Laid-Open Gazette No. Hei 5-201763. According to this method, infusibilized fibers obtained by spinning a carbonaceous pitch and subjecting the spun carbonaceous pitch to infusibilization are filled into a container by forced charging or free fall. The fibers are then calcined and molded under a uniaxial pressure, thereby manufacturing a carbon preform.
According to a method disclosed in Japanese Pat. Appln. Laid-Open Gazette No. Hei 5-59863, infusibilized fibers obtained by infusibilizing pitch fibers, and/or precarbonized fibers obtained by precarbonizing infusibilized fibers and having an oxygen/carbon atomic ratio of 0.10 to 0.52, are carbonized under pressure or with a press machine. The resultant fibers are further carbonized or graphitized as required under normal pressure, thereby manufacturing a carbon preform.
According to a method disclosed in Japanese Pat. Appln. Laid-Open Gazette No. Hei 1-203267, precarbonized fibers, which are obtained by precarbonizing, in an inert atmosphere at 350° to 800° C. infusibilized fibers obtained by infusibilizing pitch fibers, and which have a hydrogen/carbon atomic ratio of 0.41 or less, are carbonized under pressure or with a press machine, thereby manufacturing a carbon preform.
Furthermore, according to a method disclosed in Japanese Pat. Appln. Laid-Open Gazette No. Hei 6-172030, precursor fibers of infusibilized carbon fibers are molded under a uniaxial pressure at a processing temperature lower than a temperature at which infusibilization is carried out, and the resultant fibers are carbonized under normal pressure, thereby manufacturing a carbon preform.
When these methods are employed, the carbon preform can be manufactured by using necessary amounts of respective raw material fibers in accordance with the final size, thickness, or fiber volume content (Vf) of the target preform, without wasting the fibers to a certain degree. The carbonizing step of the infusibilized fibers, precarbonized fibers, or precursor fibers of carbon fibers is executed simultaneously with the molding step, thereby simplifying the steps.
According to the conventional manufacturing methods, however, an internal defect of the preform cannot sometimes be removed completely. Therefore, a further improvement is demanded in the manufacturing method.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a method for manufacturing a carbon preform and a carbon/carbon composite material each having a very high yield and an excellent moldability in accordance with a simple process.
More specifically, the first aspect of the present invention relates to a method for manufacturing a carbon preform comprising the steps of charging a container with pitch fibers obtained by melt spinning a carbonaceous pitch to fill the container during spinning, infusibilizing the thus filled pitch fibers, and calcining and molding the infusibilized pitch fibers under a uniaxial pressure.
The second aspect of the present invention also relates to a method for manufacturing a carbon/carbon composite material, wherein the carbon preform obtained in the above manufacturing method is densified.
The carbon preform defined in the present invention refers to a product obtained by calcining infusibilized fibers under a uniaxial pressure and molding the calcined fibers.
The methods of manufacturing a carbon preform and a carbon/carbon composite material according to the present invention will be described in detail.
The pitch fibers defined in the present invention refer to fibers obtained by melt spinning a carbonaceous pitch using a known method and having an average diameter with a lower limit of 5 μm, preferably 7 μm, and an upper limit of 100 μm, preferably 30 μm, more preferably 15 μm, and most preferably 10 μm.
The type of carbonaceous pitch is not particularly limited and a known one can be employed in the present invention. It is particularly preferable to employ a coal- or petroleum-derived pitch having a softening point of 100° to 400° C. preferably 150° to 350° C. The carbonaceous pitch can be either an optical isotropic or anisotropic pitch. An optical anisotropic pitch containing 60 to 100% of optical anisotropic phase is preferably employed.
The spinning speed of the pitch fibers is usually 50 to 2,000 m/min, preferably 100 to 1,000 m/min, and more preferably 150 to 500 m/min. The filament count can be any arbitrary value in the range of 500 to 60,000, preferably 500 to 12,000.
The pitch fibers are filled into the container by charging during spinning.
The container into which the pitch fibers are to be filled by charging preferably has air-permeable bottom and/or side surface. Although the material of the container is not particularly limited, stainless steel is preferably employed. In particular, SUS 304 defined in JIS (Japanese Industrial Standard) is preferably employed.
It is desirable that the rate of hole area (porosity) of the side and/or bottom surface of the container that serves as a measure of air permeability be 10 to 80%, preferably 20 to 70%, and more preferably 30 to 60%. If the porosity is less than the lower limit of this range, the air permeability is decreased, so that drying of the greige goods and infusibilization cannot be performed efficiently. If the porosity is larger than the upper limit of the above-mentioned range, the fibers tend to separate apart in the steps after filling, making it difficult to maintain the shape of the preform.
The fibers can be filled into any shape as far as they can be filled uniformly. A shape close to the target carbon/carbon composite material is preferable so that the steps of forming the carbon/carbon composite material as the final molded product into a desired shape can be eliminated as much as possible. A cylindrical shape, e.g., a polygonal prism or a circular cylinder, is preferably employed, and a circular cylinder is preferably more employed. When the carbon/carbon composite material is used to form a brake material or the like, a circular cylindrical annular container in which another circular cylinder is concentrically at the center of a circular cylinder is preferably employed. A disk-shaped brake material having a concentric hole at the center is formed by using this circular cylindrical annular container.
The inner diameter (in the case of the circular cylindrical annular container, the inner diameter of the outer circular cylinder) can be determined arbitrarily in accordance with the size of the carbon preform, and is desirably set to 100 to 150%, preferably 110 to 130%, of the outer diameter of the target carbon preform.
In the present invention, the way of filling the pitch fibers in the container is not particularly limited as far as the pitch fibers can be filled uniformly. Usually, the container is placed on a movable table, and can be rotated and/or traversed in a predetermined direction within a plane on the table by either one or a combination of the following items (1) to (3):
(1) The container is traversed in the x-axis direction.
(2) The container is traversed in the x- and y-axis directions.
(3) The container is rotated about an arbitrary position inside or outside the bottom surface of the container as the center.
Traverse means to pivot or to move right to left on said table and includes a so-called zigzag movement.
As a preferable, practical combination of items (1), (2) and (3), the container is reciprocally moved in the x-axis direction while it is rotated about the barycenter within the bottom surface of the container as the center.
It is desired that a rotation speed of the container at a charge filling point be lower than the spinning speed of the pitch fibers. More specifically, a spinning speed/rotation speed ratio is 1 to 200, preferably 10 to 100, and more preferably 20 to 60. When determining this speed ratio, not only the rotation speed of the container but also the moving speed of the reciprocal movement must be considered in a strict sense. However, the moving speed of the reciprocal movement is substantially negligible since it is lower as compared with that of the rotation speed.
The pitch fibers should be uniformly filled in the container while rotating the container simultaneously, such that a fiber volume content (Vf) of the carbon/carbon composite material is uniform at any portion. In attaining this object, the moving distance, the moving speed, the moving time and the like of the container with respect to the reciprocal movement can be controlled arbitrarily in accordance with the size or shape of the container. Preferably, two to ten charge filling positions are divisionally provided in the reciprocal direction, and the pitch fibers may be repeatedly filled in the container with a cycle of one to ten minutes by shifting the filling position while changing the respective charge filling times to be proportional to area ratios of the respective divisional portions. For example, three charge filling positions can be divisionally set in the reciprocal direction at the outer periphery, the intermediate portion, and the inner periphery, and the respective filling times can be changed in accordance with a ratio of (1.8 to 6):(1.2 to 4):(1).
If the speed ratio is less than the above-mentioned range, the pitch fibers may be blown off by the centrifugal force and cannot thus be uniformly filled in the container or the fibers may be disconnected, which is not preferable. If the speed ratio exceeds the above-mentioned range, a crack or deformation may occur in the carbon preform, or the pitch fibers cannot be uniformly filled in the container, which is not preferable.
In the carbon preform manufactured in this manner by filling, fibers tend to orient in the reciprocal direction. Hence, when a carbon/carbon composite material obtained by densifying such a carbon preform is utilized as a high-speed rotating body, e.g., a brake disk, it has an endurance against a shear stress which is generated by centrifugal force. Furthermore, this carbon preform can prevent occurrence of an internal defect, e.g., a crack, and can hold a shape substantially close to that of the target molded product even after calcination under pressure.
In the present invention, it is desirable that an areal fiber weight (mass per unit area) of the pitch fibers in the container be 4 to 100 kg/m 2 , preferably 8 to 40 kf/m 2 , the fiber volume content (Vf) thereof be 0.5 to 30 vol %, preferably 1 to 10 vol %, and more preferably 3 to 6 vol %, and a bulk density thereof be 10 to 500 kg/m 3 , preferably 20 to 300 kg/m 3 , and more preferably 30 to 100 kg/m 3 .
If the areal fiber weight, the fiber volume content (Vf) or the bulk density is below the above-mentioned range, the shape holding ability of the carbon preform deteriorates, which is not preferable. If the areal fiber weight, fiber volume content (Vf), or the bulk density exceeds the above-mentioned range, a crack or deformation occurs in the carbon preform, leading to brittle fracture, which is not preferable.
Spinning and charge filling can be performed with or without greige goods. When greige goods are to be used, known ones, e.g., water or silicon-based greige goods, can be used. If the air-permeable container described above is used for drying the greige goods, the greige goods can be dried efficiently within 15 hours or less, preferably 7 hours or less, under normal pressure at a temperature of 100° C. or less, preferably 80° C. or less.
Although continuous fibers are mainly preferably used as the pitch fibers to be filled, short fibers can also be used. When short fibers are used, the length of the fiber is not particularly limited as far as its lower limit is 1 cm, preferably 5 cm, more preferably 10 cm, further more preferably 50 cm, and most preferably 1 m, and short fibers having an arbitrary length can be used. While being filled in the container, if the pitch fibers are cut partly or entirely so as to reach the lower limit mentioned above and are mixed, a filling density can be made uniform. In this case, mixing proportions of the continuous fibers and the cut fibers can be set arbitrarily. If the length of the short fibers does not reach the lower limit mentioned above, the bending strength and the tensile strength of the carbon/carbon composite material obtained by using this carbon preform decrease, which is not preferable.
It is preferable that the pitch fibers charged and filled in the container be directly subjected to infusibilization without being extracted from the container, so that occurrence of an internal defect, e.g., a crack, can be prevented.
Infusibilization can be performed in an oxidizing gas atmosphere at a temperature of 50° to 400° C., preferably 100° to 350° C. As the oxidizing gas, air, oxygen, oxynitride, oxysulfide, a halogen, or a mixture thereof can be used as required.
A wind velocity in which the above oxidizing gas passes through the pitch fibers filled in the air-permeable container is 0.2 to 4 m/sec, preferably 0.5 to 2 m/sec. If the container to be filled has an air permeability as described above, infusibilization can be performed more uniformly and more efficiently while requiring a lower gas pressure as compared to a case wherein it does not have air permeability. Thus, the shape of the fibers as they are filled can be easily maintained since a gas pressure can be lowered.
If the wind velocity is larger than the upper limit of the above-mentioned range, the pitch fibers filled in the container move around undesirably due to the influence of the wind pressure, so that the uniformity in areal fiber weight, fiber volume content or a bulk density of the fibers during filling cannot be easily maintained, which is not preferable. If the wind velocity is lower than the lower limit of the above-mentioned range, non-uniform infusibilization of the pitch fibers sometimes takes place in the container, leading to a crack, which is not preferable.
The infusibilization time is a time period after which the fiber no longer exhibits a heat fusibility. The lower limit of the infusibilization time is 10 minutes, preferably 30 minutes, and the upper limit thereof is 20 hours, preferably 10 hours.
If the infusibilization time does not reach the above-mentioned time range, the infusibilized fibers fuse together to easily cause cracking. If the infusibilization time exceeds the above-mentioned time range, the fiber loses its flexibility. Then, the shape of the fiber cannot be maintained, which is not preferable.
It is possible to transfer, before calcination and molding, the infusibilized fibers in the container which are obtained by infusibilization to a die for a uniaxial pressing while maintaining their shape. Alternatively, it is also preferable that the pitch fibers be uniaxially pressed and calcined in a container having a predetermined shape where they are filled and infusibilized. It is desirable that the material of the die be stainless steel, preferably SUS 304, graphite, or a carbonaceous material, e.g., a carbon/carbon composite material.
Calcination and molding under a uniaxial pressure can be achieved usually within 10 minutes to 10 hours, preferably 30 minutes to 4 hours, with a compression ratio of 5 to 20, preferably 6 to 15, and more preferably 7 to 10, and a temperature range of from an infusibilization temperature up to 2,000° C., preferably 300° to 1,500° C., and more preferably 400° to 1,000° C. The compression in this case can be performed with stroke control of the die as well in accordance with a desired thickness of the carbon preform. If the compression ratio of the stroke does not reach the lower limit of the above-mentioned range, the shape maintaining ability of the carbon preform becomes low, which is not preferable. If the compression ratio of the stroke exceeds the upper limit of the abovementioned range, a crack or deformation occurs in the carbon preform to easily lead to brittle fracture, which is not preferable.
Regarding the atmosphere of this case, calcination is preferably performed in a vacuum or under a reduced pressure, or a non-oxidizing atmosphere of nitrogen gas, argon gas, helium gas, or the like under a reduced pressure, elevated pressure, or normal pressure. The calcination can be performed even in an oxidizing atmosphere, e.g., air, as far as it is performed at a comparatively low temperature, e.g., 400° to 600° C., within a short period of time.
Examples of molding under a uniaxial pressure include molding under uniaxial pressure while heating the die, or uniaxial cold pressure molding and thereafter heating while maintaining compression. The thickness of the carbon preform can be arbitrarily controlled by employing these methods.
Regarding the calcination mentioned above, it is preferable that the product be calcined at a uniform temperature entirely so that it can substantially maintain the target shape.
Thus, the carbon preform is obtained. The fiber volume content (Vf) of this preform is 20 to 80 vol %, preferably 25 to 70 vol %. The lower limit of the bulk density is 100 kg/m 3 , preferably 500 kg/m 3 , more preferably 550 kg/m 3 , and most preferably 600 kg/m 3 . The upper limit of the bulk density is 2,000 kg/m 3 , preferably 1,900 kg/m 3 , and most preferably 1,850 kg/m 3 .
If the fiber volume content (Vf) or the bulk density does not reach the lower limit of the above-mentioned range, the thermal conductivity in the direction off thickness and the mechanical physical properties, e.g., the bending strength or tensile strength, of the preform and the carbon/carbon composite material as the final molded product are lowered, which is not preferable. The shape maintaining ability also decreases, which is not preferable. If the fiber volume content (Vf) or the bulk density exceeds the upper limit of the above-mentioned range, a crack or deformation occurs in the carbon preform to lead to brittle fracture, which is not preferable.
Needle punching can also be performed before or after calcination and molding under a uniaxial pressure, in a direction perpendicular to a laminating direction of the fibers, preferably in the direction of thickness of the entire carbon preform. If needle punching is performed, not only the shape of the carbon preform can be maintained easily, but also the thermal conductivity of the carbon preform and the carbon/carbon composite material obtained by densifying the carbon preform in the direction of thickness can be improved, thereby improving the performance of the resultant heat resistant material and the brake material.
The lower limit of the thermal conductivity of the carbon preform in the direction of thickness at 25° C. is 0.1 W/m.K, preferably 0.2 W/m.K, and more preferably 0.3 W/m.K, and its upper limit is 2.0 W/m.K, preferably 1.0 W/m.K, and more preferably 0.8 W/m.K.
If the thermal conductivity of the carbon preform does not reach the lower limit of the above-mentioned range, the thermal conductivity of the carbon/carbon composite material as the final molded product also tends to decrease, which is not preferable for the raw material of a heat resistant material or slidable material.
The carbon preform can be subjected to calcination prior to densification. In this case, calcination is executed in a non-oxidizing atmosphere at 400° to 3,000° C., preferably 500° to 2,500° C.
The carbon preform obtained in this manner is densified, thereby obtaining a carbon/carbon composite material.
A method for densifying the carbon preform is not particularly limited as far as it can form a carbonaceous matrix, and a known method can be used to perform densification repeatedly until a target bulk density is achieved. In particular, a method in which a carbonaceous matrix is deposited and densified by chemical vapor deposition, and a method in which a carbonaceous matrix employing a pitch as a starting material and/or a carbonaceous matrix made of a phenolic resin, a furan resin or the like is impregnated, calcined and densified, or a method as a combination of these methods is preferably employed.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in detail by way of following Examples and Comparative Examples.
EXAMPLE 1
An inner cylinder having the same height as that of an outer cylinder was concentrically arranged in the outer cylinder. A conical lid was placed on the top portion of the inner cylinder. An annular cylindrical container was thus formed. This annular cylindrical container was made of SUS 304, and had the inner cylinder with an outer diameter of 100 mm, the outer cylinder with an inner diameter of 400 mm and a height of 300 mm, and a porosity of 50%. The interior of the cylindrical container was divided into three portions at a pitch of 50 mm into the outer periphery, the intermediate portion and the inner periphery in the reciprocal direction. Pitch fibers having an average diameter of 13 μm, which were obtained by melt spinning an optical anisotropic petroleum-derived pitch having a softening point of 280° C. at a rate of 300 m/min, were filled in this annular cylindrical container uniformly to a height of 230 mm with (spinning speed)/(the rotation speed off the container)=30 to achieve an areal fiber weight of 14 kg/m 2 , while repeatedly moving the filling position every two minutes with respective filling times at the ratio of 1:1.7:2.3!. At this time, the fiber volume content (Vf) and the bulk density of the pitch fibers filled in the container were 5 vol % and 60 kg/m 3 , respectively.
While maintaining the shape as they were filled, the pitch fibers were subjected to infusibilization in air together with the cylindrical container. Then, while maintaining the shape as they were infusibilized, the pitch fibers were transferred from the cylindrical container to a graphite cylindrical die for uniaxial pressing. Calcination and molding were performed at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 10. Then, a carbon preform having a fiber volume content (Vf) of 37 vol % and a bulk density of 630 kg/m 3 was obtained.
When this carbon preform was extracted from the die, it maintained its shape completely. When this carbon preform was subjected to a non-destructive inspection by an X-ray CT scanner and thereafter cutting inspection, no internal defect, e.g., a crack, was observed. A good preform was thus obtained. When the thermal conductivity of this preform was measured at 25° C. in the direction of thickness, it was 0.6 W/m.K.
The thermal conductivity was calculated in accordance with JIS A 1412-1977 (flat plate comparison method). The sample was made into a length of 200 mm±3%, a width of 200 mm±3%, and a thickness of 10 to 25 mm. As a standard plate, one obtained by coating glass-wool with a polycarbonate resin was used. The sample and the standard plate were stacked and sandwiched between a high-temperature heat source and a low-temperature heat source, and the thermal conductivity was calculated in accordance with the following equation (1):
λ=λ.sub.0 ×(/.sub.0)×(θ.sub.2 -θ.sub.1)/(θ.sub.3 -θ.sub.2) (1)
where θ 1 is the low temperature-side surface temperature (°C.) of the standard plate, θ 2 is the high temperature-side surface temperature (°C.) of the standard plate and the low temperature-side surface temperature of the sample, θ 3 is the high temperature-side surface temperature (°C.) of the sample, λ is the thermal conductivity (W/m.K) of the sample at an average temperature ((θ 3 +θ 2 )/2), λ 0 is the thermal conductivity (W/m.K) of the standard plate at an average temperature ((θ 2 +θ 1 )/2), and and 0 are the thicknesses (m) of the sample and the standard plate, respectively.
The carbon preform obtained in this manner was impregnated with a meso pitch having a softening point of 280° C., and was carbonized by heating at 1,500° C. under a uniaxial pressure of 980 kPa. A carbon/carbon composite material obtained by repeating impregnation and carbonization twice each had no internal defect and was thus good as the brake material.
EXAMPLE 2
The same pitch fibers as those of Example 1 were filled in a cylindrical container under the same conditions as in Example 1 except that (spinning speed)/(rotation speed of the container) was set to 60. At this time, the fiber volume content (Vf) and the bulk density of the pitch fibers filled in the container were 8 vol % and 110 kg/m 3 , respectively.
While maintaining the shape as they were filled, the pitch fibers were subjected to infusibilization in air together with the cylindrical container. Then, while maintaining the shape as they were infusibilized, the pitch fibers were transferred from the cylindrical container to a graphite cylindrical die for uniaxial pressing. Calcination and molding were performed at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 10. Then, a carbon preform having a fiber volume content (Vf) of 60 vol % and a bulk density of 1110 kg/m 3 was obtained.
When this carbon preform was extracted from the die, it maintained its shape completely. When this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner and thereafter cutting inspection, no internal defect, e.g., a crack, was observed. A good preform was thus obtained. When the thermal conductivity of this preform was measured at 25° C. in the direction of thickness, it was 0.6 W/m.K.
EXAMPLE 3
The same pitch fibers as those of Example 1 were filled in a cylindrical container under the completely same conditions as in Example 1. At this time, the fiber volume content (Vf) and the bulk density of the pitch fibers filled in the container were 5 vol % and 60 kg/m 3 , respectively.
While maintaining the shape as they were filled, the pitch fibers were subjected to infusibilization in air together with the cylindrical container. Then, while maintaining the shape as they were infusibilized, the pitch fibers were transferred from the cylindrical container to a graphite cylindrical die for uniaxial pressing. Calcination and molding were performed at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 6. Then, a carbon preform having a fiber volume content (Vf) of 26 vol % and a bulk density of 510 kg/m 3 was obtained.
When this carbon preform was extracted from the die, it maintained its shape completely. When this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner and thereafter cutting inspection, no internal defect, e.g., a crack, was observed. A good preform was thus obtained. When the thermal conductivity of this preform was measured at 25° C. in the direction of thickness, it was 0.6 W/m.K.
EXAMPLE 4
The same pitch fibers as those of Example 1 were filled in a cylindrical container under the same conditions as in Example 1 except that as the cylindrical container, are made of SUS 304 and having a porosity of 25% was employed. At this time, the fiber volume content (Vf) and the bulk density of the pitch fibers filled in the container were 5 vol % and 60 kg/m 3 , respectively.
While maintaining the shape as they were filled, the pitch fibers were subjected to infusibilization in air together with the cylindrical container. Then, while maintaining the shape as they were infusibilized, the pitch fibers were transferred from the cylindrical container to a graphite cylindrical die for uniaxial pressing. Calcination and molding were performed at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio off 10. Then, a carbon preform having a fiber volume content (Vf) of 39 vol % and a bulk density of 660 kg/m 3 was obtained.
When this carbon preform was extracted from the die, it maintained its shape completely. When this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner and thereafter cutting inspection, no internal defect, e.g., a crack, was observed. A good preform was thus obtained. When the thermal conductivity of this preform was measured at 25° C. in the direction of thickness, it was 0.5 W/m.K.
EXAMPLE 5
The interior of a cylindrical container made of SUS 304 and having an outer diameter of 400 mm, a height of 300 mm and a porosity of 50% was divided into four portions at a pitch of 50 mm into the outer periphery, intermediate portion (1), intermediate portion (2) and the inner periphery in the reciprocal direction. Pitch fibers having an average diameter of 13 μm, which were obtained by melt spinning an optical anisotropic petroleum-derived pitch having a softening point of 280° C. at a rate of 300 m/min, were filled in this cylindrical container uniformly to a height of 230 mm with (spinning speed)/(rotation speed of the container)=30 to achieve an areal fiber weight of 14 kg/m 2 , while repeatedly moving the filling position every 2.5 minutes with respective filling times at the ratio of 1:3:5:7!. At this time, the fiber volume content (Vf) and the bulk density of the pitch fibers filled in the container were 5 vol % and 60 kg/m 3 , respectively.
While maintaining the shape as they were filled, the pitch fibers were subjected to infusibilization in air together with the cylindrical container. Then, while maintaining the shape as they were infusibilized, the pitch fibers were transferred from the cylindrical container to a graphite cylindrical die for uniaxial pressing. Calcination and molding were performed at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 10. Then, a carbon preform having a fiber volume content (Vf) of 39 vol % and a bulk density of 660 kg/m 3 was obtained.
When this carbon preform was extracted from the die, it maintained its shape completely. When this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner and thereafter cutting inspection, no internal defect, e.g., a crack, was observed. A good preform was thus obtained. When the thermal conductivity of this preform was measured at 25° C. in the direction of thickness, it was 0.7 W/m.K.
Comparative Example 1
Pitch fibers having an average diameter of 13 μm, which were obtained by melt spinning an optical anisotropic petroleum-derived pitch having a softening point of 280° C., were subjected to infusibilization in air, thus obtaining infusibilized fibers. These infusibilized fibers were filled in a cylindrical graphite die for uniaxial pressing which had an outer diameter of 400 mm and an inner diameter of 100 mm, to a height of 230 mm divisionally with the same filling times as in Example 1 in accordance with continuous drop deposition from the top. The thus filled fibers were then subjected to calcination and molding at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 10. A carbon preform having a fiber volume content (Vf) of 42 vol % and a bulk density of 700 kg/m 3 was thus obtained.
When this carbon preform was extracted from the die, although it maintained its shape and no cracks were formed, a swell was observed at the central portion. When this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner in the direction of thickness, a crack having a length of about 130 mm and a width of about 4 to 5 mm was found in the internal portion of the preform-mentioned to the swell. This crack was confirmed in later cutting inspection as well. As a result, this product could not be used as a carbon preform.
Comparative Example 2
Pitch fibers having an average diameter of 13 μm, which were obtained by melt spinning an optical anisotropic petroleum-derived pitch having a softening point of 280° C., were subjected to infusibilization in air, thus obtaining infusibilized fibers. These infusibilized fibers were filled in a cylindrical graphite die for uniaxial pressing which had a diameter of 400 mm, to a height of 230 mm divisionally with the same filling times as in Example 5 in accordance with continuous drop deposition from the top. The thus filled fibers were then subjected to calcination and molding at 1,000° C. for one hour under a uniaxial pressure by hot pressing with a stroke compression ratio of 8. A carbon preform having a fiber volume content (Vf) of 40 vol % and a bulk density of 680 kg/m 3 was thus obtained.
When this carbon preform was extracted from the die, it maintained its shape, and no cracks were observed. Also, no change in thickness caused by a swell was detected. Thus, this carbon preform seemed to have a good moldability. When, however, this carbon preform was subjected to a non-destructive inspection by the X-ray CT scanner, a crack having a length of about 220 mm and a width of 1 to 2 mm was found inside the preform. This crack was confirmed in later cutting inspection as well. As a result, this product could not be used as a carbon preform.
EFFECTS OF THE INVENTION
According to the manufacturing method of the present invention, a carbon preform and a carbon/carbon composite material having a good moldability can be manufactured at a very high yield with a simple process. | A method for manufacturing a carbon preform comprising the steps of charging a container with pitch fibers obtained by melt spinning a carbonaceous pitch to fill therein during spinning, infusibilizing the thus filled pitch fibers, and calcining and molding the infusibilized pitch fibers under a uniaxial pressure, and a method for manufacturing a carbon/carbon composite material comprising densifying the carbon preform. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
TECHNICAL FIELD
[0002] The present disclosure relates to toilets. More specifically, the present disclosure is related to removing unpleasant odor.
BACKGROUND OF INVENTION
[0003] Toilets are commonly used by people to dispose waste such as human feces and urine. Inevitably, users of the toilets are faced with the unpleasant odor and smell of the waste.
[0004] Although air fresheners and candles may provide a way to mask or eliminate the unpleasant odor, using these products may also cause the scent and odor to mix and become even more unpleasant. Furthermore, the scent and odor may linger and cause embarrassment to others. These odors are amplified when multiple people are using the same toilets, or a user is using a public bathroom this embarrassment may be more.
[0005] The ability to eliminate or reduce gases emanating during or after the discharge of waste, would dramatically reduce the likelihood that odors would become trapped or even linger. Users may relieve themselves without risking embarrassment. Residential and commercial toilet seats on the market do not provide an odor removing feature.
SUMMARY OF INVENTION
[0006] The present disclosure is directed to an odor removing system. The system includes a seat, which includes one or more inlets, a hole, and one or more vent slots, seat hinges to which the seat is pivotally attached, that allow various ranges of seat movement, an odor canal attached to the seat, and an odor channel that transfers waste gases to a ventilation system, outside, or a pipe. In an embodiment, a seat may be sloped such that the rear portion of the seat that is near the seat hinge is at a higher level than the front portion of the seat.
[0007] In an embodiment, the sloped seat may include one or more inlets and vent slots underneath the seat. The seat may be attached to an odor canal, which may be attached to a toilet. The odor canal may be an U-shaped odor canal, which extends around the the toilet and includes one or more gas intake openings, which may be attached to the seat, and one or more emitting end, which may be located at the odor canal.
[0008] In an embodiment, the odor channel is attached to one or more emitting end of the odor canal and transfers waste gases or unpleasant odor into a ventilation system or a pipe that may be located inside a wall. In an embodiment, the odor channel may transfer waste gases or unpleasant odor to directly outside.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present disclosure will be described by way of non-limiting embodiments, with reference to the following drawings, in which
[0010] FIG. 1 is a perspective view of an odor-removing system attached to a toilet, according to an embodiment without a seat cover;
[0011] FIG. 2 is a perspective view of an odor-removing system, according to an embodiment without a seat cover;
[0012] FIG. 3 is a bottom side view of an odor-removing toilet seat, according to an embodiment;
[0013] FIG. 4 is a topside view of an odor-removing system attached to a toilet, according to an embodiment; and
[0014] FIG. 5 is a side view of an odor removing system attached to a toilet, according to an embodiment.
DETAILED DESCRIPTION OF INVENTION
[0015] Reference will now be made in detail to various embodiments of the present disclosure. It should be understood that the scope of the present disclosure is not intended to be limited to those various referenced embodiments. On the contrary, the present disclosure is intended to cover not only the described embodiments, but also various alternatives, modifications, equivalents and other embodiments, which may be included within the spirit and scope of the disclosure as defined by the claims.
[0016] For convenience of explanation, in certain embodiments, the odor removing system is described as being installed on a toilet. Lines may be drawn in greater thickness or elements may be illustrated in enlarged sizes in exaggeration of ordinary scale thereof in the drawings, for the sake of clarity and convenience of explanation. Further, since the terminology used herein is defined in consideration of functions in the present disclosure, it can vary depending on the intention or practice of a user or operator. For example, throughout the present disclosure, the phrase “attached to,” is used to broadly describe various embodiments. It is noted that “attached to” may also mean “joined to” “fastened to”, “fixed to”, “connected to”, “linked to”, “secured to”, “appended to”, “coupled to”, “bound to”, “hitched to”, “riveted to”, or other equivalents thereof. Therefore, definitions of the terms or wordings should be made based on the content throughout the description.
[0017] FIG. 1 is a prospective side view of an odor removing system, according to an embodiment. In this embodiment, an odor removing system comprising: a seat ( 10 ), seat hinges ( 20 ), an odor canal ( 30 ), and an odor channel ( 40 ). In an embodiment, the seat ( 10 ) is attached to a toilet bowl ( 2 ) using seat hinges ( 20 ). In an embodiment, a seat cover ( 50 ) may be included. Although some embodiments of the seat system are described as being implemented in a toilet ( 1 ), the scope of this disclosure is not limited thereto. For example, the odor removing system may be implemented in other settings such as aircrafts, a car seat, or an office seat.
[0018] A seat ( 10 ) and a seat cover ( 50 ) may be configured in various designs. In an embodiment, a seat ( 10 ) may be sloped such that the rear portion of the seat ( 10 ) that is near the seat hinge is at a higher level than the front portion of the toilet seat ( 10 ) that can be lifted. The rear portion of the seat ( 10 ) facilitates the movement of waste gases into an odor canal ( 30 ). In an embodiment, the seat ( 10 ) may be completely enclosed except for an inlet ( 12 ), a hole ( 15 ) and one or more vent slots ( 11 ). When the seat ( 10 ) is in use, cool air enters the toilet bowl ( 2 ) through an inlet ( 13 ). Cool air entering the toilet bowl ( 2 ) from the inlet ( 12 ) causes warmer waste gases to rise. The seat ( 10 ) is sloped such that rising waste gases and the unpleasant odor emanating from the toilet bowl ( 2 ) during and after the discharge of human waste are guided into vent slots ( 11 ) underneath the seat ( 10 ) to the odor canal ( 30 ). The seat ( 10 ) may have various configurations such as flat, raised, soft, hard, rounded, or a combination of surface designs. Embodiments of the disclosure are not limited to the aforementioned seat designs. The seat ( 10 ) in other embodiments of the disclosure, therefore, may incorporate other seat designs not mentioned herein.
[0019] The seat ( 10 ) and seat cover ( 50 ) may be made of various materials. In an embodiment, a toilet seat is made of plastic. The seat ( 10 ) may be in other materials, such as, various metals, ceramic, rock, and wood. The seat ( 10 ) may be in a color and material that match the toilet ( 1 ) for aesthetic purposes. Embodiments of the present disclosure are not limited to the aforementioned seat ( 10 ) and cover ( 50 ) materials.
[0020] In an embodiment, the seat ( 10 ) and seat cover ( 50 ) may be attached to the toilet ( 1 ) using one or more seat hinges ( 20 ), which allow pivotal movement of the seat ( 10 ) and seat cover ( 50 ). In an embodiment, the seat hinges ( 20 ) may include two center brackets ( 21 ), which function as female brackets, and four matching brackets ( 23 ), which function as male brackets that interlock with the center brackets ( 21 ). In some embodiments, seat hinges ( 20 ) may also include a single hinge bar or multiple hinge bars that fasten together and create pivotal movement.
[0021] In an embodiment, the seat hinges ( 20 ) may be configured to include seat hinge technologies such as, automated or assisted opening and closing mechanisms, easy clean configurations, seat sliding and raising mechanisms, and mechanisms allowing for easy seat removal. Seats hinges ( 20 ) in embodiments of the present disclosure are not limited to the aforementioned configurations, materials, or technology.
[0022] In an embodiment, cool air entering an inlet ( 12 ), which is located in the front portion of the seat ( 10 ), guides waste gases and unpleasant odors to be funneled from a toilet bowl ( 2 ) through vent slots ( 11 ), into an odor canal ( 30 ), which is attached the rear portion of the seat ( 10 ) where the vent slots ( 11 ) are located. The odor canal ( 30 ) may be U-shaped. The odor canal ( 30 ) may extend around the left and right sides of the toilet ( 1 ), creating two odor canal arms ( 31 ) on the left and right halves of the odor canal ( 30 ) embracing the toilet ( 1 ). In an embodiment, each odor canal arm ( 31 ) is leveled with the vent slots ( 11 ) of the seat ( 10 ) when the seat ( 10 ) is in the lowered position as shown in FIG. 1 . In an embodiment, the end of each odor canal arms includes an intake entry ( 32 ) that is attached to the seat ( 10 ) and completely covers one end of the vent slots ( 11 ) near the seat hinges ( 20 ). Accordingly, waste gases and unpleasant odor are siphoned into the odor canal ( 30 ) through intake entries ( 32 ) located at the end of each odor canal arm ( 31 ). In an embodiment, each intake entry ( 32 ) is attached to the seat ( 10 ), which creates an airtight connection between one end of the vent slot ( 11 ) and the intake entry ( 32 ) and guides waste gas and unpleasant odor to flow to the odor canal ( 30 ). In an embodiment, the airtight connection between the intake entry ( 32 ) and one end of the vent slot ( 11 ) prevents waste gas or odor leakage and facilitates the movement of waste gases to the odor canal ( 30 ). The odor canal ( 30 ) may be configured in different forms and shapes. Two odor canal arms ( 30 ) may be joined directly to each other, or may use a connector ( 34 ) to connect to the odor canal arms ( 30 ). In an embodiment, the odor canal ( 30 ) may be hollow or include an airway so the waste gas and odor may flow through. The odor canal ( 30 ) may be in Y-shape without the connector ( 34 ).
[0023] In an embodiment, the emitting opening ( 33 ) of an odor canal ( 30 ) is positioned behind the odor canal ( 30 ), which may be attached behind the toilet ( 1 ).
[0024] The odor canal ( 30 ) may be made of various materials. In an embodiment, an odor canal ( 30 ) is made of plastics. The odor canal ( 30 ) may be made of a material or color similar to the material or color of the toilet ( 1 ) for aesthetic purposes. An odor canal ( 30 ) in other embodiments may made of other materials, such as, ceramics, metals, and wood. Embodiments of the present disclosure are not limited to the aforementioned odor canal ( 30 ) materials. An odor canal ( 30 ) in an embodiment of the present disclosure may consist of other materials not mentioned herein.
[0025] Waste gases entering the odor canal ( 30 ) from the toilet bowl ( 2 ) are transferred to the odor channel ( 40 ) through the emitting opening ( 33 ). In an embodiment, the odor channel ( 40 ) extends from the odor canal ( 30 ), and transfers waste gases into a ventilation system ( 60 ), outside or a pipe.
[0026] In an embodiment, an odor channel ( 40 ) configuration may include venting technology. For example, in some embodiments, an odor channel ( 40 ) may be configured to include air admittance valves, sterilization vents, temperature actuated flow reduction devices, and trap/venting devices. Embodiments of the disclosure are not limited to the aforementioned venting technologies. Therefore, an odor channel ( 40 ) in an embodiment of the disclosure may include other venting technologies not mentioned herein. Odor channels may be in a variety of materials, which include, but are not limited to, ceramic, plastic, and lined piping.
[0027] FIG. 2 is perspective view of an odor-removing system attached to a toilet ( 1 ), according to an embodiment. In this embodiment, a seat ( 10 ) and odor canal ( 30 ) are attached to a toilet ( 1 ) with seat hinges ( 20 ). The seat hinges ( 20 ) have female bracket ( 21 ), which is attached to a toilet bowl ( 2 ) and interlocked between two male brackets ( 23 ), according to an embodiment. The male brackets ( 23 ) and female bracket ( 21 ) are fastened together with a hinge bar ( 24 ).
[0028] In an embodiment, the odor removing system moves waste gases from the toilet bowl ( 2 ) into the odor canal ( 30 ). As cool air flows into the inlet ( 12 ) of the seat ( 10 ), thermal buoyancy induces the upward movement of waste gases because waste gases are warmer than the cool air that flows into the inlet ( 12 ). In an embodiment, the sealed design of the seat ( 10 ) forces the rising waste gases into the intake entries ( 32 ) of the odor canal ( 30 ).
[0029] In an embodiment, the odor channel ( 40 ) may be extended to outside of house or building so the odor removing system expels waste gases directly in to the atmosphere. In an embodiment, the odor removing system uses atmospheric pressure to draw warm air emitted during or after the discharge of waste, from the toilet bowl to the atmosphere. This atmospheric pressure, along with the buoyancy of the waste gases, also facilitates the movement of waste gases through the odor removing system.
[0030] In other embodiments, odor removing system may be configured to utilize other mechanisms for gas removal, such as, vacuum power, fan power, and flush power mechanisms. Embodiments of the disclosure, however, are not limited to the aforementioned gas removal mechanisms. Therefore, gas removal mechanisms not mentioned herein may be incorporated into odor canals ( 30 ) in other embodiments of the present disclosure.
[0031] FIG. 3 provides a bottom view of a seat ( 10 ) in an embodiment. According to an embodiment, cool air passes through the inlet ( 13 ) located at the front portion of a seat ( 10 ). The cool air pushes waste gases and unpleasant odor from toilet bowl ( 2 ) to vent slots ( 11 ). Waste gases and unpleasant odors are traveled to the vent slots ( 11 ) located at the rear portion of the seat ( 10 ) near the seat hinges ( 20 ). In an embodiment, the vent slots ( 11 ) are located underneath the toilet seat ( 10 ). The odor canal ( 30 ) is attached to the seat ( 10 ). Each intake entry ( 32 ) of the odor canal ( 30 ) is aligned with one end of the vent slots ( 11 ) when the seat ( 10 ) is in the lowered position. The vent slots ( 11 ) and odor canal ( 30 ) create waste gas pathways so the waste gases and odor flow to the canal. From the odor canal the waste gases and unpleasant odor are transferred to an odor-removing channel ( 40 ), wherein the waste gases and unpleasant odor are expelled into the atmosphere, a pipe, or a ventilation system.
[0032] In an embodiment, a seat ( 10 ) and an odor canal ( 30 ) rely on the natural movement of the waste gases to transfer the gases from the toilet bowl to an odor-removing channel ( 40 ). In other embodiments, a seat ( 10 ) and odor canal may be configured to utilize other mechanisms for gas removal, such as vacuum, fan, and flush powered mechanisms. Seats ( 10 ) and odor canals ( 30 ) in embodiments of the disclosure are not limited to utilizing the aforementioned gas removal mechanisms, and other gas removal mechanisms may be incorporated into seats ( 10 ) and odor canals ( 30 ) in other embodiments of the disclosure.
[0033] FIG. 4 provides a perspective topside view of an odor removing system, according to an embodiment. An odor canal ( 30 ) attaches to the rear portion of a seat ( 10 ) and extends around a toilet to an odor channel ( 40 ). An odor channel ( 40 ) is attached to the odor canal ( 30 ) and extend directly into the atmosphere or attach to a ventilation stack through a wall behind the toilet ( 1 ).
[0034] According to an embodiment, an odor canal ( 30 ) is in a U-shaped configuration, with both odor canal arms ( 31 ) attached to the rear portion of the seat ( 10 ), and attached to the toilet ( 1 ) by seat hinges ( 20 ). As cool air enters the toilet bowl from an inlet ( 13 ), the rising waste gases are migrated from the toilet bowl into the body of the odor canal. The gases are siphoned into the canal through intake entries ( 32 ) located at each end of each odor canal arm ( 31 ), which is aligned with each end of the vent slots ( 11 ). Thereafter, the waste gases are led into an odor channel ( 40 ), which is attached to a emitting opening ( 33 ) at the center of the odor canal ( 30 ). In an embodiment, the odor canal ( 30 ) bends around the base of the toilet ( 1 ) and extends to the left and right sides of the seat ( 10 ).
[0035] FIG. 5 provides a perspective side view of an odor removing system, according to an embodiment. In this embodiment, an odor removing system is attached to a toilet ( 1 ) and the odor channel ( 40 ) may be located behind the toilet ( 1 ). The odor removing system is also connected to a ventilation system ( 60 ). In an embodiment, pressure from the ventilation system ( 60 ) draws waste gas from a toilet bowl ( 2 ), through the odor removing system and into the ventilation system ( 60 ). In other embodiments, the placement and direction of an odor channel ( 40 ) may vary to permit installation of the odor removing system into different venting systems and appliances. The ventilation system may be located inside a wall as depicted in FIG. 5 , or may be located outside a wall.
[0036] It should be appreciated that like reference numerals in the present disclosure are used to identify like elements illustrated in one or more of the figures, wherein these labeled figures are for purposes of illustrating embodiments of the present disclosure and not for purposes of limiting the same.
[0037] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus prescribed embodiments of the present disclosure, persons of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims. | An odor removing system allows a user to remove waste gases and unpleasant odor emanating during or after the discharge of human waste. The system includes a seat with one or more inlets and vent slots to guide waste gases from a toilet bowl into an odor canal. Seat hinges to which the seat is pivotally attached, allows various ranges of seat movement. An odor canal attached to the seat that siphons waste gases and unpleasant odor introduced by the seat vent slots and transfers waste gases and unpleasant odor to an odor channel, attached to the odor canal. The odor channel disposes the waste gases and unpleasant odor to a pipe, a ventilation system or outside. | 4 |
FIELD OF THE INVENTION
This invention relates generally to paint trays and more specifically to a multiple use paint tray assembly for holding one or more removable paint containers.
BACKGROUND OF THE INVENTION
In my U.S. copending patent application Ser. No. 09/258,219 titled Paint System filed Feb. 26, 1999, which is incorporated herein by reference, I describes a method of insitu blending different color paints using a paint pad applicator in conjunction with a paint tray that has multiple individual paint compartments. Each of the paint tray compartments holds a different color paint. For example, one compartment can hold blue paint, another compartment can hold red paint and still another compartment can hold white paint. Also, if desired, some of the paint compartments can hold paint of the same color. In order to change the insitu blending one needs to change the color of the paint in one or more of the paint compartments. As certain colors are additive one can change the color of paint in a paint compartment by adding a paint of another color, which is usually done by trial and error. To eliminate trial and error mixing one could empty the paint compartment and refill the compartment with fresh paint of the desired color. However, if a paint tray has multiple compartments it is difficult to empty only one of the compartments as the paints from the other compartments are likely to mix with each other as the user tries to pour the paint from the paint tray back into a paint container. Also a user may want to use only a single paint container rather than multiple paint containers.
The present invention comprises a paint tray assembly which allows a painter to apply paint from one paint container and if multiple removable paint containers are used to empty the paint in one of the removable paint containers without having to empty the paint in all the rest of the paint containers. This allows a user to change the insitu blending without having to add paint to a container through a process of trial and error.
SUMMARY OF INVENTION
The present invention is a paint tray assembly comprising a paint tray having a trough and a plurality of paint containers located therein with at least one of the paint containers removable. The removable paint container has a retaining member for preventing the accidental displacement of the removable paint container and a first axle housing and a second axle housing for supporting an axle of a paint applicator roller. The paint containers each are laterally positioned to form a side-by-side fit within the trough of the paint tray allowing for the retaining member to engage the paint tray to prevent the accidental displacement of the removable paint container when paint is being applied to a paint pad. If multiple removable paint containers are used each of the removable paint containers can be removed from the trough of the paint tray without the removal of other removable paint containers.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an perspective view of the paint tray assembly of the present invention.
FIG. 2 is a cross sectional view of paint tray assembly of FIG. 1 taken along the lines 2 — 2 , showing the second removable paint container held in a paint tray.
FIG. 3 is a blow-up a portion of FIG. 2 showing the engagement between a U-shaped member on the paint container and a protrusion the paint tray
FIG. 4 is a top view showing the transfer of paint from the removable paint containers to a paint pad by the rotation of paint roller applicators.
FIG. 5 is a perspective view showing an embodiment of a removable paint container.
FIG. 6 is a perspective view showing an alternative embodiment of a removable paint container.
FIG. 7 is a perspective view showing a paint applicator roller used in the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a perspective view of the paint tray assembly 10 of the present invention. Paint tray assembly 10 comprises a paint tray 11 ; a first removable paint container 21 having a first paint applicator roller 24 , a second removable paint container 22 having a second paint applicator roller 25 and a third removable paint container 23 having a third paint applicator roller 26 .
Paint tray 11 includes a base 12 , a back wall 13 , a first side wall 14 , a second side wall 15 , a skirt 16 (shown in FIG. 2 ), a ramp 17 and a protrusion 30 located proximate the junction of skirt 16 and ramp 17 . A first ramp support 18 supports one side of the paint tray and a second ramp support 19 supports the other side of the paint tray to hold the paint tray in an upright condition. Paint tray 11 also includes a paint trough 20 defined by base 12 , back wall 13 , skirt 16 (shown in FIG. 2 ), first side wall 14 and second side wall 15 . In the embodiment shown three paint containers are shown in a side by side condition in paint trough 20 . In this condition the paint tray can be used for insitu blending of different color paints. A feature of the present invention is that if the user decides that only one color paint is to be applied as opposed to blending of different color paints the user can remove the individual paint containers 21 , 22 and 23 which allows the paint tray 11 to be used as a conventional one compartment paint tray.
FIG. 1 shows paint trough 20 having a first removable paint container 21 having a U-shaped retaining member 21 a , a second removable paint container 22 having a U-shaped retaining member 22 a , and a third removable paint container 23 having a U-shaped retaining member 23 a . The removable containers are used for holding paints, preferable of different colors for use in tasks which requires the use of various paint color combinations in order to obtain insitu blending. As shown, located within first removable paint container 21 is a first paint applicator roller 24 that is rotatably supported in paint container 21 . Similarly, a second paint applicator roller 25 is rotatably supported in paint container 22 and a third paint applicator roller 26 is rotatably supported in paint container 23 . The paint applicator rollers are used for transferring paint from the respective paint containers to a portion of a paint pad. The transfer of paint from the paint containers to the paint pad is done by the rotation of the rollers. As each of the rollers rotate they absorb paint from their respective removable paint containers and transfer the paint to the section or area of the paint pad that they engage.
FIG. 4 is a top view showing the transfer of paint to a paint pad 54 from a first removable paint container 51 by the rotation of a first paint roller applicator 55 . Similarly, a second removable paint container 52 having a second paint roller applicator 56 and a third removable paint container 53 having a third paint roller applicator 57 transfer paint to a paint pad 54 . As shown, removable paint container 51 , 52 , 53 are located in a side-by-side relationship within a trough 58 of a paint tray 59 . As the paint roller applicators rotate, the roller applicators absorb paint from the respective containers and carry the paint upward to where the paint is transferred to the paint pad from the roller applicator.
FIG. 2 is a cross sectional view of paint tray assembly 10 of FIG. 1 taken along the lines 2 — 2 of FIG. 1 showing the engagement of the second removable paint container 22 with paint tray 11 while second removable paint container 22 holds second paint applicator roller 25 . As shown, a base 29 of second removable paint container 22 engages the base 12 of paint tray 11 while a vertical extending wall 31 of second removable paint container 22 engages the back wall 13 and the skirt 16 of paint tray 11 to hold the paint container in a snug condition to prevent the removable paint containers from moving from side to side. Although located in a snug condition the paint containers are sufficiently spaced laterally so as to allow for removable of an individual paint container without having to remove an adjacent paint container.
Located within second removable paint container 22 is second paint applicator roller 25 . Second paint applicator roller 25 is rotatably supported in place within removable paint container 22 by the engagement of an axle 28 , protruding from opposite ends of second paint applicator roller 25 . The axle 28 can engage axle housings such as axle housings 45 and 46 (shown in FIG. 5 ) or axle housing 38 and 39 (shown in FIG. 6 ) of second removable paint container 22 . As was previously mentioned, the transfer of paint from the paint containers to the paint pad is accomplished by the rotation of roller 25 . As roller 25 rotates roller 25 absorbs paint from removable paint container 22 and transfers the paint to the section or area of the paint pad where roller 25 engages the paint pad.
FIG. 2 shows a retaining member 22 a of second removable paint container 22 engaging a protrusion 30 of paint tray 11 to hold paint container in position. A blow-up of the engagement between retaining member 22 a and vertical protrusion 30 of tray 11 is shown in FIG. 3 . illustrating that retaining member 22 a comprises a U-shaped member that fits snugly over the protrusion to prevent both lateral and downward movement of paint tray 22 . As shown in FIG. 2 and FIG. 3 , when a force of F 1 , which likely are forces created during the transfer of paint from the roller 25 to a paint pad, is applied on second removable paint container 22 the engagement of U-shaped retaining member 22 a to protrusion 30 prevents the rocking or displacement of second removable paint container 22 with respect to paint tray 11 . In addition, the retaining members provide a gripping region to allow a user to grasp an individual container and lift the container free of the paint tray.
FIG. 5 is a perspective view showing an embodiment of a removable paint container 32 . Removable paint container 32 includes a base 33 having outer edges and a vertically extending wall 34 connected to the outer edges of base 33 which defines a first side wall 36 , a second side wall 37 , a back wall 40 and front wall 41 . Securely attached to front wall 41 is a U-shaped retaining member 35 for engaging protrusion 30 (shown in FIGS. 1-3 ) of the paint tray 10 .
Located on first side wall 36 of removable paint container 32 is a first indented wall 36 a having a first axle housing 38 located therein for supporting a paint applicator roller axle. Located on the second side wall 37 of removable paint container 32 is a second indented wall 37 a having a second axle housing 39 located therein for supporting a paint applicator roller axle. A feature of the axle housings are that the paint applicator roller axles that are housed within the axle housings are allowed to rotate within the axle housings which in turn allows the paint applicator rollers to rotate and transfer paint to the paint pad.
The use of the removable paint container 42 allows a user to quickly use and change several different paint colors while retaining the reusability of the various paints. A user can have a plethora of removable paint containers each holding a different color paint. The user than would place the removable paint container with the desired paint combinations within the trough of the paint tray 11 . When a new paint combination is desire, the user would then remove the removable paint container holding the paint that the user will not be using. The unused paint from that container can then be set aside for later use or else can be poured back into a paint can. Once the paint task has been completed the user can pour all of the paint back to the original containers and clean or dispose of the removable paint containers. This can result in reduced paint cost and less of a mess for the user to clean up.
FIG. 6 is a perspective view showing an alternative embodiment of a removable paint container 42 . As shown, the first wall 43 and the second wall 44 of removable paint container 42 does not contain an indented wall as compared to the removable paint container embodiment of FIG. 5 . In addition, to support a roller applicator axle, removable paint container 42 has a first U-shape axle housing 45 integral to the first side wall 43 and a second U-shape axle housing 46 integral to the second side wall 44 .
FIG. 7 is a perspective view showing a paint applicator roller 47 used in the present invention. Paint applicator roller 47 has a cylindrical body having a first end 47 a and a second end 47 b with a paint absorbing surface 48 for the transferring of paint from the removable paint container to a painting pad. The paint absorbing surface of each paint applicator roller can differ in their absorption ability depending on the material used in the roller.
Located through the central axis 49 of paint applicator roller 47 is an axle 50 having a first end 50 a and a second end 50 b with the first end 50 a of axle 50 protruding from first end 47 a of paint applicator roller 47 and second end 50 b of axle 50 protruding from second end 47 b of paint applicator roller 47 . Protruding ends 50 a and 50 b of axle 50 engage the axle housings of a removable paint container to support paint applicator roller 47 within the removable paint container while allowing the ends of axle 50 to rotate within the housing.
The present invention also includes a method of making a paint tray assembly 10 having removable paint carrying containers 22 , 23 , and 24 comprising: (1) making a paint tray 11 having a ramp 17 , a trough 20 and a protrusion 30 located at the junction of ramp 17 and the trough 20 ; (2) molding a plurality of removable paint containers such as removable paint container 22 having a U-shaped retaining member 22 a , a first axle housing 38 and a second axle housing 39 . The containers are formed so as to be laterally fitable within the trough 20 of the paint tray 11 . (3) Inserting the removable paint container 22 and similarly removable paint containers such as paint containers 21 and 23 laterally within the trough 20 of the paint tray 11 with the U-shape retaining member 22 a of the removable paint container 22 engaging the protrusion 30 of the paint tray 11 in a locking manner. (4) Connecting a paint applicator roller 25 to the removable paint container 22 .
While the invention has been shown and described with respect to application of multiple paints to a single paint pad applicator it should be understood that the present invention can also be used to hold and apply multiple paint to a paint roller. In the paint roller mode the individual rotatable paint roller applicators in the removable containers are not needed as the paint roller can be rolled directly in each of the paint roller containers.
In the embodiment shown each of the paint containers located in the paint trough are removable to allow for emptying of the paint therein. If desired, one of the paint containers can be a permanent part of the paint tray. If the paint container is a permanent part of the paint tray the paint located in the permanently mounted paint container can be emptied from the paint tray by temporarily removing the removable paint container and then emptying the permanent paint container. When completed the removable paint container can be replaced with the paint therein and the permanent paint container can be refilled. For example, in the embodiment shown in FIG. 1 any of the removable paint containers could be made into a permanent container by adhesively securing the bottom of the removable container to the base of the paint tray 11 . In an alternate embodiment one of the paint containers could be molded directly into the paint tray so as to be a permanent paint container that extended only partway across the paint tray 11 . | Briefly, the present invention is a paint tray assembly comprising a multi-use paint tray having a trough located therein and at least one removable paint containers retained in a lateral fit within the trough of the paint tray with the removable paint container being separately removable from the trough of the paint tray to allow for individual emptying of paint compartments in the paint tray. | 1 |
PRIORITY CLAIM
This application is a divisional of U.S. patent application Ser. No. 10/755,527 filed Jan. 9, 2004, the contents of which are hereby incorporated by reference.
FIELD OF THE INVENTION
This invention relates generally to cleaning by use of a high pressure water stream and sanitizing by use of an ozone/water stream and, more specifically, to a cleaning and sanitizing method and apparatus in which the high pressure water stream and the ozone/water stream are discharged together, closely adjacent each other but without mixing.
BACKGROUND OF THE INVENTION
The following United States Patents disclose apparatus and methods of using ozone together with a cleaning fluid: U.S. Pat. No. 5,236,512 granted Aug. 17, 1993, to Ernest E. Rogers, Blaine A. Frandsen and Lamont Hislop; U.S. Pat. No. 5,493,754, granted Feb. 27, 1996 to Russell Gurstein and Edgar York; U.S. Pat. No. 5,815,869, granted Oct. 6, 1998 to John M. Hopkins; U.S. Pat. No. 5,839,155, granted Nov. 24, 1998 to Edward D. Berglund, Sung K. Cho and Lowell H. Schiebe; U.S. Pat. No. 6,115,862 granted Sep. 12, 2000 to Theodore R. Cooper, Allyson T. Toney and John B. McParlane; U.S. Pat. No. 6,348,227, granted Feb. 19, 2002, to Luis D. Caracciolo; U.S. Pat. No. 6,455,017, granted Sep. 24, 2002, to John R. Kasting, Dwayne H. Joines and John D. Winings; U.S. Pat. No. 6,458,398, granted Oct. 1, 2002 to Durand M. Smith, Dale S. Winger and Joshuan Brown, and U.S. Pat. No. 6,638,364, granted Oct. 28, 2003 to Gene Harkins and John M. Hopkins.
U.S. Pat. No. 6,455,017 discloses various uses of ozone as a sterilant. In this patent, it is stated that ozone cannot be combined with detergent or other cleaning agents since these are vulnerable to ozone attack. It is also stated that the ozone will destroy both its own effectiveness and that of the cleaning agent rather than attacking pathogens. U.S. Pat. No. 6,455,017 discloses directing a detergent cleaning solution, preferably under pressure, onto a surface to be cleaned. Then following the removal of the soils by the detergent an aqueous ozone rinse is applied to the surface. It is stated that the ozone rinse functions to sanitize the object being cleaned and remove residual detergent. The method of U.S. Pat. No. 6,455,017 involves first directing the cleaning solution onto the surface under pressure, and then rinsing the surface by directing a flow of the ozonated water onto the surface.
U.S. Pat. No. 5,865,995, granted Feb. 2, 1999 to William R. Nelson, and U.S. Pat. No. 6,361,688, granted Mar. 26, 2002, also to William R. Nelson, disclose systems for producing “ozonated water”, also termed “ozone/water”. As well be described, the selected one of the systems is combined in a novel way in the system of the present invention.
An object of the present invention is to deliver a high pressure cleaning water stream and an ozone/water stream substantially simultaneously to a surface to be cleaned and sanitized. The invention is basically characterized by delivering the high pressure water stream and the ozone/water stream closely adjacent to each other but without mixing. The high pressure water stream removes particles from the surface and the ozone/water stream sanitizes the surface almost simultaneously.
SUMMARY OF THE INVENTION
The cleaning and sanitizing system of the present invention is basically characterized by a first discharge nozzle from which a stream of high pressure water is discharged and a second discharge nozzle from which a stream of ozone/water is discharged. The first and second nozzles are positioned adjacent to each other so that the water and ozone/water streams are contiguous but the ozone/water is not delivered in the high pressure water stream. The high pressure water stream is discharged at a pressure high enough that it will exert a cleaning force on a surface to be cleaned and would convert the ozone into oxygen if the ozone/water stream were to be delivered into the high pressure water stream. In preferred form, the pressure of the high water pressure stream is at least about 100 p.s.i. More preferably, the pressure of the high pressure water stream is between 100 p.s.i. and about 2000 p.s.i. The pressure of the ozone/water stream is smaller than the pressure of the high pressure water stream and is sufficiently small that the ozone is not converted into oxygen.
According to one aspect of the invention, the ozone/water stream concentrically surrounds the high pressure water stream.
According to another aspect of the invention, the high pressure water and the ozone/water are discharged as closely spaced substantially parallel stream.
The nozzles for discharging the high pressure water and the ozone/water can be movable to the object that is to be cleaned. Or, the discharge nozzles can be fixed and the article to be cleaned can be moved relative to the nozzles.
In an embodiment of the cleaning and sanitizing system of the present invention, a circulating flow path of ozone/water is provided. Along this path, one or more high pressure water discharge nozzles are provided. An ozone/water nozzle is associated with each high pressure water nozzle. The high pressure water stream may be used to “pump” or “aspirate” ozone/water from the circulating system. As ozone/water is removed from the system, new water is delivered to the ozone/water generator and additional ozone is added to the water in the generator.
Other objects, advantages, and features of the invention will become apparent. From the description of the best mode set forth below, from the drawings, from the claims and from the principles that are embodied in the specific structure that are illustrated and described.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.
FIG. 1 is a fragmentary side elevational view showing a workman in the process of cleaning and sanitizing an object, by use of a high pressure water stream and an ozone/water stream;
FIG. 2 is a side elevational view of the wand shown in FIG. 1 , showing a portion of the wand in longitudinal section, such view showing a first nozzle discharging high pressure water stream surrounded by a second nozzle discharging an ozone/water stream;
FIG. 3 is a somewhat schematic view of a second embodiment of the wand, showing the high pressure water nozzle and stream and the ozone/water nozzle and stream in a side-by-side relationship;
FIG. 4 is a view of an apparatus for conveying chickens or other fowl along a path that is between stationary nozzles for delivering a high pressure water stream, for cleaning the fowl, and an ozone/water stream, for sanitizing the fowl; and
FIG. 5 is a flow diagram of a system embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a workman 10 holding a wand 12 that is adapted to discharge a high pressure water stream, for cleaning, and an ozone/water stream for sanitizing. The two streams 14 , 16 are being discharge against an object 18 that needs to be cleaned and sanitized. FIG. 2 shows the high pressure water stream 14 surrounded by the ozone/water stream 16 . FIG. 3 shows the high pressure water stream 14 and the ozone/water stream 16 being discharged in a side by side relationship.
Referring to FIG. 2 , the wand 12 has a grip portion 20 that the workman 10 grips with one hand 22 . The workman's other hand 24 grips an elongated central portion of the wand 12 . In this embodiment, the wand 12 includes a conduit 26 that extends through the wand 12 from an inlet 28 . to an outlet 30 . The inlet 28 is connected to a source of high pressure water 32 . The outlet 30 is in the form of a discharge nozzle that discharges a stream of the high pressure water 14 . Wand 12 includes a tubular outer wall 34 that surround the high pressure water conduit 26 . An annular passageway 35 is defined by and radially between the two tubular walls 26 , 34 . A cone 38 is provided at the outlet of the annular passageway 36 . A conduit 40 delivers ozone from a source 42 into the passageway 36 . The ozone/water flows through passageway 36 , and through diagonal ports in cone 38 and discharges as an annular stream 16 surrounding stream 14 , Streams 16 , 14 do not directly impinge. They extend substantially parallel to each other along a relative small diameter combined stream path.
The conduits 28 , 40 includes suitable on-off valves that are not shown. This is because they are not a part of the present invention but can be like the many valves that are available for controlling fluids that flow through conduits.
FIG. 3 shows a wand 12 that includes a high pressure water conduit 26 ′ positioned closely adjacent an ozone/water conduit 36 ′. As previously described, the high pressure water stream 14 and the ozone/water stream 16 are discharged in close proximity to each other but neither infringes directly on the other. The ozonated water is sprayed through an opening 37 . There is no attempt to mix the ozone/water stream 16 with the high pressure water stream 14 . As is well known by a person of ordinary skill in the art, the high pressure water conduit 26 ′ will include an off/on valve and the ozone/water stream 36 ′ will also include an off/on valve. The valves may also control the pressure and discharge flow rate of the two streams 14 , 16 , in a known matter.
FIG. 1 shows an overhead hose reel 44 on a pulley 46 . Pulley 46 is adapted to travel along a rod or a line 48 . The reel 44 is preferably a dual reel. It supports a high pressure water hose 50 and an ozone/water hose 52 . As the worker 10 walks forwardly from the position shown in FIG. 1 , the pulley 46 will move forwardly on the rod or line 48 . In a manner that is known to those skilled in the art, a first coiled hose 54 and a second coil hose 56 extend downwardly from the reel 44 . The coils 54 , 56 are in the nature of coil springs. They will extend when the operator 10 and the wand 12 move forwardly. They will retract when the operator 10 and the wand 14 move rearwardly.
FIG. 4 is substantially like FIG. 6 in the aforementioned U.S. Pat. No. 6,348,227 B1. A conveyor 60 is shown conveying a fowl F. (e.g. a chicken or a turkey) or some other animal or object along a path, through a processing area between high pressure water and ozone/water streams discharging from nozzles 62 . In addition to the nozzles 62 , the system 59 may include brushes 64 as described in U.S. Pat. No. 6,348,227 B1. The nozzles 62 are constructed to discharge a stream of high pressure wash water 14 closely adjacent a stream of ozone/water, but without direct mixing of the two streams.
As has been described, the high pressure water stream 14 and the ozone/water stream 16 may be brought to the object or article to be cleaned and sanitized. Or, the high pressure water stream 14 and the ozone/water stream 16 may be discharged from stationary nozzles (e.g. nozzles 62 ) towards a moving object or objects (e.g. fowl that are moved relative to the stationary nozzles 62 ). FIG. 5 shows a cleaning and sanitizing system that utilizes the present invention. High pressure water is pumped from source 32 into conduit 50 and from conduit 50 to the nozzle 30 (shown in FIG. 2 ), 30 ′ (shown in FIG. 3 ) that forms the high pressure water stream 14 . Ozonated water (ozone/water) is delivered from apparatus 80 into conduit 52 which leads to nozzles from the ozone streams 16 . The apparatus 80 for admixing ozone to water may_be one of the apparatuses disclosed in the aforementioned U.S. Pat. Nos. 5,865,995 and U.S. Pat. No. 6,361,688. The contents of these patents are hereby incorporated herein by this specific reference.
The ozonated water conduit 52 forms a closed loop with the apparatus 80 . A pump 82 pumps the ozone/water in conduit 52 to the recirculated liquid inlet of a contact tank 84 . See inlet 112 in U.S. Pat. No. 6,361,688 leading into contact tank 36 disclosed in that patent. The high pressure water stream 14 will pump or aspirate the ozone/water and remove it from the closed loop conduit 52 . Because some of the ozonated water is discharged from the water nozzles 30 , 30 ′, new water is added at 86 into admixture with the recirculated ozone/water that is moved by pump 82 into the inlet of the contact chamber 84 .
Preferably, the cleaning water that is discharged from the nozzles 30 , 30 ′ is water only. That is, it does not include a detergent or some other chemical. The surface to be cleaned is cleaned by the force of the high pressure water stream rather than by a detergent or other additive to the water stream. The ozone/water stream is delivered directly on the surface that is being cleaned by the water stream and there is no chemical present with which the ozone may react.
The illustrated embodiments are only examples of the present invention, and therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials, and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments that are illustrated and described herein, but rather are to be determined by the following claims, interpreted according to accepted doctrine of claim interpretation, including the use of the doctrine of equivalence. | A high pressure water stream ( 14 ) is discharged onto a surface to be cleaned. An ozone/water stream ( 16 ) is discharged on the same surface for sanitizing the surface. The high pressure water and ozone/water streams ( 14, 16 ) are discharged simultaneously along closely adjacent paths that are either parallel (FIG. 3 ) or concentric (FIG. 2 ). The water pressure is at least about 100 p.s.i. and is preferably between 100 p.s.i. and 1000 p.s.i. The nozzles that discharge the streams ( 14, 16 ) may be movable relative to the object(s) that receives the high pressure water and ozone/water (FIG. 1 ) Or, they may be fixed and the object may be movable relative to them (FIG. 4 ). | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application Ser. No. 14/006,703 filed Sep. 13, 2013, which is a national filing of PCT application Serial No. PCT/1B2012/051300, filed Mar. 19, 2012, published as WO 2012/127403 A2 on Sep. 27, 2012, which claims the benefit of U.S. Provisional application No. 61/467,044 filed Mar. 24, 2011, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The following generally relates to spectral imaging and more particularly to a spectral imaging detector, and is described in connection with computed tomography (CT). However, it is also amenable to other imaging modalities.
BACKGROUND OF THE INVENTION
[0003] A conventional computed tomography (CT) scanner includes a rotating gantry rotatably mounted to a generally stationary gantry. The rotating gantry supports an x-ray tube and a detector array, which is mounted on the rotatable gantry opposite the x-ray tube, across an examination region. The rotating gantry and hence the x-ray tube and the detector array rotate around the examination region about a longitudinal or z-axis. The x-ray tube is configured to emit radiation that traverses the examination region (and a portion of a subject or object in the examination region) and illuminates the detector array. The detector array detects the radiation and generates electrical signals indicative of the examination region and the subject or object disposed therein. A reconstructor reconstructs the projection data, generating volumetric image data.
[0004] For spectral CT, the scanner may include an energy-resolving detector array such as a double-decker detector array. An example portion of a double-decker detector array 100 is shown in FIG. 1 . The detector 100 includes a plurality of detector modules 102 aligned with respect to each other along a substrate 104 in an x-direction 106 . Each module 102 includes first and second scintillator rows 108 and 110 optically coupled to corresponding first and second detection regions 112 and 114 of a photodiode substrate 116 . The first and second scintillator rows 108 and 110 are arranged with respect to each other such that the first scintillator row 108 is above the second scintillator element 110 with respect to the incoming radiation 120 . Generally, lower energy x-rays photons tend to be absorbed in the upper scintillator row 108 and higher energy x-ray photons tend to be absorbed in the lower scintillator row 110 . The first and second scintillator rows 108 and 110 and the detection regions 112 and 114 extend along a z-direction 122 , forming multiple rows of detector elements.
[0005] With the detector array 100 of FIG. 1 , the resolution of the detector array 100 in the x-direction 106 generally is limited by a finite thickness 124 of the photodiode substrate 116 of each module 102 in the x-direction 106 , which has been on the order of one hundred (100) microns to four hundred (400) microns. Unfortunately, thinner photodiode substrates are fragile and not well-suited for constructing detector modules such as the detector modules 102 of the detector array 100 .
SUMMARY OF THE INVENTION
[0006] Present aspects of the application provide new and/or improved techniques that address the above-referenced problems and others.
[0007] In accordance with one aspect, a method includes obtaining a photosensor substrate having two opposing major surfaces. One of the two opposing major surfaces includes at least one photosensor row of at least one photosensor element, and the obtained photosensor substrate has a thickness equal to or greater than one hundred microns. The method further includes optically coupling a scintillator array to the photosensor substrate. The scintillator array includes at least one complementary scintillator row of at least one complementary scintillator element, and the at least one complementary scintillator row is optically coupled to the at least one photosensor row and the at least one complementary scintillator element is optically coupled to the at least one photosensor element. The method further includes thinning the photosensor substrate optically coupled to the scintillator producing a thinned photosensor substrate that is optically coupled to the scintillator and that has a thickness on the order of less than one hundred microns.
[0008] According to another aspect, an imaging detector includes at least one detector tile including a tile substrate and a plurality of detector modules arranged along an x-direction along the tile substrate. A detector module includes a scintillator array having at least one scintillator row of scintillator elements extending along a z-direction coupled to at least one photosensor row of photosensor elements of a photosensor substrate. The photosensor substrate is coupled to the scintillator array and has an initial thickness that is equal to or greater than one hundred microns, and the photosensor substrate of the imaging detector has a thinned thickness of less than one hundred microns.
[0009] According to another aspect, a method includes assembling an imaging detector module of an imaging system, wherein the imaging detector module includes a scintillator optically coupled to a photosensor substrate, which has a thickness less than one hundred microns.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
[0011] FIG. 1 schematically illustrates a perspective view of a prior art double-decker spectral detector array.
[0012] FIG. 2 schematically illustrates an example imaging system with a spectral detector array including a detector tile with a plurality of detector modules.
[0013] FIG. 3 schematically illustrates a side view of a detector module from the z-direction.
[0014] FIGS. 4-12 illustrate a method for assembling the detector module of FIG. 3 .
[0015] FIG. 13 illustrates an embodiment in which a support carrier is utilized to facilitate making the individual photo-sensor substrates.
DETAILED DESCRIPTION OF EMBODIMENTS
[0016] FIG. 2 schematically illustrates an imaging system 200 such as a computed tomography (CT) scanner. The imaging system 200 includes a generally stationary gantry portion 202 and a rotating gantry portion 204 . The rotating gantry portion 204 is rotatably supported by the generally stationary gantry portion 202 via a bearing (not shown) or the like.
[0017] A radiation source 206 , such as an x-ray tube, is supported by the rotating gantry portion 204 and rotates therewith around an examination region 208 about a longitudinal or z-axis 210 in connection with a frame of reference shown at 212 . A source collimator 214 collimates radiation emitted by the radiation source 206 , producing a generally cone, fan, wedge or otherwise-shaped radiation beam that traverse the examination region 208 .
[0018] An energy-resolving detector array 218 subtends an angular arc opposite the examination region 208 relative to the radiation source 206 and detects radiation that traverses the examination region 208 . The illustrated detector array 218 includes a plurality of tiles 220 . Each tile 220 includes a plurality of detector modules 222 1 , . . . , 222 N (wherein N is an integer), arranged on a tile substrate 242 , with respect to each other, along the x-direction. The plurality of detector modules 222 1 , . . . , 222 N are also referred to herein as detector modules 222 .
[0019] Each detector module 222 includes a plurality of rows 224 1 , . . . , 224 M (wherein M is an integer equal to or greater than one, and collectively referred to as 224 ) of scintillator elements 226 1 , . . . , 226 K and 228 1 , . . . , 228 K (wherein K is an integer, and collectively referred to as 226 and 228 ) extending along the z-direction. In the illustrated embodiment, M=2, and the detector module is a spectral detector module. The rows of scintillator elements 226 and 228 are optically coupled to a corresponding plurality of rows 230 1 , . . . , 230 M (collectively referred to as 230 ) of photosensor elements 232 1 , . . . , and 234 1 , . . . (collectively referred to as 232 and 234 ) of a photosensor substrate 236 extending along the z-direction.
[0020] Each detector module 222 also includes electrically conductive pathways or pins 238 . Where the detector module 222 further includes processing electronics 240 incorporated into the photosensor substrate 236 (as shown), the electrically conductive pathways or pins 238 are used to route power and digital signals from the processing electronics 240 to the tile substrate 242 . Where the processing electronics 240 are located external to the photosensor substrate 236 , the electrically conductive pathways or pins 238 are used to route signals from the photosensor elements 232 and 234 to the tile substrate 242
[0021] As described in greater detail below, the photosensor substrate 236 , in one instance, has an x-axis thickness of less than one hundred (100) microns. With such a photosensor substrate, the detector array 218 can include more detector modules 222 for a given x-axis length relative to a configuration of the detector array with a thicker photosensor substrate (i.e., greater than 100 microns), and hence provide higher resolution in the x-direction. In one instance, such a detector array may include thirty (30) to sixty (60) percent more detector modules 222 . Such a detector array may be considered a high definition detector array.
[0022] A reconstructor 246 reconstructs the signals generated by the detector array 218 and generates volumetric image data indicative of the examination region 208 . Generally, the data from the different rows 230 of photosensor elements 232 and 234 can be individually processed for spectral information and/or combined (e.g., by summing the outputs of the different elements in the same ray path) to produce conventional non-spectral CT data.
[0023] A subject support 248 is configured to position the object or subject in the x, y, and/or z directions with respect to the examination region 208 before, during and/or after scanning the object or the subject.
[0024] A general purpose computing system serves as an operator console 250 , and includes an output device such as a display, an input device such as a keyboard, mouse, and/or the like, one or more processor and computer readable storage medium (e.g., physical memory). The console 250 allows the operator to control operation of the system 200 , for example, allowing the operator to select a spectral imaging protocol and/or spectral imaging reconstruction algorithm, initiate scanning, etc.
[0025] FIG. 3 schematically illustrates a side view of a detector module 222 from the z-axis direction. For explanatory purposes, the detector module 222 is shown as having two scintillator rows 224 1 and 224 2 and two corresponding photosensor rows 230 1 and 230 2 . However, as discussed above, the detector module 222 may have one or more of each of the scintillator rows 224 and the photosensor rows 224 .
[0026] The detector module 222 includes the photosensor substrate 236 . The illustrated photosensor substrate 236 has a thickness 300 on the order of fifty (50) microns (plus or minus a predetermined tolerance), such as a thickness value from a range of ten (10) to ninety (90) microns, twenty-five (25) to seventy-five (75) microns, forty (40) to sixty (60) microns, and/or other thickness value in one or more other ranges. A suitable material of the photosensor substrate 236 includes, but is not limited to silicon.
[0027] The photosensor substrate 236 includes a first major surface 302 , with a first region 304 and a second region 306 , and a second opposing major surface 308 . The photosensor rows 230 1 and 230 2 are located in the first region 304 of the first major surface 302 . The photosensor row 230 1 is an upper row, which is closer to the radiation source 206 (FIG. 1 ) and hence the incoming radiation, and the photosensor row 230 2 is a lower row, which is farther from the radiation source 206 ( FIG. 1 ) and hence the incoming radiation.
[0028] The scintillator row 224 1 is an upper scintillator element, which is closer to the radiation source 206 ( FIG. 1 ) and hence the incoming radiation, and the scintillator row 224 2 is a lower row, which is farther from the radiation source 206 ( FIG. 1 ) and hence the incoming radiation. As discussed herein, the upper scintillator row 224 1 is optically coupled to the corresponding upper photosensor row 230 1 and the lower scintillator row 224 2 is optically coupled to the corresponding lower photosensor row 230 2 .
[0029] In the illustrated embodiment, the upper and lower scintillator row 224 1 and 224 2 are rectangular shaped and are about equal in size. However, it is to be understood that other shapes and different sized scintillator row 224 1 and 224 2 are contemplated herein. Furthermore, spacing between the scintillator row 224 1 and 224 2 can be smaller or larger. Moreover, as the depths (and material) of the scintillator rows 224 can influence energy separation and/or x-ray statistics, the depths, generally, are such that the upper scintillator row 224 1 is primarily responsive to lower energy photons and the lower scintillator row 224 2 is primarily responsive to higher energy photons.
[0030] The photosensor substrate 236 optionally includes the processing electronics 240 (for processing signals from the photosensor elements 232 and 234 ) that are part of the photosensor substrate 236 . As such, there will be fewer electrical pathways from the photosensor substrate 236 to the tile substrate 242 , and z-axis widths of the photosensor elements 232 and 234 can be narrowed, increasing detector resolution in the z-direction. A non-limiting example of a photosensor substrate with processing electronics incorporated therein is described in patent application PCT/IB2009/054818, filed Oct. 29, 2009, and entitled “Spectral Imaging Detector” (WO/2010/058309), which is incorporated herein by reference in its entirety.
[0031] In the illustrated embodiment, the sides of the scintillator rows 224 not affixed to the substrate 236 are surrounded by reflective material 312 , which extends over the entire first major surface 302 . The combination of the scintillator rows 224 and the reflective material 312 is referred to herein as scintillator array 310 . In another embodiment, the reflective material 312 can be omitted. In yet another embodiment, the reflective material 312 may only cover the first region 304 .
[0032] FIGS. 4-12 describe an approach for assembling the detector array 218 .
[0033] At 402 , a photosensor substrate having a thickness of greater than one hundred (100) microns is obtained. For example, in one instance, the photosensor substrate 236 is obtained. An example of the substrate 236 is schematically illustrated in FIG. 5 and includes the two photosensor rows 232 and 234 , a region 502 for the processing electronics 240 , electrically conductive pads 504 for electrical components, and electrically conductive pads 506 for the electrically conductive pins 238 .
[0034] Note that in FIG. 5 the photosensor rows 232 and 234 , the region 502 and the pads 504 and the pads 506 are on a same surface plane 508 of the first major surface 302 of the photosensor substrate 236 . FIG. 6 schematically shows an embodiment in which the scintillator array 310 to be affixed to the photosensor substrate 236 includes a first surface 602 with a recess 604 and a second surface 606 in the recess 604 for the processing electronics 240 , the electrical components, and the electrically conductive pins 238 .
[0035] At 404 , various electronics are mounted to the photosensor substrate. For example, and as schematically shown in FIG. 7 , an integrated chip 702 (including the processing electronics 240 and/or other components) is mounted to the region 502 , electrical components 704 (e.g., passive components) are mounted to the electrically conductive pads 504 , and the electrically conductive pins 238 connected to a lead frame 708 are mounted to the electrically conductive pads 506 .
[0036] At 406 , a scintillator is affixed to the photosensor substrate with the installed electronics, forming a scintillator-photosensor assembly. For example, FIG. 8 schematically shows the photosensor substrate 236 with the scintillator array 310 affixed thereto via an optical adhesive, forming a scintillator-photosensor assembly 804 . Note that there are cavities 806 between the electrically conductive pins 238 .
[0037] At 408 , electrical pins mounted in act 404 above are secured in the scintillator—photosensor substrate assembly. For example, FIG. 9 schematically shows the scintillator—photosensor assembly 804 with adhesive 902 in cavities 806 between the electrically conductive pins 238 . Note that the lead frame 708 has been removed from the scintillator—photosensor assembly 804 .
[0038] At 410 , the photosensor substrate is thinned to a thickness of fifty (50) microns or less. For example, FIG. 10 schematically shows the scintillator—photosensor assembly 804 with a thinned photosensor substrate 236 having a thickness of fifty (50) microns or less. In one instance, the photosensor substrate 236 can be thinned via grinding. Other thinner techniques are also contemplated herein.
[0039] At 412 , a detector tile is created from a plurality of the scintillator—photosensor assemblies 804 . For example, FIGS. 11 and 12 respectively show bottom and top perspective views in which a plurality of the scintillator—photosensor assemblies 804 are physically and electrically connected to the tile substrate 242 via the pins 238 forming the tile 220 . Note the tile substrate 242 also includes electrically conductive pins 1102 for the physically and electrically connecting the tile 220 to the detector array 218 .
[0040] It is to be appreciated that the ordering of the above acts is not limiting. As such, other orderings are contemplated herein. In addition, one or more acts may be omitted and/or one or more additional acts may be included, and/or one or more acts may occur concurrently.
[0041] FIG. 13 illustrates an embodiment in which a support carrier 1302 is utilized to facilitate making the individual substrates 236 . In one instance, a sheet 1304 of material including a plurality of substrates 236 is processed and thinned, for example, to a thickness of less than one hundred microns. The sheet 1304 is then transferred to the support carrier 1302 . The processing electronics 240 are mounted to the plurality of substrates 236 . The individual substrates 236 are then cut from the sheet using a laser, mechanical saw, etc. and left on the carrier 1302 . A vacuum chuck feature of the carrier is activated after the individual substrates 236 are cut. The scintillator array 310 is then optically coupled to the bonded to the individual substrates 236 and cured. The resulting assemblies can then be further processed as described herein.
[0042] Variations are contemplated.
[0043] In another embodiment, the processing electronics 240 are located external to the photosensor substrate 236 .
[0044] In another embodiment, the module 222 includes a single scintillator row optically couple to a single photosensor row.
[0045] Additionally or alternatively, in yet another instance, each scintillator row and each photosensor row respectively includes a single scintillator element and a single photosensor element.
[0046] The invention has been described with reference to the preferred embodiments. Modifications and alterations may occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be constructed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A method includes obtaining a photosensor substrate ( 236 ) having two opposing major surfaces. One of the two opposing major surfaces includes at least one photosensor row ( 230 ) of at least one photosensor element ( 232, 234 ), and the obtained photosensor substrate has a thickness equal to or greater than one hundred microns. The method further includes optically coupling a scintillator array ( 310 ) to the photosensor substrate. The scintillator array includes at least one complementary scintillator row ( 224 ) of at least one complementary scintillator element ( 226, 228 ), and the at least one complementary scintillator row is optically coupled to the at least one photosensor row ( 230 ) and the at least one complementary scintillator element is optically coupled to the at least one photosensor element. The method further includes thinning the photosensor substrate optically coupled to the scintillator producing a thinned photosensor substrate that is optically coupled to the scintillator and that has a thickness on the order of less than one hundred microns. | 7 |
BACKGROUND OF THE INVENTION
[0001] The application relates to geologic modeling, and in particular to the interactive creation of a computerized model of a geologic domain cut by multiple fault surfaces and geologic horizons.
[0002] Accurate modeling of a subsurface domain, such as a reservoir under investigation for possible petroleum content, or in more general terms a geologic basin, is critical to the ongoing investigation of that domain. Drilling exploratory wells is an expensive undertaking, as is a full-scale seismic or magnet survey, and accurate decision-making requires accurate geological mapping.
[0003] Information about the geologic horizons present in a reservoir is clearly an important first step. Knowledge of the type and thickness of sedimentary strata gives a geologist key information in visualizing the subsurface structure. In most areas, however, strata are cut with numerous faults, making the analytical task considerably more complicated. Geologic mapping requires that the faults be identified and that the amount of the slippage along the fault plane be quantified. The amount of slippage, or “throw”, can range from little to no actual movement nn the case have a fracture, to a distance of hundreds of kilometers along a major fault zone such as the San Andreas fault of Calif.
[0004] A 3-D model of a geologic domain would be a highly useful tool for geologists and exploration planning managers. That technology lies at the intersection between geology, geophysics, and 3-D computer graphics, and several inherent problems need to be overcome in such a product. First, data is often incomplete. The volumes in question range from the earth's surface down many thousands of feet, and data is generally difficult to obtain. Moreover, the data that is available, often in the nature of seismic survey results and well log data, is subject to considerable processing and interpretation. Second, a large measure of professional judgment goes into the rendering of any such analysis, so that the goal of any analytical tool cannot be a complete result, but rather should be aimed at assisting the geologist of to bring her judgment to bear in the most of efficient and effective manner possible.
[0005] A further difficulty stems from the inherent complexity of the problem. A typical petroleum reservoir, for example, will include a minimum of 20-50 fault surfaces up to a maximum of several hundred. A user could manually deal with a small number of fault surfaces, but this level of complexity is literally overwhelming. And not only is the task made more difficult by the sheer number of data points, but the data themselves are also highly complex. Fault structures can assume a number of shapes and configurations that are extremely difficult to depict and visualize.
[0006] The prior art offers several products, all of which fall short of an effective solution. For example, a computer program marketed under the name “Petrel”, provided by Schlumberger Limited, offers the capability of producing smoothed fault surfaces, but the system has difficulty dealing with complex fault structures. Another product, called Go-CAD, produced by Earth Decision Sciences, is similarly challenged by complex surfaces. Both of these products offer 3-D visualization tools, but those do not offer the user sufficient flexibility to produce a model that is ready for a geologist's interpretation.
[0007] Finally, Dynamic Graphics, Inc, of Alameda, Calif., offers a product called Earth Vision, which is aimed at this problem. That program works with a fault network, constructed on a binary tree, but that data structure is not presented in a way that users can adopt with high productivity, and it has difficulty dealing with vertical or near-vertical faults.
[0008] Thus, no product has emerged combining ease of use and the ability to deal with masses of complex data, coupled with the ability to produce a result ready for interpretation by a geologist. Those tasks remain unsolved in the prior art.
SUMMARY OF THE INVENTION
[0009] Particular aspects of the present invention are described in the claims, specification and drawings.
[0010] One aspect of the invention is a method for modeling a geological domain in a computer system, in which the computer system includes data processing and data storage modules, one or more user input devices and a display device, in which the system first receives data relating to faults within the domain. Then there is created a surface plot for each fault described in the data, each surface plot being extended to divide the domain in two portions, and the surface plots are combined into a fault network containing all faults described in the data and displayed on the display apparatus. The network display is modified in response to user input, including the first step of rotating the display about its horizontal and vertical axes as desired to inspect the same. Then the system receives manual truncation commands and truncates indicated fault portions responsive to the same. Responsive to a command initiating automatic truncation, the system selects portions of fault surfaces for truncation according to preselected criteria and truncates the same. Finally, the system stores network information, including a record of changes made, for future use.
[0011] In one embodiment, a computer-assisted method for modeling a geologic domain begins by creating a surface plot for each fault in the domain, each surface plot being extended to bisect the domain and including active areas and extended areas. Next, the system truncates selected ones of the surface plots by removing selected portions of the same from the model, leaving defined fault plots in the model. Then a binary tree data structure is built, based on the topological relation between defined fault plots. The system identifies volumetric geologic structures defined at each leaf nodes of the binary tree. The next step consists of traversing the binary tree, and at each data node analyzing pairs of the geologic structures on separate branches to determine whether the structures are separated by a defined fault plot, entering any pair of structures not separated by a defined fault plot in a fused block list.
[0012] Another aspect of the invention is a data structure for representing a fault network within a geologic domain, including a binary tree. In the binary tree, each data node represents a fault within the domain, including properties associated therewith; branches of the tree are based upon topological relationships between adjacent nodes; and leaf nodes represent volumetric entities bounded by faults within the domain. Associated with the tree is a fused block table, listing pairs of volumetric entities not separated by physical faults within the domain.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a flowchart of the embodied process of the present invention.
[0014] FIG. 2 depicts initial data plots according to an aspect of the present invention.
[0015] FIG. 3 illustrates a gridding technique employed in the present invention.
[0016] FIG. 4 depicts a fault network model according to an aspect of the invention.
[0017] FIG. 5 is a flowchart illustrating a method of building the fault surface model of an aspect of the invention.
[0018] FIG. 6 is a 2D depiction of the fault model of an aspect of the invention.
[0019] FIG. 7 illustrates the fault surface model after truncation according to an aspect of the invention.
[0020] FIG. 8 illustrates the fault block model constructed according to an aspect of the invention.
[0021] FIGS. 9 a and 9 b illustrate a method for dealing with an issue raised in the course of building geologic models.
[0022] FIG. 10 is a flowchart outlining the process of proceeding from a fault surface model to a fault block model according to an aspect of the invention.
[0023] FIG. 11 illustrates a final horizon model constructed according to an aspect of the invention.
DETAILED DESCRIPTION
[0024] The following detailed description is made with reference to the figures. Preferred embodiments are described to illustrate the present invention, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a variety of equivalent variations on the description that follows.
[0025] The process of the present invention operates on a computer system that provides a central processing unit, data storage, human interface devices (keyboard, mouse, etc.) and display unit. Any reasonably powerful desktop system will suffice to operate the system, with typical minimum characteristics being 20 GB of disk storage, 1 GB RAM and a 1 GHz processor.
[0026] The system described below is an interactive process in which the computer performs calculations and organizes data displays, and the human user provides both simple operational choices as well as sophisticated professional judgments. There are no operating system or computer language constraints. One embodiment of the system was written in C++, designed to operate on Linux, Unix or Windows XP operating systems. Those in the art will understand how to adapt the system to various environments.
[0027] FIG. 1 depicts an embodiment of the process 10 of the present invention. In general, the process begins with data collecting at step 12 , after which of all the surfaces are created at step 14 . Once the fault surfaces are created, a fault surface model is generated at step 16 , and then a fault block model is created at step 18 . Each of these steps involves a number of sub-steps, as are explained in the sections below.
[0028] Data collection, in step 12 , involves gathering data from a number of sources. Typically, data will be available from seismic surveys from existing mapping, or from well logging. Those in the art will understand the nature and limitations inherent in each of these data sources, as well as the techniques employed to employ such data to assemble a composite map. Data can be input in any of the many conventional methods.
[0029] A first step is to process the available data and assemble an initial plot. FIG. 2 shows a geologic volume 100 with seven faults, F 1 -F 7 plotted. Fault F 1 is plotted from “depth fault sticks” derived from seismic survey data. As can be seen, such data provide a complete and detailed depiction of the fault surface. Remaining faults F 2 -F 7 are plotted from depth midlines, which are derived from existing maps. Data are often incomplete, however, requiring judgment in the extrapolation from known data points to complete fault surfaces. The depth midlines of faults F 6 and F 7 , for example, provide known data points that are limited in both the vertical and horizontal extent of the fault. As will be seen below, the present invention allows geologists to deal with such problems.
[0030] Having sets of data, the system progresses to step 14 ( FIG. 1 ), generation of fault surfaces. Typical practice in the art would call for projecting the fault to derive a function describing the surface in three dimensions, referenced to the plane of the earth's surface. This problem involves the field of 3-D graphics, which offers a number of solutions to such problems. To be useful in the environment of fault mapping, a solution must offer a combination of rapid calculation, easy visualization and straightforward modification. Other criteria include the size of the resulting data structure, the ease of associating properties with the data, the ability to identify precisely the relationship between a given point and fault surfaces, and the ability method to honor fault data.
[0031] It should be noted that the present system generates 3-D views of the geologic domain and fault surfaces. As can easily be seen in later drawings, fault relationships can be highly complex, and only by visualizing them in three dimensions can one gain a full understanding of individual faults and the relationships with a fault network. The graphics capability of both the computer language and operating system chosen for implementation, as well as that of the platform on which the system is run, must support powerful graphics capabilities. At a minimum, such a system must have sufficient computing and graphics power to calculate and manipulate surfaces rapidly. The ability to rotate a display on three axes is also important for adequate analysis of faults.
[0032] Historically, faults have been represented on maps using various projection techniques, such as drawing lines and polygons onto known horizons. That method presents a number of problems, however, and a much preferable technique is found in development of a vertical scalar field, in which a function is defined for z=f(x, y). As seen in FIG. 3 a , projecting onto a vertical scalar field in a cardinal direction A presents a wholly trivial task for simple planar fault 22 , and only slightly more complicated for more curved surfaces such as fault 24 , producing in both cases a set of z values as a function of x and y. It can be seen, however, that the problem becomes more complicated toward the ends of fault 26 , as the curvature approaches the vertical. Folded fault 26 , however, is simply not amenable to conventional techniques, as multiple points in the z direction correspond to single values on the x axis.
[0033] A solution is seen in FIG. 3 b , where the issue of folding is addressed by rotating the frame of reference used in producing the grid. Here the conventional frame of reference is rotated to allow projection of fault 28 , so that values in the z direction can be represented as a function of x′ and y′. It has been found that employing rotated gridding offers the best solution to the difficulties associated with mapping complex fault networks.
[0034] The resulting data structure is a collection of individual points. A number of techniques are known in the graphics art for working with such data sets, and it has been found most advantageous to employ b-spline multi-resolution smoothing to develop a smooth, continuous surface plot.
[0035] Polygonal meshes are widely employed in 3-D graphics, but their utility in the fault network environment is limited by the difficulty of working with such surfaces for data enquiries, such as associating properties with data points, or the important question of whether a given point lies on one side or the other of a fault surface. It was thus decided not to rely on polygonal meshes as a primary surface generation technique. On the other hand, polygonal mesh techniques allow the effective and rapid visualization of surfaces, and to that end, the smoothing step is followed by the insertion of a polygon mesh onto the surface as a visualization and graphics tool, employing known techniques.
[0036] The process described above for a single fault data set is reiterated for each identified fault, producing in the example here, a fault surface network 102 , shown in FIG. 4 . The seven fault data sets represented in FIG. 2 have been converted here to fault surfaces F 1 -F 7 in three dimensions. At this point, the surface representations are not subjected to adjustments based on judgments about the likely geological reality, but rather the objective is a comprehensive set of surface representations that reflect all available data.
[0037] Other embodiments could employ other mathematical techniques, so long as such approaches produce a result that meets the criteria of accuracy, power and ease of use. A parametric surface representation, for example, or a vector-oriented approach could be substituted for the rotated grid structure described above.
[0038] The application of systematized judgment to the fault surface network occurs in step 16 ( FIG. 1 ), where the fault surfaces are processed to produce a fault surface model, which represents the most likely depiction of geologic reality for the geologic domain under study.
[0039] The sub-process 30 for generating the fault surface model is shown in FIG. 5 . In general, this process can be described as first processing the individual faults (steps 34 - 40 ); then processing fault intersections (steps 42 - 48 ); followed by fault truncation (step 50 ) and building a fault relationships table (step 52 ). Each of these actions is discussed in detail below. The completed fault surface model 104 is shown in FIG. 7 .
[0040] Each fault surface is inserted into the fault surface model by analyzing and characterizing fault surface properties. For purposes of visualization, the fault surface network 102 of FIG. 4 can be thought of as an “in process” depiction of the fault surface model, as explained below.
[0041] Each fault is analyzed by estimating the active area of the fault (step 36 , FIG. 5 ), and then extending the fault surface in all linearly and laterally to bisect the geologic domain (step 38 , FIG. 5 ). The active area of the fault surface is that portion of the surface that corresponds (or more accurately, is believed to correspond) to an actual faulted surface in the domain—a surface formed by at least a fracture, and more usually movement along the fault plane, in the rock mass. A number of techniques for estimating active area are known in the art. In one embodiment of the invention, a convex hull calculation is performed, as follows. Input data is first converted to a 2D field, ignoring the z dimension, and calculations are based on the input data as extended by user-defined extensions in the strike and dip directions of the fault surface. One embodiment of the invention employs the Jarvis march algorithm to accomplish this result, while another utilizes the Graham scan. The former is simple and easy to implement, the latter slightly more efficient at run time. Either can be selected, or another from those described in the literature. All produce an output consisting of a polygon, which in the present application represents the fault active area. It is desirable to smooth the edges of the active area, which can be done using a number of known algorithms.
[0042] Once the active area of the fault is defined, the fault surface is extended so that the extended surface bisects the geologic domain. This can be seen clearly in FIG. 6 , where the fault surface model is projected on a 2D surface for purposes of visualization. There, fault F 4 includes an active area 104 and two extensions 106 and 108 . This bisection process is a key step in the binary space partitioning process, discussed in detail below. It should be noted that faults such as fault F 4 can be extended by simply carrying the surface in exactly the same direction as the final segments of the active area, or, as in other embodiments, an algorithm can be applied that extrapolates the fault generally parallel to the overall strike of the fault. It is generally preferred to emphasize calculation speed and storage requirements in selecting the method for calculating the position of the extrapolated area.
[0043] The last piece of data needed to characterize a fault surface is the direction of “up”. The need for that data will be obvious from the discussion below, and it is generally preferred simply to calculate the direction of a vector orthogonal to the fault surface, located at the center of the active area, as the idea of “up” and “down” in this context has mathematical, not purely physical, meaning. The arrows shown for each fault in FIG. 6 illustrate the results of this action.
[0044] After fully characterizing the individual faults, the relationships between faults are analyzed, in steps 42 - 48 ( FIG. 5 ). These steps, and those that follow immediately afterward, can be generally described as “fault truncation”, or the deletion from the model of surface areas that most likely are not real faults in the rock mass. This process is necessary because the underlying fault data inevitably contains errors, as illustrated in FIG. 4 . There it can easily be seen that a number of plotted faults intersect, with active portions of both faults extending past each other in X-patterns. In fact, such formations are vanishingly rare on the ground. In instances where a young fault cuts across an existing, older fault, movement along the younger (or the more active, whatever the age relationship) fault quickly disrupts the X-pattern, producing in its stead two T's, offset by the throw distance along the fault. Therefore, when one observes crossing patterns such as those seen in FIG. 4 , it is safe to assume that the data are wrong and that some corrective action should be taken. The following steps assemble the data required for deciding what form such action should take.
[0045] First, each active intersection is identified and classified (step 44 ). Intersections are simply lines where two faults share the same set of points, so these can be quickly found and labeled using well-known techniques. In the example of FIGS. 4 and 5 , intersections 110 a - e between faults F 1 and F 2 , F 2 and F 3 , and F 4 and F 3 meet that criterion. Three types of intersections are possible, involving (1) two active areas, (2) two extrapolated areas, or (3) one active and one extrapolated area. Of those, only intersections involving two actives areas are investigated here. That limitation flows from the purpose of the extrapolated areas in defining relationships among fault surfaces, as explained more fully below, and the process of fault truncation, which seeks to identify the true picture of faults in the rock mass.
[0046] The points of intersection define lines, which subdivide each fault, and the resulting areas are identified as “truncatable areas”, which simply means areas bounded either by a fault end line and an intersection or two intersections. These are areas that can be cut out of the model as desired. A number of faults have no intersections, and thus no truncatable areas, such as faults F 5 , F 6 and F 7 . Others have a number of truncatable areas 112 a -I; fault F 3 , for example has five such areas.
[0047] The truncation process—the elimination of fault segments that most likely do not exist in the rock mass—can proceed either manually or automatically. The former takes advantage of the ability to exercise professional judgment in selecting which fault segments to delete. In complex situations, many situations arise in which no blind application of rules exists that can completely supplant the judgment of an experience geologist. On the other hand, in a geologic domain that includes hundreds of fault surfaces, not the seven treat in the example here, many truncation decisions can be made based on the algorithm presented below. Leaving those decisions to a geologist would be a misuse of those resources.
[0048] A preferred solution is to divide the task between manual and automatic modes. One preferred process would have a geologist begin by identifying those decisions requiring professional judgment and making those decisions. The remainder can be made in automatic mode. Such an approach uses the two available skills—experienced judgment and computational power—to best advantage.
[0049] The manual mode proceeds by displaying the completed fault surface model of FIG. 4 , following the calculations through step 48 ( FIG. 5 ). In one embodiment, the user can employ a mouse to select truncatable areas for truncation, with appropriate keystroke or other command means for executing the truncations. It is important to reiterate that the graphics display must permit rotation about three axes, complete zooming and similar capabilities to allow the geologist to apply knowledge quickly and move on.
[0050] In automatic mode, the system takes advantage of the fact that the larger portions of active areas are those more likely to be actually present. Thus, for example, in looking at fault F 4 , even one of minimal training can surmise that the portions of F 4 lying above fault F 3 are more likely to be correctly shown than the two areas lying below F 3 . Thus, the automatic truncation algorithm examines each identified intersection, determines the possible truncations at that intersection, and selects that truncation producing the smallest amount of surface area.
[0051] For example, consider intersection 110 b , best seen in FIG. 6 . Four truncatable areas extend from that intersection, 112 b , 112 c , 112 d and 112 j . The system would calculate the areas of each truncatable area, but it can be seen that the result of such calculation would have area 112 j as the smallest. In automatic mode, that area would be automatically truncated. Interface systems for that process are within the skill of those in the art, but one embodiment would include the ability to specify the order in which faults are selected for automatic analysis, for example. Another embodiment would offer a semi-automatic mode, in which the system would perform the calculations, select areas for truncation and seek user approval before performing the truncation.
[0052] Under either truncation regime, the system builds a rule table that reflects the changes made during truncation. Such a table is shown below, and there it can be seen that one format for truncation rules is in general form “X truncated<above><below>Y”, reflecting the topological relationship between faults. The rules shown indicate, for example, that fault F 1 is not truncated at all; that F 2 is truncated above F 1 ; that F 3 is truncated above F 1 and below F 2 ; and the F 4 is truncated above F 3 . The rules table has broader ramifications, as will be seen below. The system should make the rules table readily available to the user.
TABLE 1 F1 F2 Above F1 F3 Above F1 Above F2 F4 Below F3
[0053] FIG. 7 shows the fault surface model 104 following truncation operations. It is important that the system retain a full record of every truncation made, and that a simple interface be provided for reviewing and possible undoing all truncations. Given the role that judgment plays in this process, it is crucial to be able to identify possible mistakes and to repair them with minimum effort.
[0054] The goal of the analysis, it should be remembered, is not the fault structure per se, but that to use the fault structure as a tool for better understanding the geologic domain. Therefore, the next step is to move from the fault surfaces to the fault blocks—the geologic units bounded by the fault surfaces. The key point of the present method is to use the fault surfaces, and the relationships between them, to define the volumes bounded between them. A general description of the method employed here is that of binary space partitioning trees, data structures that provide both a geometrical relationship and search structure for the geologic domain.
[0055] This process is analogous to the use of binary tree structures in developing search algorithms and in 3-D graphic applications. First, faults are classified in terms of their relations to other fault surfaces. Then a binary tree structure is assembled and optimized. Here, however, the “leaf” nodes of the tree will represent fault blocks.
[0056] The classification process starts with the assembly of a fault relationship table, which lists each fault and topologically classifies every other fault as being above that surface, below that surface or straddling that surface. That information flows from the earlier steps of extending each surface to bisect the geologic domain, as well as defining the “up” direction for each surface. For the example under discussion, the initial fault relationship table is shown in Table 1, as follows:
TABLE 2 Above Below Straddle F1 F4, F5, F6, F7 F2, F3 F2 F4, F5, F6, F7 F1, F3 F3 F5, F6, F7 F1, F2, F4 F4 F5, F6, F7 F2 F1, F3 F5 F2, F3, F4, F6, F7 F1 F6 F1, F2, F3, F4, F5 F7 F7 F1, F2, F3, F4, F5, F6
[0057] Table 1 reflects the situation shown in FIGS. 4 and 6 , prior to truncation. Particular attention should be paid to the “straddle” category. As mentioned above, the goal of this process is a binary tree, and by definition, straddles involve situations where one surface is both above and below another. The following discussion shows how that situation is handled.
[0058] As a first step in that solution, truncation removes a number of the straddle situations. Table 2 shows fault relationships reflecting FIG. 7 a , after truncation. As evident there, truncation of both F 2 and F 3 above F 1 , for example, eliminates both of those straddle situations.
TABLE 3 Above Below Straddle F1 F2, F3, F4, F5, F6, F7 F2 F3, F4, F5, F6, F7 F1 F3 F4, F5, F6, F7 F1, F2 F4 F5, F6, F7 F2 F1, F3 F5 F2, F3, F4, F6, F7 F1 F6 F1, F2, F3, F4, F5 F7 F7 F1, F2, F3, F4, F5, F6
[0059] The remaining straddles are dealt with in the course of building a binary tree. The basic process of building a binary tree is well known in the art and therefore will not considered in depth here, except as bears directly on the process at hand. In general that process goes forward by selecting a root node and successive branch nodes, with successive nodes placed above or below the previous node, based on the topological relationship between the respective fault surfaces. Here, selection of the root node is based on two criteria: First, that a node be selected having the minimum number straddles; and second, that among nodes passing the first criterion, the node selected should offer the best balance between numbers of “Above” and “Below” listings. It is highly preferable that the chosen node have no “straddles,” but in some circumstances that situation cannot be avoided.
[0060] Choices for the root node thus become F 1 , F 6 and F 7 , as those surfaces have no straddling faults. None of these offer well-balanced structures, but the best is F 6 , so that one is chosen as the root node. As to the immediate branches, only F 7 lies above F 6 , so that fault occupies the “above” branch. Of the five faults lying below F 6 , only F 1 has not straddling faults, so that fault is chosen, producing the following initial tree structure:
[0061] Next, the relationships table is reconstructed for each branch of the tree. Here, F 7 is the only fault on the “above” branch, so no table is required there. The new table, showing the branch “F 1 below F 6 ”, is as follows:
TABLE 4 Above Below Straddle F2 F3, F4, F5 F3 F4, F5 F2 F4 F5 F2 F3 F5 F2, F3, F4
[0062] Both F 2 and F 5 lack straddles, and both of them are equally unbalanced, so selection of the next node is optional between these two. Construction of the remainder of the tree follows directly, producing the following structure:
[0063] It must be emphasized that this example shows the principles involved, but it in now way reflects the scope of a project encountered in the field. Seven faults can easily be analyzed by hand, and a tree easily construction. Several hundred faults presents an entirely different problem, and the resulting tree structure is not easily constructed. Moreover, a binary tree of that size involves considerable recursive optimization, clearly a task for a computer.
[0064] The binary tree presents a fault block model, in which each leaf of the tree represents a fault block, a volume bounded by faults. The resulting fault block model 120 is shown in FIG. 8 , in which the faults previously emphasized have become the boundaries between volumes in the geologic domain. Blocks A-H correspond to the following leaf nodes of the binary tree previously constructed:
[0065] Because the analytical work involved in tasks such as reservoir or basin characterization focuses on the fault blocks, not the faults, this development offers the opportunity to organize data into a structure that is more easily accessed than previously.
[0066] As noted above, the scenario discussed above is highly simplified for ease of understanding. An important aspect of fault network analysis needs to be added in order to generate models that conform to geologic reality.
[0067] This problem arises because the binary tree structure discussed so far is not capable of dealing with certain situations. The paradigm configuration is shown in FIG. 9 a , where two faults F 11 and F 12 intersect at an angle (rather than having one fault terminate against another, as discussed above). The drawing shows the faults and their sense of direction, together with their respective extended areas (shown as dashed lines).
[0068] Based on the discussion above, it is clear that the extended sections should be truncated, which would generate the following truncation rules table:
TABLE 5 F11 Above F2 F12 Above F3
[0069] The binary tree structure for that network could assume either of the following forms:
The latter tree yields the block structure shown in FIG. 9 b . As can be seen, block C is clearly defined by faults F 11 and F 12 , but blocks A and B are separated by a portion of F 12 that does not exist in the geologic domain.
[0070] Whether one begins with F 11 or F 12 , however, it is clear that the rule calling for the identification of a fault block at every leaf node will produce three fault blocks, not the two blocks that a visual inspection would suggest. In other words, the binary tree approach, by itself, can produce results that do not mirror reality.
[0071] What is required is to add an analysis step to the binary tree process, as reflected in the process 50 shown in FIG. 10 . At step 52 the fault surface model is created, followed by fault truncation, step 54 . That step is followed by the binary tree construction, step 56 . These steps are discussed in detail above, as is step 58 , identifying fault blocks at the leaf nodes of the tree.
[0072] To avoid the problem of improper fault blocks, step 60 is introduced. There, the system traverses the tree, and at each data node (that is, a fault node), the pairs of fault blocks above and below that node are analyzed to ensure that each pair of blocks is in fact separated by a real fault, not a truncated fault section. For example, one can consider the branches stemming from the F 1 node of the binary tree derived from FIGS. 6 and 7 , above. Block A lies above that node, and blocks B, D, E, C and F lie below it. The system analyzes each pair of blocks to determine whether a real fault separates them. Here, blocks A and B are separated by F 1 ; A and E by F 1 , and so on.
[0073] In the event that a combination is found where two blocks are not separated by a real fault, those blocks are entered on a fused block list, in step 62 . It should be noted that as used here, the term “fused” should not be understood as implying that the blocks are in fact joined, but rather that the blocks should be treated as a single geologic unit by the system. For example, in later processing, the system may perform manipulations of the model to allow for throw along various faults; here, the amount of throw would be constrained to zero, because no physical fault exists. In analyzing the tree derived from FIG. 9 , therefore, blocks A and B would be shown on the binary tree as separate, but based on the entry in the fused blocks list, the system would track the fact that they should be treated as a single physical entity.
[0074] An important result of this analysis is that when considering the data structure required to represent that fault network, the binary tree alone is not sufficient to describe the model. Rather, the binary tree and the fused block list must be treated together.
[0075] The final step in the process is integrating the fault block model into a reservoir model, reflecting not only fault information but also data concerning other horizons in the domain. Techniques for such data integration are known to those in the art and are not set out here FIG. 11 shows reservoir model 130 . As can be seen, this rendering depicts faults F 1 -F 7 in context within the reservoir. In addition to data from seismic or map sources, specific horizon data is also obtained typically from logging data from wells 132 .
[0076] While the present invention is disclosed by reference to the preferred embodiments and examples detailed above, it is understood that these examples are intended in an illustrative rather than in a limiting sense. Computer-assisted processing is implicated in the described embodiments. Accordingly, the present invention may be embodied in methods for analyzing fault networks, systems including logic and resources to carry out fault network and reservoir analysis, media impressed with logic to carry out reservoir, basin or fault network analysis, or computer-accessible services that carry out computer-assisted fault network and reservoir analysis. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the invention and the scope of the following claims. | A method for modeling a geological domain in a computer system, in which the computer system includes data processing and data storage modules, one or more user input devices and a display device, in which the system first receives data relating to faults within the domain. Then there is created a surface plot for each fault described in the data, each surface plot being extended to divide the domain in two portions, and the surface plots are combined into a fault network containing all faults described in the data and displayed on the display apparatus. The network display is modified in response to user input, including the first step of rotating the display about its horizontal and vertical axes as desired to inspect the same. Then the system receives manual truncation commands and truncates indicated fault portions responsive to the same. Responsive to a command initiating automatic truncation, the system selects portions of fault surfaces for truncation according to preselected criteria and truncates the same. Finally, the system stores network information, including a record of changes made, for future use. | 6 |
[0001] This application is a continuation-in-part of pending U.S. patent application Ser. No.10/423,286, filed Apr. 24, 2003, which is a continuation-in-part of pending U. S. patent application Ser. No. 10/150,465 filed May 17, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 10/093,292, filed Mar. 6, 2002, each of the pending applications or issued patents being incorporated herein in their entirety by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to building components, and more specifically composite lightweight building panels which can be selectively interconnected to fabricate structures such as modular buildings, load bearing with wall panels, or applied as cladding to building frames.
BACKGROUND OF THE INVENTION
[0003] Due to the high cost of traditional concrete components and the extensive transportation and labor costs associated therein, there is a significant need in the construction industry to provide a lightweight, precast, composite building panel which may be transported to a building site and assembled to provide a structure with superior strength and insulative properties. Previous attempts to provide these types of materials have failed due to the extensive transportation costs, low insulative values and thermal conductivity associated with prefabricated concrete wire reinforced products. Further, due to the brittle nature of concrete, many of these types of building panels become cracked and damaged during transportation.
[0004] More specifically, the relatively large weight per square foot of previous building panels has resulted in high expenses arising not only from the amount of materials needed for fabrication, but also the cost of transporting and erecting the modules. Module weight also placed effective limits on the height of structures, such as stacked modules, e.g. due to limitations on the total weight carried by the foundations, footings and lowermost modules. Furthermore, there is substantial fabrication labor expense that can arise from efforts needed to design reinforcement, and the materials and labor costs involved in providing and placing reinforcement materials. Accordingly, it would be useful to provide a system for modular construction which is relatively light, can be readily stacked to heights greater than in previous configurations and, preferably, inexpensive to design and manufacture.
[0005] Further, in many situations panels or modules are situated in locations where it is desirable to have openings therethrough to accommodate doorways, windows, cables, pipes and the like. In some previous approaches, panels were required to be specially designed and cast so as to include any necessary openings, requiring careful planning and design and increasing costs due to the special, non-standard configuration of such panels. In other approaches, panels were cast without such openings and the openings were formed after casting, e.g. by sawing or similar procedures. Such post-casting procedures as cutting, particularly through the thick and/or steel-reinforced panels as described above, is a relatively labor-intensive and expensive process. In many processes for creating openings, there was a relatively high potential for cracking or splitting of a panel or module. Accordingly, it would be useful to provide panels and modules which can be post-fitted with openings such as doors and windows in desired locations and with a reduced potential for cracking or splitting.
[0006] One further problem associated with metallic wire materials used in conjunction with concrete is the varying rates of expansion and contraction. Thus with extreme heating and cooling the metallic wire tends to separate from the concrete, thus creating cracks, exposure to moisture and the eventual degradation of both the concrete and wire reinforcement due to corrosion.
[0007] One example of a composite building panel which attempts to resolve these problems with modular panel construction is described in U.S. Pat. No. 6,202,375 to Kleinschmidt (the '375 patent). In this invention, a building system is provided which utilizes an insulative core with an interior and exterior sheet of concrete and which is held together with a metallic wire mesh positioned on both sides of an insulative core. The wire mesh is embedded in concrete, and held together by a plurality of metallic wires extending through said insulative core at a right angle to the longitudinal plane of the insulative core and concrete panels. Although providing an advantage over homogenous concrete panels, the composite panel disclosed in the '375 patent does not provide the necessary strength and flexure properties required during transportation and high wind applications. Further, the metallic wire mesh materials are susceptible to corrosion when exposed to water during fabrication, and have poor insulative qualities due to the high heat transfer qualities of metallic wire. Thus, the panels disclosed in the '375 patent may eventually fail when various stresses are applied to the building panel during transportation, assembly or subsequent use. Furthermore, these panels have poor insulative qualities in cold climates due to the high heat transfer associated with the metallic wires.
[0008] Other attempts have been made to use improved building materials that incorporate carbon fiber. One example is described in U.S. Pat. No. 6,230,465 to Messenger, et al. which utilizes carbon fiber in combination with a steel reinforced precast frame with concrete. Unfortunately, the insulative properties are relatively poor due to the physical nature of the concrete and steel, as well as the excessive weight and inherent problems associated with transportation, stacking, etc. Further, previously known prefabricated building panels have not been found to have sufficient tensile and compressive strength when utilizing only concrete and insulative foam materials or wire mesh. Thus, there is a significant need for a lightweight concrete building panel which has increased tensile and compressive strength, and which utilizes one or more commonly known building materials to achieve this purpose.
[0009] Accordingly, there is a significant need in the construction and building industry to provide a composite building panel which may be used in modular construction and which is lightweight, provides superior strength and has high insulative values. Further, a method of making these types of building panels is needed which is inexpensive, utilizes commonly known manufacturing equipment, and which can be used to mass produce building panels for use in the modular construction of warehouses, low cost permanent housing, hotels, and other buildings.
SUMMARY OF THE INVENTION
[0010] It is thus one aspect of the present invention to provide a composite wall panel which has superior strength, high insulating properties, is lightweight for transportation and stacking purposes and is cost effective to manufacture. Thus, in one embodiment of the present invention, a substantially planar insulative core with interior and exterior surfaces is positioned between concrete panels which are reinforced with carbon fiber grids positioned substantially adjacent to the insulative core and which is interconnected to a plurality of diagonal carbon fiber strands. In a preferred embodiment of the present invention, the interior layer of concrete is comprised of a low-density concrete. Furthermore, as used herein, insulative core may comprise any type of material which is thermally efficient and has a low heat transfer coefficient. These materials may include, but are not limited to, Styrofoam®-type materials such as expanded polystyrenes, extruded polystyrenes, extruded polypropylene, polyisocyanurate, combinations therein and other materials, including wood materials, rubbers, and other materials well known in the construction industry.
[0011] It is yet another aspect of the present invention to provide a superior strength composite wall panel which utilizes carbon fiber materials which are oriented in a novel geometric configuration which interconnects the insulative core and both the interior and exterior concrete panels. In one embodiment of the present invention, a plurality of carbon fibers are oriented in a substantially diagonal orientation through the insulative core and which may be operably interconnected to carbon fiber mesh grids positioned proximate to the interior and exterior surfaces of the insulative core and which operably interconnect both the interior and exterior concrete panels to the insulative core. Preferably, the carbon fiber mesh grid is comprised of a plurality of first carbon fiber strands extending in a first direction which are operably interconnected to a plurality of second carbon fiber strands oriented in a second direction. Preferably, the carbon fiber mesh grids are embedded within the interior and exterior concrete panels.
[0012] It is a further aspect of the present invention to provide a lightweight, composite concrete building panel which is adapted to be selectively interconnected to a structural steel frame. Thus, in one embodiment of the present invention attachment hardware is selectively positioned within the building panel during fabrication which is used to quickly and efficiently interconnect the panel to a structural frame.
[0013] It is another aspect of the present invention to provide a low density concrete building panel which has sufficient compressive strength to allow a s second building panel to be stacked in a vertical relationship, on which can support a vertical load in the form of a floor truss or other structural member. Alternately, it is another aspect of the present invention to provide a composite lightweight building panel which can be utilized in a corner adjacent to a second building panel, or aligned horizontally with a plurality of building panels in a side by side relationship.
[0014] It is a further aspect of the present invention to provide a composite wall panel with an insulative core which has superior compressive strength than typical composite materials comprised of Styrofoam® and other similar materials. Thus, in another aspect of the present invention, a plurality of anti-compression pins are placed throughout the insulative core and which extend substantially between the interior and exterior surfaces of the insulative core. Preferably, these pins are comprised of ceramic, fiberglass, carbon-fiber or other materials which are resistant to compression and do not readily transfer heat.
[0015] It is another aspect of the present invention to provide a composite wall panel which can be easily modified to accept any number of exterior textures, surfaces or cladding materials for use in a plurality of applications. Thus, the present invention is capable of being finished with a brick surface, stucco, siding and any other type of exterior surface. In one embodiment of the present invention, a paraffin protective covering is provided on the exterior surface for protection of the exterior surface during manufacturing. The paraffin additionally prevents an excessive bond between the individual bricks and exterior concrete wall to allow the removal of a cracked or damaged brick and additionally has been found to reduce cracking in the bricks due to the differential shrinkage of the exterior concrete layer and clay brick. Furthermore, other types of materials such as drywall and other interior finishes can be applied to the interior concrete panel as necessary for any given application.
[0016] It is yet a further aspect of the present invention to provide a novel exterior cladding configuration which allows broken or cracked bricks to be quickly and effectively replaced. Thus, in one embodiment of the present invention a beveled brick design is provided wherein a rear portion of the brick has a greater diameter than a front end, and is embedded into the exterior concrete layer during the forming process. This design provides superior strength, and allows a damaged brick to be chiseled free and quickly replaced with a new brick by applying a glue or epoxy material.
[0017] It is yet another aspect of the present invention to provide a composite modular wall panel which can be used to quickly and efficiently construct modular buildings and temporary shelters and is designed to be completely functional with regard to electrical wiring and other utilities such as telephone lines, etc. Thus, the present invention in one embodiment includes at least one utility line which may be positioned at least partially within the composite wall panel and which accepts substantially any type of utility line which may be required in residential or commercial construction, and which can be quickly interconnected to exterior service lines. This utility line may be oriented in one or more directions and positioned either near the interior concrete panel, exterior concrete panel, or both.
[0018] It is yet another aspect of the present invention to provide a novel surface configuration of the insulative core which assures a preferred spacing between the surface of the insulative core and the carbon fiber grid. This surface configuration is applicable for a front surface, a rear surface, or both depending on the application. More specifically, the spacing is designed to provide a gap between the interior and/or the exterior surface of the insulative core and the carbon fiber grids to assure that concrete or other facing materials become positioned between the surface of the insulative core and the carbon fiber grid. This improved and consistent spacing enhances the strength and durability of the insulative panel when interconnected to the facing material, carbon fiber grids and transverse fibers and/or steel pre-stressing strands.
[0019] Thus, in one embodiment of the present invention the insulative core may have an interior and/or an exterior surface which is undulating, i.e., wavy alternative embodiments may have channels or protruding rails, spacer “buttons”, a “waffleboard” configuration, or other shapes which create a preferred spacing between the surface of the insulative material and the fiber grids. Preferably, the spacing apparatus, channels, rails or other spacers are integrally molded with the insulative core to reduce labor and expenses. Alternatively, these spacing apparatus may be interconnected to the insulative foam after manufacturing, and may be attached with adhesives, screws, nails, staples or other interconnection means well known by one skilled in the art.
[0020] Thus, in one embodiment of the present invention, a low density, substantially planar carbon reinforced concrete building panel is provided, and which comprises:
[0021] a foam core having an inner surface, an outer surface, an upper end, a lower end, and a plurality of perimeter edges, said foam core comprising at least one cut-out portion extending substantially between at least two of said plurality of perimeter edges;
[0022] a first concrete material positioned adjacent said outer surface of said foam core;
[0023] a first carbon fiber material positioned within said first concrete material;
[0024] a second carbon fiber material positioned within said at least one cut-out portion of said foam core and extending through said foam core beyond said outer surface and in operable contact with said first carbon fiber material;
[0025] at least one first reinforcing bar positioned proximate to said at least one carbon fiber material within said cut-out portion, and extending substantially between said upper end and said lower end of said foam core; and
[0026] a second concrete material positioned within said cut-out portion of said foam core, and extending substantially from said upper end to a lower end of said foam core.
[0027] It is a further aspect of the present invention to provide a lightweight, durable building panel which utilizes concrete and expanded polystyrene materials, along with a unique geometry of carbon fiber, steel reinforcing rods, and wire mesh to create a building panel with superior strength and durability. The building may utilize one or more reinforcing materials such as carbon fiber, wire mesh or steel reinforcing bars positioned along 1) a perimeter edge; 2) an interior portion within the perimeter edge; or 3) both along the perimeter edges and within a predetermined interior portion of the building panel. Thus, in another embodiment of the present invention a lightweight, durable concrete building panel is provided, comprising:
[0028] a substantially planar concrete panel comprising an inner surface, an outer surface, an upper end and a lower end, and a substantially longitudinal axis defined between said upper end and said lower end;
[0029] a first carbon fiber grid positioned within said substantially planar concrete panel between said upper end and said lower end and positioned proximate to said inner surface;
[0030] a foam core having an inner surface and an outer surface positioned within said substantially planar concrete panel and extending substantially between said upper end and said lower ends of said substantially planar concrete panel;
[0031] at least one carbon fiber shear strip extending through said foam and oriented in a substantially linear direction between said upper end and said lower ends of said substantially planar concrete panel;
[0032] at least one first reinforcing bar positioned proximate to said at least one carbon fiber shear strip, and extending substantially between said upper end and said lower end of said substantially planar concrete panel; and
[0033] a wire mesh material positioned above said upper surface of said foam core and proximate to said outer surface of said substantially planar concrete panel.
[0034] In a preferred embodiment of the present invention, the insulative core is comprised of a plurality of individual insulative panels. The seam of the insulative panels preferably has a cut-out portion which is used to support reinforcing materials such as rebar, carbon fiber or other material.
[0035] It is a further aspect of the present invention to provide a method of fabricating an insulative concrete building panel in a controlled manufacturing facility which is cost effective, utilizes commonly known building materials and produces a superior product. It is a further aspect of the present invention to provide a manufacturing process which can be custom tailored to produce a building panel with custom sizes, allows modifications for windows and doors, and which utilizes a variety of commonly known materials without significantly altering the fabrication protocol.
[0036] Thus, in one aspect of the present invention, a method for fabricating a lightweight, durable concrete building panel is provided, comprising the steps of:
[0037] a) providing a form having an upper end, a lower end, and lateral edges extending therebetween;
[0038] b) positioning a first concrete material into a lower portion of said form;
[0039] c) positioning a first grid of carbon fiber material into said first layer of concrete material;
[0040] d) positioning a foam core onto said first layer of concrete material, said layer of foam core having a plurality of cut-out reinforced sections, said reinforced sections comprising a second grid of carbon fiber material extending into said first layer of concrete material and a reinforcing bar extending substantially along an entire length of said reinforced section and positioned proximate to said second grid of carbon fiber material.
[0041] e) positioning a second layer of concrete within said plurality of reinforced sections; and
[0042] f) removing said lightweight, concrete building panel from said form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] [0043]FIG. 1 is a cross-sectional top plan view of a composite building panel which represents one embodiment of the present invention;
[0044] [0044]FIG. 2 is a cross-sectional top plan view of a composite building panel end section which represents one embodiment of the present invention;
[0045] [0045]FIG. 3 is a cross-sectional top plan view of a composite building panel end return section which represents one embodiment of the present invention;
[0046] [0046]FIG. 4 is a cross-sectional top plan view of a composite building panel window return section, which represents one embodiment of the present invention;
[0047] [0047]FIG. 5 is a cross-sectional top plan view of a composite building panel bottom section, which represents one embodiment of the present invention;
[0048] [0048]FIG. 6 is a cross-sectional top plan view of a composite building panel bottom section, which represents one embodiment of the present invention;
[0049] [0049]FIG. 7 is a cross-sectional top plan view of a composite building wall panel section, which represents one embodiment of the present invention;
[0050] [0050]FIG. 8 is a cross-sectional top plan view of a composite architectural panel with a three-sided rib cut out portion and further including expansion joints;
[0051] [0051]FIG. 9 is a cross-sectional top plan view of a composite architectural panel and including a four-sided mid rib cut out section;
[0052] [0052]FIG. 10 is a cross-sectional front elevation view of an architectural building panel shown at a bearing pocket seat and operably interconnected to a steel girder;
[0053] [0053]FIG. 11 is a cross-sectional top plan view of a first architectural building panel positioned adjacent a second architectural building panel, and further disclosing a thermally broken closed end rib joint;
[0054] [0054]FIG. 12 is a cross-sectional elevation view taken at line AA of FIG. 9, and identifying the carbon fiber web material and other internal components of the architectural panel;
[0055] [0055]FIG. 13 is a cross-sectional front elevation view of an architectural composite building panel and depicting a floor to floor fire barrier positioned adjacent a horizontal floor section;
[0056] [0056]FIG. 14 is a cross-sectional front elevation view of a hardwall panel taken at amid rib section;
[0057] [0057]FIG. 15 is a cross-sectional top plan view of two adjoining composite building panels shown interconnected to a structural steel support member, and the associated hardware;
[0058] [0058]FIG. 16 is a cross-sectional front elevation view showing one composite building panel operably positioned above a second composite building panel;
[0059] [0059]FIG. 17 is a cross-sectional top plan view of a composite building panel used in one embodiment to support a vertical load;
[0060] [0060]FIG. 18 is a cross-sectional top plan view of a load bearing composite wall building panel with a reinforced pilaster portion;
[0061] [0061]FIG. 19 is a cross-sectional top plan view of an alternative composite wall panel;
[0062] [0062]FIG. 20 is a cross-sectional front elevation view depicting the carbon fiber grid and other internal components taken at section BB of FIG. 17;
[0063] [0063]FIG. 21 is a cross-sectional top plan view showing a residential composite wall panel with a substantially square shaped cut out portion;
[0064] [0064]FIG. 22 is a cross-sectional top plan view of a residential composite wall panel shown at an end rib;
[0065] [0065]FIG. 23 is a cross-sectional top plan view of a residential composite building panel shown at a corner rib;
[0066] [0066]FIG. 24 is a cross-sectional front elevation view of a residential composite building panel shown at a top rib; and
[0067] [0067]FIG. 25 is a cross-sectional front elevation view of a residential composite building panel shown at a bottom rib.
DETAILED DESCRIPTION
[0068] Referring now to the drawings, FIG. 1 is a cross-sectional top plan view of one embodiment of the present invention which depicts a novel composite building panel 2 . More specifically, the building panel 2 is generally comprised of an insulative core 4 which has an interior surface 36 and exterior surface 38 and a substantially longitudinal plane extending from a lower portion to an upper portion of said insulative core 4 . Positioned within the insulated core 4 are one or more cut-outs 34 extending from the interior surface 36 and oriented toward an exterior surface 38 . In a preferred embodiment, a thermal break 82 is provided at the apex of the cut-out and which has a dimension of at least about ½ inch and more preferably 1.0-2.0 inches and which separates the interior concrete layer 14 from the exterior concrete layer 16 . The thermal break 82 provides a layer of insulation core 4 , and hence improves the thermal efficiency and heat transfer characteristics of the building panel 2 .
[0069] Positioned within each of the insulative core cutout portions 34 is an interior carbon fiber grid 6 which extends through the insulative core cutout 34 and is positioned adjacent to and more preferably operably connected to the exterior carbon fiber grid 8 . The exterior carbon fiber grid 8 is further embedded within an exterior concrete layer 16 , and which represents in one embodiment an exterior face of the composite building panel 2 . As appreciated by one skilled in the art, the exterior concrete layer 16 may additionally include various types of exterior cladding 20 such as bricks, stucco, and other similar materials depending on the application. As further depicted in FIG. 1, the overall strength of the composite building panel 2 is increased by utilizing one or more reinforcing bars 24 within each of the insulative core cut-outs 34 , or alternatively using prestressed cable 22 . Although the total panel thickness 52 is preferably between about 6 and 10 inches, depending on the application the panel thickness may vary between about 4 and 16 inches as appreciated by one skilled in the art.
[0070] Referring now to FIG. 2, a cross-sectional top plan view of a composite building panel end section is depicted herein. More specifically, the end section has components similar to the panel section shown in FIG. 1, but which has an additional insulative core cut-out portion 34 positioned near the panel end. The insulative core cut-out portion 34 further comprises a plurality of reinforcing bars 24 positioned adjacent an interior carbon fiber grid 6 , and further includes an optional thermal/vapor barrier 12 which is utilized to increase the panel thermal efficiency, and thus prevent excessive heat loss. The thermal/vapor barrier 12 may be comprised of foam materials, polypropylenes, polyethylenes, rubbers, and other thermal/vapor barrier materials well known in the construction industry.
[0071] Referring now to FIG. 3, a cross-sectional top plan view of a composite building panel end return section is depicted herein. More specifically, the architectural panel end return section is designed for use on the end of a wall panel and includes an insulated cut-out portion 34 which further comprises additional thermal/vapor barrier materials 12 to further improve the heat transfer characteristics of the panel. Notwithstanding these differences, the remaining portion of the composite building panel 2 is similar to the embodiments shown in FIGS. 1 and 2, and includes an insulation core 4 with at least one interior carbon fiber grid 6 and an exterior carbon fiber grid 8 , the exterior carbon fiber grid 8 being embedded in an exterior concrete layer 16 .
[0072] Referring now to FIG. 4, a cross-sectional top plan view of a composite building panel window return section is provided herein. More specifically, the panel return section is used in applications adjacent to window and door openings, and which includes an interior insulative core 4 positioned between two insulative core cut-out portions 34 anc having a total diameter 52 of preferably about 6-8 inches. Each of the insulative core cut-out portions 34 are comprised of an interior carbon fiber grid 6 , one or more reinforcing bars 24 , and thermal/vapor barriers 12 positioned within the insulative core cutout 34 and covered with an interior concrete layer 14 . The exterior face of the composite building panel 2 further comprises an exterior carbon fiber grid 8 which is embedded within the exterior concrete layer 16 .
[0073] Referring now to FIG. 5, a cross-sectional top plan view of a composite building panel bottom section is provided herein, and which further depicts an insulative core cut-out portion 34 which is used in conjunction with an interior concrete layer 14 , and an interior carbon fiber grid 6 . As further depicted in FIG. 5, both reinforcing bars 24 and prestress cable 22 are used to increase the structural integrity of the building panel bottom section. Furthermore, a weep tube 44 is provided to allow drainage of any moisture which may accumulate within the architectural panel bottom section. As further shown, a thermal/vapor barrier material 12 is also utilized to improve the thermal efficiency of the building panel 2 .
[0074] Referring now to FIG. 6, an alternative embodiment of the architectural panel bottom section shown in FIG. 5 is provided herein, and which generally comprises the same internal componentry with the exception of a thermal vapor barrier 12 positioned along the interior face of the architectural panel bottom section. The thermal/vapor barrier 12 as previously mentioned could be comprised of foams, plastic materials, concrete, wood, drywall or other commonly used materials which are well known in the construction industry.
[0075] Referring now to FIG. 7, an alternative embodiment of a wall panel section is provided herein, and more specifically comprises a wall panel composite building panel 2 which includes an additional layer of interior carbon fiber grids 6 positioned in close proximity to an interior surface, and within an interior concrete layer 14 . As used herein, both the interior carbon fiber grid 6 and exterior carbon fiber grid 8 may be comprised of alternative materials such as wire mesh, fiberglass, and other construction materials to provide increased strength in structural integrity of the composite building panel. Preferably, however, the materials utilize a material known as “MeC-GRID™” which is a carbon composite comprised of a plurality of individual carbon fibers held together with an adhesive or epoxy.
[0076] Referring now to FIG. 8, a cross-sectional top plan view of a composite architectural building panel 2 of the present invention is provided herein, and which depicts a triangular shaped cut-out portion 34 which includes a interior carbon fiber grid 6 , one or more reinforcing bars 24 , and an interior concrete layer 14 positioned within the cut-out portion 34 . Furthermore, a plurality of expansion joints 58 are provided within the insulative core 4 which are utilized to prevent excessive compression of the concrete building panel during manufacturing, transportation, and installation, and thus substantially eliminates hairline fractures of the concrete. The expansion joints are preferably cutout portions of the insulative core material 4 , but other compressible materials may be positioned within the expansion joints 58 as appreciated by one skilled in the art.
[0077] Referring now to FIG. 9, a cross-sectional top plan view of an architectural panel with a four-sided mid rib is shown herein. More specifically, this embodiment is similar to the other architectural panels with the exception that the reinforcing rib cut-out portion 34 is four-sided as opposed to the triangular configurations shown in other embodiments. As appreciated by one skilled in the art, the cut-out portion 34 may have 9 cross-sectional geometric shapes which are triangular, rectangular, square, cylindrical, oblong or any other theoretical shape. As further depicted in FIG. 9, a plurality of expansion joints 58 are also utilized in this embodiment to help prevent cracking and the ultimate failure of the concrete materials.
[0078] Referring now to FIG. 10, an alternative embodiment of the present invention is provided herein and which depicts a cross-sectional front elevation view of a composite building panel 2 operably connected to a steel structural column 60 . As provided herein, the composite building panel 2 further utilizes a thermal/vapor barrier 12 , and is interconnected by the use of a slotted lateral connector hardware 64 configuration which has a plurality of bolts or other attachment hardware embedded in the interior concrete layer 14 , and which is operably interconnected to the steel structural column 60 . As further shown in FIG. 10, an interconnection stud 80 is embedded in the interior concrete layer 14 on a lower portion of the building panel 2 , and which rests on a bearing angle with gussets 62 for vertical support. To provide horizontal adjustments between the structural column 60 and the composite building panel 2 , a threaded fastener 74 may be rotated.
[0079] Referring now to FIG. 11, a cross-sectional top plan view of two architectural panels positioned adjacent one another are provided herein, and which further include a thermally broken closed-end rib joint. More specifically, FIG. 11 depicts a first composite building panel 2 positioned adjacent a second composite building panel, and which includes a insulative core 4 with a insulative core cut-out portion 34 positioned substantially adjacent to one another. Each of the insulative core cut-out portions 34 may include one or more reinforcing bars 24 , an interior carbon fiber grid 6 , as well as a thermal vapor barrier 12 . The exterior face comprises a exterior concrete layer 16 which includes an embedded exterior carbon figure grid 8 . Positioned between the first composite building panel 2 and the second composite building panel is a foam rope 54 which is generally compressible and which impedes heat transfer between an interior and exterior structure of the composite building panels 2 . Furthermore, a caulking material 56 may be positioned around the foam rope 54 to further improve the seal between the two building panels and improve the thermal efficiency.
[0080] Referring now to FIG. 12, a cross-sectional front elevation view taken at line “AA” of FIG. 8 is provided herein. More specifically, the cross-sectional view identifies an architectural panel at the rib joint, and depicts the insulative core 4 , the interior carbon fiber grid 6 , the exterior carbon fiber grid 8 , and the reinforcing bar 24 materials which are embedded within the composite building panel 2 for structural integrity. Furthermore, an interior concrete layer 14 may be positioned along an interior face of the composite building panel 2 , or other materials such as wood, dry-wall, and other known construction materials.
[0081] Referring now to FIG. 13, a cross-sectional front elevation view of an architectural composite building panel 2 which depicts a floor to floor fire barrier is provided herein. More specifically, a concrete floor slab 68 is positioned in a horizontal orientation and positioned adjacent to a vertical composite building panel 2 of the present invention. To provide a floor to floor fire barrier, a mineral wall board 66 may be provided in one or more locations in association with non interior concrete layer 14 to prevent the heat transfer between two adjacent floors in a building structure. As further depicted in FIG. 13, the insulative core cut-out 34 is shown within the insulative core 4 , and further includes a plurality of interior carbon fiber grids 6 , as well as an exterior carbon fiber grid 8 which is embedded in a exterior concrete layer 16 . Furthermore, a plurality of reinforcing bars 24 may be provided as shown to provide additional structural integrity to the building panel 2 .
[0082] Referring now to FIG. 14, a cross-sectional front elevation view of a hardwall panel taken at a mid rib section is provided herein, and which generally depicts an insulative core 4 positioned between an exterior concrete layer 16 , an interior concrete layer 14 , and a interior carbon fiber grid 6 and exterior carbon fiber grid 8 . The insulative core cut-out portion 34 further includes one or more reinforcing bars 24 or prestressed cables 22 , and which also includes an interior carbon fiber grid 6 which extends substantially from the exterior concrete layer 16 to the interior concrete layer 14 for strength.
[0083] Referring now to FIG. 15, an alternative embodiment of the present invention is provided herein, and which depicts two composite building panels 2 operably interconnected to a steel structural column 60 . More specifically, a unistrut channel with posts 70 is shown interconnected to an interior surface of each of the composite building panels 2 , and are embedded into the insulative core 4 and into an interior concrete layer 14 . These unistrut channels with parts 70 are further used in combination with a column clip 72 and threaded fasteners 74 to interconnect each of the composite building panels 2 to a steel structural column 60 . By utilizing this type of attachment hardware, steel structural buildings may be quickly assembled utilizing the lightweight composite building panels of the present invention. As further depicted in FIG. 15, a foam rope 54 and caulking material 56 may be utilized for sealing and heat transfer purposes between each of the composite building panels 2 .
[0084] Referring now to FIG. 16, a cross-sectional front elevation view showing one composite building panel operably positioned below a second composite building panel 2 is provided herein. More specifically, a compressible gasket seal 76 is positioned between the first composite building panel 2 and a second composite building panel positioned vertically on top of the first composite building panel 2 . At the location where the composite building panels 2 are stacked, a insulative core cut-out portion 34 is provided, which includes one or more interior carbon fiber grid 6 which are interconnected to an exterior carbon fiber grid 8 , and which are embedded in concrete along with either prestressed cable 22 or steel 5 reinforcing bars 24 . By utilizing an insulative core 4 and interior and exterior carbon fiber grids, 6 and 8 , respectively, it has been found that the composite building panels 2 of the present invention may be stacked vertically for lengths up to about 40 to 60 feet in an economical and safe manner.
[0085] Referring now to FIG. 17, a cross-sectional top plan view of a composite building 10 wall panel 2 used in one embodiment to support a vertical load is provided herein. As shown in this embodiment, both the exterior carbon fiber grids 8 and interior carbon fiber grids 6 are positioned within a exterior concrete layer 16 and into concrete layer 14 , respectively, and which are interconnected with either prestressed cable 22 and another layer of interior carbon fiber grid 6 material. By providing the additional structural integrity with the interior and exterior carbon fiber grids, it has been found that the wall panels may be used to vertically support other panel walls, or can be load bearing to support trusses and other structural frame work.
[0086] Referring now to FIG. 18, a cross-sectional top plan view of a load bearing composite wall building panel 12 with a reinforced “pilaster” portion 78 is provided herein. More specifically, the insulative core cut-out portion 34 comprises a plurality of prestressed cable 22 , or alternatively reinforcing bars 24 , and are used in combination with an interior carbon fiber grid 6 and interior concrete layers 14 to provide a reinforced load bearing panel wall which is capable of compressive structural loads of at least about 3500 psi.
[0087] Referring now to FIG. 19, a cross-sectional of plan view of an alternative composite wall panel 2 is provided herein, and which further identifies a insulative core cut-out 34 which is used in combination with prestressed cable 22 , and interior carbon fiber grid 6 and exterior carbon fiber grid 8 . The carbon fiber grids are further embedded in an exterior concrete layer 16 , an interior concrete layer 14 , and which provide a strong wall panel for numerous construction applications. As further depicted in this drawing, the wall panel 2 has a width of about 6 inches, which includes a 2 inch layer of exterior concrete 16 , a 2 inch layer of interior concrete 14 , and a 4 inch layer of insulation core 4 .
[0088] Referring now to FIG. 20, a cross-sectional front elevation view depicting the carbon fiber grid and other internal components taken at section BB of FIG. 17 is provided herein. More specifically, the interior carbon fiber grid 6 is shown extending substantially between an exterior concrete layer 16 to an interior concrete layer 14 , and further interconnected to a exterior carbon fiber grid 8 and an interior carbon fiber grid 6 . By utilizing these materials in combination with the lightweight insulated core 4 , a lightweight, structurally reinforced wall panel can be constructed and transported in a cost effective manner.
[0089] Referring now to FIG. 21, a cross-sectional top plan view is provided which depicts a multi-unit residential wall panel, and depicting a middle rib cut-out 34 provided herein.
[0090] More specifically, the insulative cut-out 34 in this embodiment includes a substantially square shaped cut-out portion 34 which includes a interior concrete layer 14 , a interior is carbon fiber grid 6 , and one or more reinforcing bars 24 or pre-stressed cable. Preferably, the width of the insulative core cut-out 34 is about 4 inches, but as appreciated by one skilled in the art may be between about 2 and 10 inches as necessary. Furthermore, a plurality of expansion joint 58 may be provided herein to help maintain the structural integrity of the interior concrete layer 14 and the exterior concrete layer 16 . Furthermore, the residential wall panel shown in FIG. 21 is designed to be less load bearing than some other embodiments of the present invention, and would generally be utilized for exterior or interior wall applications.
[0091] Referring now to FIG. 22, a cross-sectional top plan view of a residential composite wall panel shown at an rib is provided herein. More specifically, a substantially square end rib is shown adjacent to an end portion of the wall panel 2 , and which includes an interior carbon fiber grid 6 , at least one reinforcing bar 24 , and a small layer of an insulative core material 34 which serves as a thermal break 82 between the interior concrete layer 14 and the exterior concrete layer 16 .
[0092] Referring now to FIG. 23, a cross-sectional top plan view of a residential composite building panel as shown at a corner rib is provided herein. More specifically, the interconnection of two composite building panels 2 are shown at a corner section, and which utilizes a foam rope 54 and caulking material for insulative purposes. The end sections utilize a insulative cut-out 34 which includes one or more interior carbon fiber grid 6 , one or more reinforcing bars 24 or prestressed cable 22 , and a thermal/vapor barrier 12 . By utilizing the combination of these materials, additional structural integrity can be achieved at the corner sections between two composite building panels 2 .
[0093] Referring now to FIG. 24, a cross-sectional front elevation view of a residential composite building panel shown at a top rib is provided herein. More specifically, the insulative core cut-out portion 34 includes one or more reinforcing bars 24 and a plurality of interior carbon fiber grids 6 which are interconnected to an exterior carbon fiber grid 8 . As further depicted in FIG. 24, a thermal break 82 is provided with a one to two inch layer of insulated core material 4 , and which is positioned between the exterior concrete layer 16 and the interior concrete layer 14 . The notch created from the top of the building panel upper end 36 and the upper portion of the insulative core cut-out 34 may be utilized to support structural beams, floor joists or other structural members comprised of wood, concrete, steel or other well known materials used in residential or commercial construction.
[0094] Referring now to FIG. 25, a cross-sectional front elevation view of a residential composite building panel shown at a bottom rib is provided herein. More specifically, the bottom rib comprises a insulative core cutout 34 which utilizes one or more reinforcing bars 24 or prestressed cables 22 , and which are positioned within an interior concrete layer 14 and extending outwardly toward an exterior face and into an exterior concrete layer 16 . As further shown, the exterior concrete layer 16 further comprises an exterior carbon fiber grid 8 . By utilizing the insulative core cut-out 34 and other structural components described herein, structural integrity and strength is provided to the bottom rib of the residential panel, and which is capable of withstanding the loading requirements necessary in a residential wall panel and capable of compressive strengths of at least about 3500 psi.
[0095] In many of the embodiment of the present invention, the insulative core 4 is manufactured in a unique process with a plurality of carbon fibers strands 10 positioned in a ribbon/tape pattern 30 which extends through the insulative core 4 and which protrudes beyond both the interior and exterior surfaces to accommodate interconnection to the interior and exterior carbon fiber grids. Alternatively, metallic materials such as wire and mesh comprised of steel or other similar materials may also be used as appreciated by one skilled in the art.
[0096] A depiction of one embodiment of the carbon fiber strands 10 and their orientation and interconnection may be seen in FIG. 12. These carbon fiber strands 10 generally have a thickness of between about 0.05 inches to 0.4 inch, and more preferably a diameter of about 0.15 inches. As more typically referred to in the art, the carbon fiber strands 10 have a given “tow” size. The tow is the number of carbon strands, and may be in the example between about 12,000-48,000 individual strands, i.e., 12K to 48K tow. The intersection points of the carbon fiber strands which are required to make the tape pattern are interconnected with a strong resin such as a thermoset which is applied under a predetermined heat and pressure. In another embodiment, the individual strands of carbon fiber may be “woven” with other strands to create a stronger ribbon/tape material 30 .
[0097] The carbon fiber strands 10 are interconnected to the interior carbon fiber grid 6 positioned substantially adjacent to the interior surface of the insulative core and with the exterior carbon fiber grid 8 positioned substantially adjacent the exterior surface of the insulative core 4 . One example of a carbon fiber grid ribbon 30 which may be used in the present invention is the “MeC-GRID™” carbon fiber material which is manufactured by Hexcel Clark-Schwebel. The interior and exterior carbon grid tape is comprised generally of looped or crossed weft and warped strands, that run substantially perpendicular to each other and are machine placed on several main tape “stabilizing strands” that run parallel to the running/rolling direction of the tape. The carbon fiber tape is then used in a totally separate process by casting it transversely through the insulating core 4 , to produce an insulated structural core panel that links together compositively the interior concrete layer 14 and exterior concrete layer 16 of the composite wall panel 2 .
[0098] With regard to the concrete utilized in various embodiments of the present application, the interior wall may be comprised of a low density concrete such as Cret-o-Lite™, which is manufactured by Advanced Materials Company of Hamburg, N.Y. This is an air dried cellular concrete which is nailable, drillable, screwable, sawable and very fire resistant. In a preferred embodiment, the exterior concrete layer 16 is comprised of a dense concrete material to resist moisture penetration and in one embodiment is created using VISCO CRETE™ or equal product which is a chemical that enables the high slumped short pot life liquification of concrete to enable the concrete to be placed in narrow wall cavities with minimum vibration and thus create a high density substantially impermeable concrete layer. VISCO-CRETE™ is manufactured by the Sika Corporation, located in Lyndhurst, N.J. The exterior concrete layer 16 is preferably about ¾ to 2 inches thick, and more preferably about 1.25 inches thick. This concrete layer has a compression strength of approximately 5000 psi after 28 days of curing, and is thus extremely weather resistant.
[0099] In a preferred embodiment of the present invention, a vapor barrier material 12 may be positioned next to or on to the exterior surface of the insulative core 4 , or alternatively on the interior surface of the insulative foam core 4 . The vapor barrier 12 impedes the penetration of moisture and thus protects the foam core from harsh environmental conditions caused by temperature changes. Preferably, the vapor barrier 12 is comprised of a plastic sheet material, or other substantially impermeable materials that may be applied to the insulative core 4 during manufacturing of the foam core, or alternatively applied after manufacturing and prior to the pouring of the exterior concrete layer 16 .
[0100] Positioned proximate to the carbon fiber sheer strip 30 is one or more reinforcing bar 36 , which are generally “rebar” materials manufactured from carbon steel or other similar metallic materials. Preferably, the reinforcing bar 36 has a diameter of at least about 0.5 inches, and more preferably about 0.75-1.00 inches. As appreciated by one skilled in the art, the reinforcing bars 36 may be any variety of dimensions or lengths depending on the length and width of the building panel 2 , and the strength requirements necessary for any given project. As additionally seen in FIG. 11, a third reinforcing bar 36 may additionally be positioned proximate to the wire mesh 38 adjacent the building panel interior surface 14 to provide additional strength and durability.
[0101] To assist in the understanding of the present invention, the following is a list of the components identified in the drawings and the numbering associated therewith:
# Component 2 Composite building panel 4 Insulative core 6 Interior carbon fiber grid 8 Exterior carbon fiber grid 10 Carbon fiber strands 12 Thermal/vapor barrier 14 Interior concrete layer 16 Exterior concrete layer 18 Utility conduit 20 Exterior cladding 22 Pre-stressed cable 24 Reinforcing bar 26 Wire mesh 28 Lifting anchor 30 Reinforced window/door frame 32 Lifting anchor reinforcing mesh material 34 Insulative core cut-out 36 Insulative core inner surface 38 Insulative core outer surface 40 Insulative core upper end 42 Insulative core lower end 44 Weep tube 46 Building panel upper end 48 Building panel lower end 50 Fabrication form 52 Panel thickness 54 Foam rope 56 Caulking 58 Expansion joint 60 Steel structural column 62 Bearing angle with gussets 64 Slotted lateral connector hardware 66 Mineral wool board 68 Concrete floor slab 70 Unistrut channel with posts 72 Column clip 74 Threaded fastener 76 Compressible gasketlseal 78 Pilaster 80 Interconnection stud 82 Thermal Break
[0102] The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commenced here with the above teachings and the skill or knowledge of the relevant art are within the scope in the present invention. The embodiments described herein above are further extended to explain best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments or various modifications required by the particular applications or uses of present invention. It is intended that the dependent claims be construed to include all possible embodiments to the extent permitted by the prior art. | An insulative, lightweight building panel is provided with a lightweight, insulative foam core and which includes one or more carbon fiber or steel reinforcements and an exterior concrete face which are manufactured in a controlled environment and can be easily transported and erected at a building site. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 10/622,320, filed Jul. 17, 2003, which is a continuation of U.S. patent application Ser. No. 09/336,266, filed Jun. 18, 1999, now U.S. Pat. No. 6,608,060, which is a continuation of International Application No. PCT/US97/23392, filed Dec. 17, 1997, which is a continuation-in-part of U.S. patent application Ser. No. 08/862,925, filed Jun. 10, 1997, now U.S. Pat. No. 6,147,080, which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned; said International Application No. PCT/US97/23392 is a continuation-in-part of U.S. application Ser. No. 08/822,373, filed Mar. 20, 1997, now U.S. Pat. No. 5,945,418, which claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned; and said International Application No. PCT/US97/23392 claims the benefit of U.S. Provisional Application No. 60/034,288, filed Dec. 18, 1996, now abandoned.
TECHNICAL FIELD OF INVENTION
The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders.
BACKGROUND OF THE INVENTION
Protein kinases are involved in various cellular responses to extracellular signals. Recently, a family of mitogen-activated protein kinases (MAPK) have been discovered. Members of this family are Ser/Thr kinases that activate their substrates by phosphorylation [B. Stein et al., Ann. Rep. Med. Chem ., 31, pp. 289-98 (1996)]. MAPKs are themselves activated by a variety of signals including growth factors, cytokines, UV radiation, and stress-inducing agents.
One particularly interesting MAPK is p38. p38, also known as cytokine suppressive anti-inflammatory drug binding protein (CSBP) and RK, was isolated from murine pre-B cells that were transfected with the lipopolysaccharide (LPS) receptor CD14 and induced with LPS. p38 has since been isolated and sequenced, as has the cDNA encoding it in humans and mouse. Activation of p38 has been observed in cells stimulated by stresses, such as treatment of lipopolysaccharides (LPS), UV, anisomycin, or osmotic shock, and by cytokines, such as IL-1 and TNF.
Inhibition of p38 kinase leads to a blockade on the production of both IL-1 and TNF. IL-1 and TNF stimulate the production of other proinflammatory cytokines such as IL-6 and IL-8 and have been implicated in acute and chronic inflammatory diseases and in post-menopausal osteoporosis [R. B. Kimble et al., Endocrinol ., 136, pp. 3054-61 (1995)].
Based upon this finding it is believed that p38, along with other MAPKs, have a role in mediating cellular response to inflammatory stimuli, such as leukocyte accumulation, macrophage/monocyte activation, tissue resorption, fever, acute phase responses and neutrophilia. In addition, MAPKs, such as p38, have been implicated in cancer, thrombin-induced platelet aggregation, immunodeficiency disorders, autoimmune diseases, cell death, allergies, osteoporosis and neurodegenerative disorders. Inhibitors of p38 have also been implicated in the area of pain management through inhibition of prostaglandin endoperoxide synthase-2 induction. Other diseases associated with IL-1, IL-6, IL-8 or TNF overproduction are set forth in WO 96/21654.
Others have already begun trying to develop drugs that specifically inhibit MAPKs. For example, PCT publication WO 95/31451 describes pyrazole compounds that inhibit MAPKs, and in particular p38. However, the efficacy of these inhibitors in vivo is still being investigated.
Accordingly, there is still a great need to develop other potent, p38-specific inhibitors that are useful in treating various conditions associated with p38 activation.
SUMMARY OF THE INVENTION
The present invention solves this problem by providing compounds which demonstrate strong and specific inhibition of p38.
These compounds have the general formula:
wherein each of Q 1 and Q 2 are independently selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems, or 8-10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NW′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 -C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 -C 3 )-alkyl; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2)N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 -C 3 )-alkyl; (C 2 -C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 -C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5-6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N (R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 ) —S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 —.
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 —, —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4-8 membered carbocyclic or heterocyclic ring;
R 2 is selected from hydrogen, (C 1 -C 3 )-alkyl, or (C 2 -C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 -C 3 )-alkyl, OH, or O—(C 1 -C 3 )-alkyl.
In another embodiment, the invention provides pharmaceutical compositions comprising the p38 inhibitors of this invention. These compositions may be utilized in methods for treating or preventing a variety of disorders, such as cancer, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, viral diseases and neurodegenerative diseases. These compositions are also useful in methods for preventing cell death and hyperplasia and therefore may be used to treat or prevent reperfusion/ischemia in stroke, heart attacks, organ hypoxia. The compositions are also useful in methods for preventing thrombin-induced platelet aggregation. Each of these above-described methods is also part of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides inhibitors of p38 having the general formula:
wherein each of Q 1 and Q 2 are independently selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems, or 8-10 membered bicyclic ring systems comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring.
The rings that make up Q 1 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
The rings that make up Q 2 are optionally substituted with up to 4 substituents, each of which is independently selected from halo; C 1 -C 3 straight or branched alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; O—(C 1 -C 3 )-alkyl; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′, S(O 2 )N(R′) 2 , N═CH—N(R′) 2 , R 3 , or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; R 3 ; OR 3 ; NHR 3 ; SR 3 ; C(O)R 3 ; C(O)N(R′)R 3 ; C(O)OR 3 ; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; N═CH—N(R′) 2 ; or CN.
R′ is selected from hydrogen, (C 1 -C 3 )-alkyl; (C 2 -C 3 )-alkenyl or alkynyl; phenyl or phenyl substituted with 1 to 3 substituents independently selected from halo, methoxy, cyano, nitro, amino, hydroxy, methyl or ethyl.
R 3 is selected from 5-6 membered aromatic carbocyclic or heterocyclic ring systems.
R 4 is (C 1 -C 4 )-alkyl optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 ; or a 5-6 membered carbocyclic or heterocyclic ring system optionally substituted with N(R′) 2 , OR′, CO 2 R′, CON(R′) 2 , or SO 2 N(R 2 ) 2 .
X is selected from —S—, —O—, —S(O 2 )—, —S(O)—, —S(O 2 )—N(R 2 )—, —N(R 2 )—S(O 2 )—, —N(R 2 )—C(O)O—, —O—C(O)—N(R 2 ), —C(O)—, —C(O)O—, —O—C(O)—, —C(O)—N(R 2 )—, —N(R 2 )—C(O)—, —N(R 2 )—, —C(R 2 ) 2 —, or —C(OR 2 ) 2 —.
Each R is independently selected from hydrogen, —R 2 , —N(R 2 ) 2 , —OR 2 , SR 2 , —C(O)—N(R 2 ) 2 , —S(O 2 )—N(R 2 ) 2 , or —C(O)—OR 2 , wherein two adjacent R are optionally bound to one another and, together with each Y to which they are respectively bound, form a 4-8 membered carbocyclic or heterocyclic ring;
When the two R components form a ring together with the Y components to which they are respectively bound, it will obvious to those skilled in the art that a terminal hydrogen from each unfused R component will be lost. For example, if a ring structure is formed by binding those two R components together, one being —NH—CH 3 and the other being —CH 2 —CH 3 , one terminal hydrogen on each R component (indicated in bold) will be lost. Therefore, the resulting portion of the ring structure will have the formula —NH—CH 2 —CH 2 —CH 2 —.
R 2 is selected from hydrogen, (C 1 -C 3 )-alkyl, or (C 2 -C 3 )-alkenyl; each optionally substituted with —N(R′) 2 , —OR′, SR′, —C(O)—N(R′) 2 , —S(O 2 )—N(R′) 2 , —C(O)—OR′, or R 3 .
Y is N or C;
A, if present, is N or CR′;
n is 0 or 1;
R 1 is selected from hydrogen, (C 1 -C 3 )-alkyl, OH, or O—(C 1 -C 3 )-alkyl. It will be apparent to those of skill in the art that if R 1 is OH, the resulting inhibitor may tautomerize resulting in compounds of the formula:
which are also p38 inhibitors of this invention.
According to another preferred embodiment, Q 1 is selected from phenyl or pyridyl containing 1 to 3 substituents, wherein at least one of said substituents is in the ortho position and said substituents are independently selected from chloro, fluoro, bromo, —CH 3 , —OCH 3 , —OH, —CF 3 , —OCF 3 , —O(CH 2 ) 2 CH 3 , NH 2 , 3,4-methylenedioxy, —N(CH 3 ) 2 , —NH—S(O) 2 -phenyl, —NH—C(O)O—CH 2 —4-pyridine, —NH—C(O)CH 2 -morpholine, —NH—C(O)CH 2 —N(CH 3 ) 2 , —NH—C(O)CH 2 -piperazine, —NH—C(O)CH 2 -pyrrolidine, —NH—C(O)C(O)-morpholine, —NH—C(O)C(O)-piperazine, —NH—C(O)C(O)-pyrrolidine, —O—C(O)CH 2 —N(CH 3 ) 2 , or —O—(CH 2 ) 2 —N(CH 3 ) 2 .
Even more preferred are phenyl or pyridyl containing at least 2 of the above-indicated substituents both being in the ortho position.
Some specific examples of preferred Q 1 are:
Most preferably, Q 1 is selected from 2-fluoro-6-trifluoromethylphenyl, 2,6-difluorophenyl, 2,6-dichlorophenyl, 2-chloro-4-hydroxyphenyl, 2-chloro-4-aminophenyl, 2,6-dichloro-4-aminophenyl, 2,6-dichloro-3-aminophenyl, 2,6-dimethyl-4-hydroxyphenyl, 2-methoxy-3,5-dichloro-4-pyridyl, 2-chloro-4,5 methylenedioxy phenyl, or 2-chloro-4-(N-2-morpholino-acetamido)phenyl.
According to a preferred embodiment, Q 2 is phenyl or pyridyl containing 0 to 3 substituents, wherein each substituent is independently selected from chloro, fluoro, bromo, methyl, ethyl, isopropyl, —OCH 3 , —OH, —NH 2 , —CF 3 , —OCF 3 , —SCH 3 , —C(O)OH, —C(O)OCH 3 , —CH 2 NH 2 , —N(CH 3 ) 2 , —CH 2 -pyrrolidine and —CH 2 OH.
Some specific examples of preferred Q 2 are:
unsubstituted 2-pyridyl or unsubstituted phenyl.
Most preferred are compounds wherein Q 2 is selected from phenyl, 2-isopropylphenyl, 3,4-dimethylphenyl, 2-ethylphenyl, 3-fluorophenyl, 2-methylphenyl, 3-chloro-4-fluorophenyl, 3-chlorophenyl, 2-carbomethoxylphenyl, 2-carboxyphenyl, 2-methyl-4-chlorophenyl, 2-bromophenyl, 2-pyridyl, 2-methylenehydroxyphenyl, 4-fluorophenyl, 2-methyl-4-fluorophenyl, 2-chloro-4-fluorphenyl, 2,4-difluorophenyl, 2-hydroxy-4-fluorphenyl or 2-methylenehydroxy-4-fluorophenyl.
According to yet another preferred embodiment, X is —S—, —O—, —S(O 2 )—, —S(O)—, —NR—, —C(R 2 )— or —C(O)—. Most preferably, X is S.
According to another preferred embodiment, n is 1 and A is N.
According to another preferred embodiment, each Y is C.
According an even more preferred embodiment, each Y is C and the R attached to those Y components is selected from hydrogen or methyl.
Some specific inhibitors of this invention are set forth in the table below.
TABLE 1
Formula Ia and Ib Compounds.
cpd
#
structure
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ia) depicted above. These methods involve reacting a compound of formula II:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula IIa:
wherein R′ is as defined above, or a leaving group reagent of formula IIb:
wherein each of L 1 , L 2 , and L 3 independently represents a leaving group.
The leaving group reagent used in this reaction is added in excess, either neat or with a co-solvent, such as toluene. The reaction is carried out at a temperature of between 25° C. and 150° C.
Leaving group reagents of formula ha that are useful in producing the p38 inhibitors of this invention include dimethylformamide dimethylacetal, dimethylacetamide dimethylacetal, trimethyl orthoformate, dimethylformamide diethylacetal and other related reagents. Preferably the leaving group reagent of formula IIa used to produce the inhibitors of this invention is dimethylformamide dimethylacetal.
Leaving group reagents of formula IIb that are useful in producing the p38 inhibitors of this invention include phosgene, carbonyldiimidazole, diethyl carbonate and triphosgene.
More preferred methods of producing the compounds of this invention utilize compounds of formula II wherein each of the variables are defined in terms of the more preferred and most preferred choices as set forth above for the compounds of this invention.
Because the source of R 1 is the leaving group reagent (C—R′ or C═O), its identity is, of course, dependent on the structure of that reagent. Therefore, in compounds where R 1 is OH, the reagent used must be IIb. Similarly, when R 1 is H or (C 1 -C 3 )-alkyl, the reagent used must be IIa. In order to generate inhibitors wherein R 1 is O—(C 1 -C 3 )-alkyl, a compound wherein R 1 is OH is first generated, followed by alkylation of that hydroxy by standard techniques, such as treatment with Na hydride in DMF, methyl iodide and ethyl iodide.
The immediate precursors to the inhibitors of this invention of formula Ia (i.e., compounds of Formula II) may themselves be synthesized by either of the synthesis schemes depicted below:
In Scheme 1, the order of steps 1) and 2) can be reversed. Also, the starting nitrile may be replaced by a corresponding acid or by an ester. Alternatively, other well-known latent carboxyl or carboxamide moieties may be used in place of the nitrile (see scheme 2). Variations such as carboxylic acids, carboxylic esters, oxazolines or oxizolidinones may be incorporated into this scheme by utilizing subsequent deprotection and functionalization methods which are well known in the art
The base used in the first step of Scheme 1 (and in Scheme 2, below) is selected from sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases that will deprotonate the position alpha to the nitrile.
Also, the addition of HX-Q 2 in the single step depicted above may be substituted by two steps—the addition of a protected or unprotected X derivative followed by the addition of a Q 2 derivative in a subsequent step.
In Scheme 2, Z is selected from COOH, COOR′, CON(R′) 2 , oxazoline, oxazolidinone or CN. R′ is as defined above.
According to another embodiment, the present invention provides methods of producing inhibitors of p38 of the formula (Ib) depicted above. These methods involve reacting a compound of formula III:
wherein each of the variables in the above formula are the same as defined above for the inhibitors of this invention, with a leaving group reagent of formula:
as described above.
Two full synthesis schemes for the p38 inhibitors of formula (Ib) of this invention are depicted below.
In scheme 3, a Q 1 substituted derivative may be treated with a base such as sodium hydride, sodium amide, LDA, lithium hexamethyldisilazide, sodium hexamethyldisilazide or any number of other non-nucleophilic bases to deprotonate the position alpha to the Z group, which represents a masked amide moiety. Alternatively, Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone. The anion resulting from deprotonation is then contacted with a nitrogen bearing heterocyclic compound which contains two leaving groups, or latent leaving groups, in the presence of a Palladium catalyst. One example of such compound may be 2,6-dichloropyridine.
In step two, the Q 2 ring moiety is introduced. This may be performed utilizing many reactions well known in the art which result in the production of biaryl compounds. One example may be the reaction of an aryl lithium compound with the pyridine intermediate produced in step 1. Alternatively, an arylmetallic compound such as an aryl stannane or an aryl boronic acid may be reacted with the aryl halide portion of the pyridine intermediate in the presence of a Pd O catalyst.
In step 3 the Z group is deprotected and/or functionalized to form the amide compound. When Z is a carboxylic acid, carboxylic ester, oxazoline or oxazolidinone, variations in deprotection and functionalization methods which are well known in the art are employed to produce the amide. Finally in step 4, the amide compound is cyclized to the final product utilizing reagents such as DMF acetal or similar reagents either neat or in an organic solvent.
Scheme 4 is similar except that the a biaryl intermediate is first generated prior to reaction with the Q1 starting material.
According to another embodiment, the invention provides inhibitors of p38 similar to those of formulae Ia and Ib above, but wherein the C═N in the ring bearing the Q 1 substituent is reduced. These inhibitors have the formula:
wherein A, Q 1 , Q 2 , R, R′, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). R 5 is selected from hydrogen, —CR′ 2 OH, —C(O)R 4 , —C(O)OR 4 , —CR′ 2 OPO 3 H 2 , —PO 3 H 2 , and salts of —PO 3 H 2 .
When R 5 is not hydrogen, the resulting compounds are expected to be prodrug forms which should be cleaved in vivo to produce a compound wherein R 5 is hydrogen.
According to other preferred embodiments, in compounds of formula Ic, A is preferably nitrogen, n is preferably 1, and X is preferably sulfur. In compounds of formula Ic or Id, Q 1 and Q 2 are preferably the same moieties indicated above for those variables in compounds of formulae Ia and Ib.
Compounds of formulae Ic and Id may be prepared directly from compounds of formulae Ia or Ib which contain a hydrogen, C 1 -C 3 alkyl or C 2 -C 3 alkenyl or alkynyl at the R 1 position (e.g., where R 1 ═R′). The synthesis schemes for these compounds is depicted in Schemes 5 and 6, below.
In these schemes, compounds of formula Ia or Ib are reduced by reaction with an excess of diisobutylaluminum hydride, or equivalent reagent to yield the ring reduced compounds of formula Ic or Id, respectively.
The addition of an R 5 component other than hydrogen onto the ring nitrogen is achieved by reacting the formula Ic or Id compounds indicated above with the appropriate reagent(s). Examples of such modifications are provided in the Example section below.
Some specific inhibitors of this invention of formula Ic are set forth in the table below.
TABLE 2
Formula Ic Compounds.
cpd
#
structure
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
According to yet another embodiment, the invention provides p38 inhibitors of the formulae:
wherein A, Q 1 , Q 2 , R, X, Y and n are defined in the same manner as set forth for compounds of formulae Ia and Ib. These definitions hold for all embodiments of each of these variables (i.e., basic, preferred, more preferred and most preferred). More preferably, in compounds of formula Ie, Q 2 is unsubstituted phenyl.
Q 3 is a 5-6 membered aromatic carbocyclic or heterocyclic ring system, or an 8-10 membered bicyclic ring system comprising aromatic carbocyclic rings, aromatic heterocyclic rings or a combination of an aromatic carbocyclic ring and an aromatic heterocyclic ring. The rings of Q 3 are substituted with 1 to 4 substituents, each of which is independently selected from halo; C 1 -C 3 alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; O—(C 1 -C 3 )-alkyl optionally substituted with NR′ 2 , OR′, CO 2 R′ or CONR′ 2 ; NR′ 2 ; OCF 3 ; CF 3 ; NO 2 ; CO 2 R′; CONHR′; SR′; S(O 2 )N(R′) 2 ; SCF 3 ; CN; N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
According to one preferred embodiment, Q 3 is substituted with 2 to 4 substituents, wherein at least one of said substituents is present in the ortho position relative to the point of attachment of Q 3 to the rest of the inhibitor. When Q 3 is a bicyclic ring, the 2 substituents in the ortho position are present on the ring that is closest (i.e., directly attached) to the rest of the inhibitor molecule. The other two optional substituents may be present on either ring. More preferably, both such ortho positions are occupied by one of said substituents.
According to another preferred embodiment, Q 3 is a monocyclic carbocyclic ring, wherein each ortho substituent is independently selected from halo or methyl. According to another preferred embodiment, Q 3 contains 1 or 2 additional substituents independently selected from NR′ 2 , OR′, CO 2 R′CN, N(R′)C(O)R 4 ; N(R′)C(O)OR 4 ; N(R′)C(O)C(O)R 4 ; N(R′)S(O 2 )R 4 ; N(R′)R 4 ; N(R 4 ) 2 ; OR 4 ; OC(O)R 4 ; OP(O) 3 H 2 ; or N═CH—N(R′) 2 .
Preferably, Q 3 is selected from any of the Q 3 moieties present in the Ie compounds set forth in Table 3, below, or from any of the Q 3 moieties present in the Ig compounds set forth in Table 4, below.
Those of skill will recognize compounds of formula Ie as being the direct precursors to certain of the formula Ia and formula Ic p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Those of skill will also recognize that compounds of formula Ig are precursors to certain of the formula Ib and Id p38 inhibitors of this invention (i.e., those wherein Q 1 =Q 3 ). Accordingly, the synthesis of formula Ie inhibitors is depicted above in Schemes 1 and 2, wherein Q 1 is replaced by Q 3 . Similarly, the synthesis of formula Ig inhibitors is depicted above in Schemes 3 and 4, wherein Q 1 is replaced by Q 3 .
The synthesis of formula If and formula Ih inhibitors is depicted below in Schemes 7 and 8.
Scheme 8 depicts the synthesis of compounds of type Ih. For example, treating an initial dibromo derivative, such as 2,6 dibromopyridine, with an amine in the presence of a base such as sodium hydride yields the 2-amino-6-bromo derivative. Treatment of this intermediate with a phenylboronic acid analog (a Q2-boronic acid) such as phenyl boronic acid in the presence of a palladium catalyst gives the disubstituted derivative which can then be acylated to the final product. The order of the first two steps of this synthesis may be reversed.
Without being bound by theory, applicants believe that the diortho substitution in the Q 3 ring of formula Ie and Ig inhibitors and the presence of a nitrogen directly attached to the Q 1 ring in formula If and Ih inhibitors causes a “flattening” of the compound that allows it to effectively inhibit p38.
A preferred formula Ie inhibitor of this invention is one wherein A is carbon, n is 1, X is sulfur, each Y is carbon, each R is hydrogen, Q 3 is 2,6-dichlorophenyl and Q 2 is phenyl, said compound being referred to as compound 201. A preferred formula Ig inhibitor of this invention is one wherein Q 3 is 2,6-dichlorophenyl, Q 2 is phenyl, each Y is carbon and each R is hydrogen. This compound is referred to herein as compound 202. Other preferred formula Ig compounds of this invention are those listed in Table 4, below.
Preferred Ih compounds of this invention are those depicted in Table 5, below. Other preferred Ih compounds are those wherein Q 1 is phenyl independently substituted at the 2 and 6 positions by chloro or fluoro; each Y is carbon; each R is hydrogen; and Q 2 is 2-methylphenyl, 4-fluorophenyl, 2,4-difluorophenyl, 2-methylenehydroxy-4-fluorophenyl, or 2-methyl-4-fluorophenyl.
Some specific inhibitors of formulae Ie, Ig and Ih are depicted in the tables below.
TABLE 3
Formula Ie Inhibitors.
cmpd
#
structure
201
203
204
205
206
207
208
209
TABLE 4
Formula Ig Inhibitors.
cpd
#
structure
202/301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
1301
TABLE 5
Compound Ih Inhibitors.
cpd
#
structure
401
402
403
404
405
406
407
408
409
410
411
412
The activity of the p38 inhibitors of this invention may be assayed by in vitro, in vivo or in a cell line. In vitro assays include assays that determine inhibition of either the kinase activity or ATPase activity of activated p38. Alternate in vitro assays quantitate the ability of the inhibitor to bind to p38 and may be measured either by radiolabelling the inhibitor prior to binding, isolating the inhibitor/p38 complex and determining the amount of radiolabel bound, or by running a competition experiment where new inhibitors are incubated with p38 bound to known radioligands.
Cell culture assays of the inhibitory effect of the compounds of this invention may determine the amounts of TNF, IL-1, IL-6 or IL-8 produced in whole blood or cell fractions thereof in cells treated with inhibitor as compared to cells treated with negative controls. Level of these cytokines may be determined through the use of commercially available ELISAs.
An in vivo assay useful for determining the inhibitory activity of the p38 inhibitors of this invention is the suppression of hind paw edema in rats with Myco bacterium butyricum -induced adjuvant arthritis. This is described in J. C. Boehm et al., J. Med. Chem., 39, pp. 3929-37 (1996), the disclosure of which is herein incorporated by reference. The p38 inhibitors of this invention may also be assayed in animal models of arthritis, bone resorption, endotoxin shock and immune function, as described in A. M. Badger et al., J. Pharmacol. Experimental Therapeutics , 279, pp. 1453-61 (1996), the disclosure of which is herein incorporated by reference.
The p38 inhibitors or pharmaceutical salts thereof may be formulated into pharmaceutical compositions for administration to animals or humans. These pharmaceutical compositions, which comprise and amount of p38 inhibitor effective to treat or prevent a p38-mediated condition and a pharmaceutically acceptable carrier, are another embodiment of the present invention.
The term “p38-mediated condition”, as used herein means any disease or other deleterious condition in which p38 is known to play a role. This includes, conditions which are known to be caused by IL-1, TNF, IL-6 or IL-8 overproduction. Such conditions include, without limitation, inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, neurodegenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, thrombin-induced platelet aggregation, and conditions associated with prostaglandin endoperoxide synthase-2.
Inflammatory diseases which may be treated or prevented include, but are not limited to acute pancreatitis, chronic pancreatitis, asthma, allergies, and adult respiratory distress syndrome. Autoimmune diseases which may be treated or prevented include, but are not limited to, glomerulonephritis, rheumatoid arthritis, systemic lupus erythematosus, scleroderma, chronic thyroiditis, Graves' disease, autoimmune gastritis, diabetes, autoimmune hemolytic anemia, autoimmune neutropenia, thrombocytopenia, atopic dermatitis, chronic active hepatitis, myasthenia gravis, multiple sclerosis, inflammatory bowel disease, ulcerative colitis, Crohn's disease, psoriasis, or graft vs. host disease.
Destructive bone disorders which may be treated or prevented include, but are not limited to, osteoporosis, osteoarthritis and multiple myeloma-related bone disorder.
Proliferative diseases which may be treated or prevented include, but are not limited to, acute myelogenous leukemia, chronic myelogenous leukemia, metastatic melanoma, Kaposi's sarcoma, and multiple myeloma.
Angiogenic disorders which may be treated or prevented include solid tumors, ocular neovasculization, infantile haemangiomas.
Infectious diseases which may be treated or prevented include, but are not limited to, sepsis, septic shock, and Shigellosis.
Viral diseases which may be treated or prevented include, but are not limited to, acute hepatitis infection (including hepatitis A, hepatitis B and hepatitis C), HIV infection and CMV retinitis.
Neurodegenerative diseases which may be treated or prevented by the compounds of this invention include, but are not limited to, Alzheimer's disease, Parkinson's disease, cerebral ischemias or neurodegenerative disease caused by traumatic injury.
“p38-mediated conditions” also include ischemia/reperfusion in stroke, heart attacks, myocardial ischemia, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
In addition, p38 inhibitors in this invention are also capable of inhibiting the expression of inducible pro-inflammatory proteins such as prostaglandin endoperoxide synthase-2 (PGHS-2), also referred to as cyclooxygenase-2 (COX-2). Therefore, other “p38-mediated conditions” are edema, analgesia, fever and pain, such as neuromuscular pain, headache, cancer pain, dental pain and arthritis pain.
The diseases that may be treated or prevented by the p38 inhibitors of this invention may also be conveniently grouped by the cytokine (IL-1, TNF, IL-6, IL-8) that is believed to be responsible for the disease.
Thus, an IL-1-mediated disease or condition includes rheumatoid arthritis, osteoarthritis, stroke, endotoxemia and/or toxic shock syndrome, inflammatory reaction induced by endotoxin, inflammatory bowel disease, tuberculosis, atherosclerosis, muscle degeneration, cachexia, psoriatic arthritis, Reiter's syndrome, gout, traumatic arthritis, rubella arthritis, acute synovitis, diabetes, pancreatic β-cell disease and Alzheimer's disease.
TNF-mediated disease or condition includes, rheumatoid arthritis, rheumatoid spondylitis, osteoarthritis, gouty arthritis and other arthritic conditions, sepsis, septic shock, endotoxic shock, gram negative sepsis, toxic shock syndrome, adult respiratory distress syndrome, cerebral malaria, chronic pulmonary inflammatory disease, silicosis, pulmonary sarcoisosis, bone resorption diseases, reperfusion injury, graft vs. host reaction, allograft rejections, fever and myalgias due to infection, cachexia secondary to infection, AIDS, ARC or malignancy, keloid formation, scar tissue formation, Crohn's disease, ulcerative colitis or pyresis. TNF-mediated diseases also include viral infections, such as HIV, CMV, influenza and herpes; and veterinary viral infections, such as lentivirus infections, including, but not limited to equine infectious anemia virus, caprine arthritis virus, visna virus or maedi virus; or retrovirus infections, including feline immunodeficiency virus, bovine immunodeficiency virus, or canine immunodeficiency virus.
IL-8 mediated disease or condition includes diseases characterized by massive neutrophil infiltration, such as psoriasis, inflammatory bowel disease, asthma, cardiac and renal reperfusion injury, adult respiratory distress syndrome, thrombosis and glomerulonephritis.
In addition, the compounds of this invention may be used topically to treat or prevent conditions caused or exacerbated by IL-1 or TNF. Such conditions include inflamed joints, eczema, psoriasis, inflammatory skin conditions such as sunburn, inflammatory eye conditions such as conjunctivitis, pyresis, pain and other conditions associated with inflammation.
In addition to the compounds of this invention, pharmaceutically acceptable salts of the compounds of this invention may also be employed in compositions to treat or prevent the above-identified disorders.
Pharmaceutically acceptable salts of the compounds of this invention include those derived from pharmaceutically acceptable inorganic and organic acids and bases. Examples of suitable acid salts include acetate, adipate, alginate, aspartate, benzoate, benzenesulfonate, bisulfate, butyrate, citrate, camphorate, camphorsulfonate, cyclopentanepropionate, digluconate, dodecylsulfate, ethanesulfonate, formate, fumarate, glucoheptanoate, glycerophosphate, glycolate, hemisulfate, heptanoate, hexanoate, hydrochloride, hydrobromide, hydroiodide, 2-hydroxyethanesulfonate, lactate, maleate, malonate, methanesulfonate, 2-naphthalenesulfonate, nicotinate, nitrate, oxalate, palmoate, pectinate, persulfate, 3-phenylpropionate, phosphate, picrate, pivalate, propionate, salicylate, succinate, sulfate, tartrate, thiocyanate, tosylate and undecanoate. Other acids, such as oxalic, while not in themselves pharmaceutically acceptable, may be employed in the preparation of salts useful as intermediates in obtaining the compounds of the invention and their pharmaceutically acceptable acid addition salts.
Salts derived from appropriate bases include alkali metal (e.g., sodium and potassium), alkaline earth metal (e.g., magnesium), ammonium and N-(C 1-4 alkyl) 4+ salts. This invention also envisions the quatemization of any basic nitrogen-containing groups of the compounds disclosed herein. Water or oil-soluble or dispersible products may be obtained by such quatemization.
Pharmaceutically acceptable carriers that may be used in these pharmaceutical compositions include, but are not limited to, ion exchangers, alumina, aluminum stearate, lecithin, serum proteins, such as human serum albumin, buffer substances such as phosphates, glycine, sorbic acid, potassium sorbate, partial glyceride mixtures of saturated vegetable fatty acids, water, salts or electrolytes, such as protamine sulfate, disodium hydrogen phosphate, potassium hydrogen phosphate, sodium chloride, zinc salts, colloidal silica, magnesium trisilicate, polyvinyl pyrrolidone, cellulose-based substances, polyethylene glycol, sodium carboxymethylcellulose, polyacrylates, waxes, polyethylene-polyoxypropylene-block polymers, polyethylene glycol and wool fat.
The compositions of the present invention may be administered orally, parenterally, by inhalation spray, topically, rectally, nasally, buccally, vaginally or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intravenous, intramuscular, intra-articular, intra-synovial, intrasternal, intrathecal, intrahepatic, intralesional and intracranial injection or infusion techniques. Preferably, the compositions are administered orally, intraperitoneally or intravenously.
Sterile injectable forms of the compositions of this invention may be aqueous or oleaginous suspension. These suspensions may be formulated according to techniques known in the art using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that may be employed are water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose, any bland fixed oil may be employed including synthetic mono- or di-glycerides. Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions may also contain a long-chain alcohol diluent or dispersant, such as carboxymethyl cellulose or similar dispersing agents which are commonly used in the formulation of pharmaceutically acceptable dosage forms including emulsions and suspensions. Other commonly used surfactants, such as Tweens, Spans and other emulsifying agents or bioavailability enhancers which are commonly used in the manufacture of pharmaceutically acceptable solid, liquid, or other dosage forms may also be used for the purposes of formulation.
The pharmaceutical compositions of this invention may be orally administered in any orally acceptable dosage form including, but not limited to, capsules, tablets, aqueous suspensions or solutions. In the case of tablets for oral use, carriers which are commonly used include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions are required for oral use, the active ingredient is combined with emulsifying and suspending agents. If desired, certain sweetening, flavoring or coloring agents may also be added.
Alternatively, the pharmaceutical compositions of this invention may be administered in the form of suppositories for rectal administration. These can be prepared by mixing the agent 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.
The pharmaceutical compositions of this invention may also be administered topically, especially when the target of treatment includes areas or organs readily accessible by topical application, including diseases of the eye, the skin, or the lower intestinal tract. Suitable topical formulations are readily prepared for each of these areas or organs.
Topical application for the lower intestinal tract can be effected in a rectal suppository formulation (see above) or in a suitable enema formulation. Topically-transdermal patches may also be used.
For topical applications, the pharmaceutical compositions may be formulated in a suitable ointment containing the active component suspended or dissolved in one or more carriers. Carriers for topical administration of the compounds of this invention include, but are not limited to, mineral oil, liquid petrolatum, white petrolatum, propylene glycol, polyoxyethylene, polyoxypropylene compound, emulsifying wax and water. Alternatively, the pharmaceutical compositions can be formulated in a suitable lotion or cream containing the active components suspended or dissolved in one or more pharmaceutically acceptable carriers. Suitable carriers include, but are not limited to, mineral oil, sorbitan monostearate, polysorbate 60, cetyl esters wax, cetearyl alcohol, 2-octyldodecanol, benzyl alcohol and water.
For ophthalmic use, the pharmaceutical compositions may be formulated as micronized suspensions in isotonic, pH adjusted sterile saline, or, preferably, as solutions in isotonic, pH adjusted sterile saline, either with or without a preservative such as benzylalkonium chloride. Alternatively, for ophthalmic uses, the pharmaceutical compositions may be formulated in an ointment such as petrolatum.
The pharmaceutical compositions of this invention may also be administered by nasal aerosol or inhalation. Such compositions are prepared according to techniques well-known in the art of pharmaceutical formulation and may be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other conventional solubilizing or dispersing agents.
The amount of p38 inhibitor that may be combined with the carrier materials to produce a single dosage form will vary depending upon the host treated, the particular mode of administration. Preferably, the compositions should be formulated so that a dosage of between 0.01-100 mg/kg body weight/day of the inhibitor can be administered to a patient receiving these compositions.
It should also be understood that a specific dosage and treatment regimen 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 judgment of the treating physician and the severity of the particular disease being treated. The amount of inhibitor will also depend upon the particular compound in the composition.
According to another embodiment, the invention provides methods for treating or preventing a p38-mediated condition comprising the step of administering to a patient one of the above-described pharmaceutical compositions. The term “patient”, as used herein, means an animal, preferably a human.
Preferably, that method is used to treat or prevent a condition selected from inflammatory diseases, autoimmune diseases, destructive bone disorders, proliferative disorders, infectious diseases, degenerative diseases, allergies, reperfusion/ischemia in stroke, heart attacks, angiogenic disorders, organ hypoxia, vascular hyperplasia, cardiac hypertrophy, and thrombin-induced platelet aggregation.
According to another embodiment, the inhibitors of this invention are used to treat or prevent an IL-1, IL-6, IL-8 or TNF-mediated disease or condition. Such conditions are described above.
Depending upon the particular p38-mediated condition to be treated or prevented, additional drugs, which are normally administered to treat or prevent that condition may be administered together with the inhibitors of this invention. For example, chemotherapeutic agents or other anti-proliferative agents may be combined with the p38 inhibitors of this invention to treat proliferative diseases.
Those additional agents may be administered separately, as part of a multiple dosage regimen, from the p38 inhibitor-containing composition. Alternatively, those agents may be part of a single dosage form, mixed together with the p38 inhibitor in a single composition.
In order that the invention described herein may be more fully understood, the following examples are set forth. It should be understood that these examples are for illustrative purposes only and are not to be construed as limiting this invention in any manner.
EXAMPLE 1
Synthesis of p38 Inhibitor Compound 1
Examples of the synthesis of several compounds of formula Ia are set forth in the following 4 examples.
A.
To a slurry of sodium amide, 90% (1.17 g., 30 mmol) in dry tetrahydrofuran (20 ml) we added a solution of benzyl cyanide (2.92 g., 25.0 mmol) in dry tetrahydrofuran (10 ml) at room temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture we added a solution of 3,6-dichloropyridazine (3.70 g., 25.0 mmol) in dry tetrahydrofuran (10 ml). After stirring for 30 minutes, the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 30% ethyl acetate in n-hexane) to give 3.71 g. (16.20 mmol ˜54%) of product as a white solid.
B.
To a slurry of sodium hydride, 95% (0.14 g.,6.0 mmol) in dry tetrahydrofuran (10 ml) we added thiophenol (0.66 g, 6.0 ml.) at room temperature. The reaction mixture was then stirred for 10 minutes. To the reaction mixture we added a solution of the product from step A., above (1.31 g., 5.72 mmol) in absolute ethanol (20 ml.). The reaction mixture was then brought to reflux and stirred there for one hour. The cool reaction mixture was concentrated in vacuo. The residue was diluted with a 1N sodium hydroxide solution (10 ml), then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo.
The residue was purified by chromatography on silica gel (eluant: 20% ethyl acetate in n-hexane) to give 0.66 g. (2.19 mmol˜40% ) of product as a white solid.
C.
A mixture of the product from step B. (0.17 g., 0.69 mmol) and concentrated sulfuric acid (5 ml) was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated.sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo to give 0.22 g. (0.69 mmol ˜100%) of compound pre-1 as an orange oil. 1 H NMR (500 MHz; CD3OD) d7.7 (d), 7.5 (d), 7.4 (m), 7.3-7.2 (m).
D.
A solution of pre-1 from step C. (0.22 g., 0.69 mmol) and N,N-dimethylformamide dimethylacetal (0.18 g., 1.5 mmol) in toluene (5 ml) was heated at 100° C. for one hour. Upon cooling, the resulting solid was filtered and dissolved in warm ethyl acetate. The product was precipitated with the dropwise addition of diethyl ether. The product was then filtered and washed with diethyl ether to give 0.038 g. of compound 1 as a yellow solid. 1 H NMR (500 MHz, CDCl3) d8.63 (s), 7.63-7.21 (m), 6.44 (d).
EXAMPLE 2
Synthesis of p38 Inhibitor Compound 2
A.
The first intermediate depicted above was prepared in a similar manner as in Example 1A, using 4-fluorophenylacetonitrile, to afford 1.4 g (5.7 mmol, ˜15%) of product.
B.
The above intermediate was prepared in a similar manner as in Example 1B. This afforded 0.49 g (1.5 mmol, 56%) of product.
C.
The above intermediate was prepared in a similar manner as Example 1C. This afforded 0.10 g (0.29 mmol, 45%) of compound pre-2. 1 H NMR (500 MHz, CDCl3) d 7.65-7.48 (m), 7.47-7.30 (m), 7.29-7.11 (m), 7.06-6.91 (m), 5.85 (s, br)
D.
Compound 2 (which is depicted in Table 1) was prepared from pre-2 in a similar manner as in Example 1D. This afforded 0.066 g of product. 1 H NMR (500 MHz, CDCl3) d 8.60 (s), 7.62-7.03 (m), 6.44 (d)).
EXAMPLE 3
Synthesis of p38 Inhibitor Compound 6
A.
The first intermediate in the preparation of compound 6 was prepared in a manner similar to that described in Example 1A, using 2,6-dichlorophenyl-acetonitrile, to afford 2.49 g (8.38, 28%) of product.
B.
The next step in the synthesis of compound 6 was carried out in a similar manner as described in Example 1B. This afforded 2.82 g (7.6 mmol, 91%) of product.
C.
The final intermediate, pre-6, was prepared in a similar manner as described in Example 1C. This afforded 0.89 g (2.3 mmol, 85%) of product. 1 H NMR (500 MHz, CD3OD) d 7.5-7.4 (dd), 7.4 (m), 7.3 (d), 7.2 (m), 7.05 (d).
D.
The final step in the synthesis of compound 6 (which is depicted in Table 1) was carried out as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) d 8.69 (s), 7.65-7.59 (d), 7.58-7.36 (m), 7.32-7.22 (m), 6.79 (d), 6.53 (d).
EXAMPLE 4
Preparation of p38 Inhibitor Compound 5
A.
The first intermediate in the synthesis of compound 5 was prepared in a similar manner as described in Example 1A, using 2,4-dichlorophenylacetonitrile, to afford 3.67 g (12.36 mmol, 49%) of product.
B.
The second intermediate was prepared in a similar manner as described in Example 1B. This afforded 3.82 g (9.92 mmol, 92%) of product.
C.
The final intermediate, pre-5, was prepared in a similar manner as described in Example 1C. This afforded 0.10 g (0.24 mmol, 92%) of product. 1 H NMR (500 MHz, CD3OD) d 7.9 (d), 7.7 (d), 7.6-7.5 (dd), 7.4-7.3 (m), 2.4 (s).
D.
The final step in the preparation of compound 5 (which is depicted in Table 1) was carried out in a similar manner as described in Example 1D. This afforded 0.06 g of product. 1 H NMR (500 MHz, CDCl3) d 8.64 (s), 7.51-7.42 (m), 7.32-7.21 (m), 6.85 (d), 6.51 (d), 2.42 (s).
Other compounds of formula Ia of this invention may be synthesized in a similar manner using the appropriate starting materials.
EXAMPLE 5
Preparation of A p38 Inhibitor Compound of Formula Ib
An example of the synthesis of a p38 inhibitor of this invention of the formula Ib is presented below.
A.
To a slurry of sodium amide, 90% (1.1 eq) in dry tetrahydrofuran was added a solution of 2,6-dichlorobenzyl cyanide (1.0 eq) in dry tetrahydrofuran at room temperature. The mixture was stirred at room temperature for 30 minutes. To the reaction mixture was added a solution of 2,6-dichloropyridine (1 eq) in dry tetrahydrofuran. The reaction was monitored by TLC and, when completed the reaction mixture was diluted with an aqueous saturated sodium bicarbonate solution. The reaction mixture was then extracted with ethyl acetate. The layers were separated and the organic layer was washed with water, brine, dried over magnesium sulfate, filtered and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield pure product.
B.
To a solution of 4-fluoro-bromobenzene (1 eq) in dry tetrahydrofuran at −78° C. was added t-butyllithium (2 eq, solution in hexanes). The reaction mixture was then stirred for 30 minutes. To the reaction mixture was added a solution of the product from Step A (1 eq) in dry THF. The reaction mixture was then monitored and slowly brought to room temperature. The reaction mixture was quenched with water then extracted with methylene chloride. The organic phase was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo. The residue was purified by chromatography on silica gel to yield the product.
C.
A mixture of the product step B and concentrated sulfuric acid was heated to 100° C. for one hour. The solution was cooled and adjusted to pH 8 with a saturated sodium bicarbonate solution. The reaction mixture was extracted with methylene chloride. The organic layer was washed with water, brine, dried over magnesium sulfate and concentrated in vacuo to give product. The final product was purified by silica gel flash chromatography
D.
A solution of the product Step C (1 eq) and N,N-Dimethylformamide dimethylacetal (2 eq) in toluene is heated at 100° C. for one hour. Upon cooling, the resulting mixture is filtered and dissolved in warm ethyl acetate. The product is precipitated with the dropwise addition of diethyl ether. The product is then filtered and washed with diethyl ether to give a p38 inhibitor of formula Ib. The final product is further purified by silica gel chromatography.
Other compounds of formula Ib of this invention may be synthesized in a similar manner using the appropriate starting materials.
EXAMPLE 6
Synthesis of p38 Inhibitor Compound 103
This example sets forth a typical synthesis of a compound of formula Ic.
A.
The p38 inhibitor compound 12 is prepared essentially as set forth for in Example 4, except that 4-fluorothiophenyl is utilized in step B.
B.
Compound 12 was dissolved in dry THF (5 ml) at room temperature. To this solution we added diisobutylaluminum hydride (1M solution in toluene, 5 ml, 5 mmol) and the reaction was stirred at room temperature for 1 hour. The reaction mix was then diluted with ethyl acetate and quenched by the addition of Rochelle salt. The layers were separated and the organic layer was isolated, washed with water, washed with brine, dried over magnesium sulfate and filtered to yield crude compound 103. The crude product was chromatographed on silica gel eluting with 2% methanol in methylene chloride. Pure compound 103 was thus obtained (210 mg, 50% yield): 1H NMR (500 Mhz, CDCl3) 7.51 (m, 1H), 7.38 (d, 2H), 7.20 (t, 2H), 7.08 (t, 2H), 6.70 (broad s, 1H), 6.30 (dd, 2H), 5.20 (s, 2H).
EXAMPLE 7
Synthesis of p38 Inhibitor Compound 201
A.
The starting nitrile shown above (5.9 g, 31.8 mmol) was dissolved in DMF (20 ml) at room temperature. Sodium hydride (763 mg, 31.8 mmol) was then added, resulting in a bright yellow-colored solution. After 15 minutes a solution of 2,5 dibromopyridine (5.0 gr., 21.1 mmol) in DMF (10 ml) was added followed by Palladium tetrakis (triphenylphosphine)(3 mmol). The solution was then refluxed for 3 hrs. The reaction was cooled to room temperature and diluted with ethyl acetate. The organic layer was then isolated, washed with water and then with brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (5.8 g, 84%) as an off white solid.
B.
The bromide produced in step A (194.8 mg, 0.57 mmol) was dissolved in xylene (15 ml). To this solution we added thiophenylstannane (200 μl, 587 mmol) and palladium tetrakis (triphenylphosphine) (25 mg). The solution was refluxed overnight, cooled, filtered and evaporated in vacuo. The crude product was chromatographed on silica gel, eluting with methylene chloride, to yield pure product (152 mg, 72%) as a yellow oil.
C.
The nitrile produced in step B (1.2 g, 3.37 mmol) was dissolved in glacial acetic acid (30 ml). To this solution we added water (120 μl, 6.67 mmol) followed by titanium tetrachloride (760 μl, 6.91 mmol), which resulted in an exotherm. The solution was then refluxed for two hours, cooled and poured into 1N HCl. The aqueous layer was extracted with methylene chloride. The organic layer was backwashed with 1N NaOH, dried over magnesium sulfate and filtered over a plug of silica gel. The plug was first eluted with methylene chloride to remove unreacted starting materials, and then with ethyl acetate to yield compound 201. The ethyl acetate was evaporated to yield pure compound 201 (1.0 g, 77%).
EXAMPLE 8
Synthesis of p38 Inhibitor Compound 110
A.
The starting nitrile (3.76 g, 11.1 mmol) was first dissolved in glacial acetic acid (20 ml). To this solution we added titanium tetrachloride (22.2 mmol) and water (22.2 mmol) and heated the solution to reflux for 1 hour. The reaction mixture was then cooled and diluted in water/ethyl acetate. The organic layer was then isolated, washed with brine and dried over magnesium sulfate. The organic layer was then filtered and evaporated in vacuo. The resulting crude product was chromatographed on silica gel eluting with 5% methanol in methylene chloride to afford pure product as a yellow foam (2.77 g, 70%)
B.
The amide produced in step A (1.54 g, 4.3 mmol) was dissolved in toluene (20 ml). We then added N,N-dimethylformamide dimethylacetal (1.53 g, 12.9 mmol), heated the resulting solution for 10 minutes then allowed it to cool to room temperature. The reaction was then evaporated in vacuo and the residue was chromatographed on silica gel eluting with 2-5% methanol in methylene chloride. The recovered material was then dissolved in hot ethyl acetate. The solution was allowed to cool resulting in the crystallization of pure product as a yellow solid (600 mg, 40%). Additional material (˜800 mg) was available from the mother liquor.
C.
The bromide from step B (369 mg, 1 mmol) was dissolved in THF (10 ml). We then added Diisobutylaluminum hydride (1.0M solution, 4 mmol), stirred the reaction at room temperature for 10 minutes, and then quenched the reaction with methanol (1 ml). A saturated solution of Rochelle salts was then added and the mixture was extracted with ethyl acetate. The organic layer was isolated, dried over magnesium sulfate, evaporated and the residue was chromatographed on silica gel eluting with 1-3% methanol in methylene chloride to afford a bright orange solid (85 mg, 23% yield).
D.
The bromide produced in step C (35.2 mg, 0.1 mmol) was dissolved in xylene (12 ml). To this solution we added thiophenol (0.19 mmol) followed by tributyltin methoxide (0.19 mmol). The resulting solution was heated to reflux for 10 minutes, followed by the addition of palladium tetrakis(triphenylphosphine) (0.020 mmol). The reaction was heated and monitored for the disappearance of the bromide starting material. The reaction was then cooled to room temperature and passed through a plug of silica gel. The plug was eluted initially with methylene chloride to remove excess tin reagent and then with 5% methanol in ethyl acetate to elute the p38 inhibitor. The filtrate was concentrated and then re-chromatographed on silica gel using 5% methanol in ethyl acetate as eluant affording pure compound 110 (20 mg, 52%).
EXAMPLE 9
Synthesis of p38 Inhibitor Compound 202
A.
The starting nitrile (2.32 g, 12 mmol) was dissolved in DMF (10 ml) at room temperature. Sodium hydride (12 mmol) was then added resulting in a bright yellow colored solution. After 15 minutes, a solution of 2,6 dibromopyridine (2.36 gr., 10 mmol) in DMF (5 ml) was added, followed by Palladium tetrakis (triphenylphosphine) (1.0 mmol). The solution was then refluxed for 3 hours. The reaction was next cooled to room temperature and diluted with ethyl acetate. The organic layer was isolated, washed with water and brine, dried over magnesium sulfate, filtered and evaporated in vacuo to a crude oil. Flash column chromatography eluting with 10% ethyl acetate in hexane afforded product (1.45 g, 42%) as a white solid.
B.
The bromo compound produced in step A (1.77 g, 5.2 mmol) was dissolved in toluene (20 ml) and the resulting solution was degassed. Under a nitrogen atmosphere, a solution of phenylboronic acid (950 mg, 7.8 mmol) in ethanol (4 ml) and a solution of sodium carbonate (1.73 g, 14 mmol) in water (4 ml) were added. The reaction mixture was heated to reflux for one hour and then was cooled to room temperature. The reaction was diluted with ethyl acetate and washed with water and brine. The organic layer was then dried with magnesium sulfate, filtered and concentrated in vacuo. The residue was purified on silica gel eluting with 30% ethyl acetate in hexane to afford product as a white solid (1.56 g, 88%).
C.
The nitrile from step B (700 mg, 2.07 mmol) was dissolved in concentrated sulfuric acid (10 ml) and heated to 80° C. for 1 hour. The reaction was then cooled to room temperature and the pH was adjusted to 8 using 6N sodium hydroxide. The mixture was next extracted with ethyl acetate. The organic layer was isolated, dried with magnesium sulfate and evaporated in vacuo to yield compound 202 as a yellow foam (618 mg, 84%).
EXAMPLE 10
Synthesis of Compound 410
A.
In a flame-dried 100 ml round-bottomed flask, 2.28 g (93.8 mmol) of magnesium chips were added to 50 ml of anhydrous tetrahydrofuran. One crystal of iodine was added forming a light brown color. To the solution was added 1.5 ml of a 10.0 ml (79.1 mmol) sample of 2-bromo-5-fluorotoluene. The solution was heated to reflux. The brown color faded and reflux was maintained when the external heat source was removed indicating Grignard formation. As the reflux subsided, another 1.0-1.5 ml portion of the bromide was added resulting in a vigorous reflux. The process was repeated until all of the bromide had been added. The olive-green solution was externally heated to reflux for one hour to ensure complete reaction. The solution was cooled in an ice-bath and added via syringe to a solution of 9.3 ml (81.9 mmol) of trimethyl borate in 100 ml of tetrahydrofuran at −78° C. After the Grignard reagent had been added, the flask was removed from the cooling bath and the solution was stirred at room temperature overnight. The grayish-white slurry was poured into 300 ml of H 2 O and the volatiles were evaporated in vacuo. HCl (400 ml of 2N solution) was added and the milky-white mixture was stirred for one hour at room temperature. A white solid precipitated. The mixture was extracted with diethyl ether and the organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford 11.44 g (94%) of the boronic acid as a white solid.
B.
In a 100 ml round-bottomed flask, 7.92 g (33.4 mmol) of 2,6-dibromopyridine was dissolved in 50 ml of anhydrous toluene forming a clear, colorless solution. 4-fluoro-2-methylbenzene boronic acid (5.09 g, 33.1 mmol) produced in step A was added forming a white suspension. Thallium carbonate (17.45 g, 37.2 mmol) was added followed by a catalytic amount (150 mg) of Pd(PPh 3 ) 4 . The mixture was heated to reflux overnight, cooled, and filtered over a pad of silica gel. The silica was washed with CH 2 Cl 2 and the filtrate was evaporated to afford a white solid. The solid was dissolved in a minimal amount of 50% CH 2 Cl 2 /hexane and chromatographed on a short column of silica gel using 30% CH 2 Cl 2 /hexane to afford 6.55 g (74%) of the 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine as a white solid.
C.
In a 50 ml round-bottomed flask, 550 mg (2.07 mmol) of 2-bromo-6-(4-fluoro-2-methylphenyl)pyridine produced in step B was dissolved in 30 ml of anhydrous tetrahydrofuran forming a clear, colorless solution. 2,6-difluoroaniline (2.14 ml, 2.14 mmol) was added followed by 112 mg (2.79 mmol) of a 60% NaH suspension in mineral oil. Gas evolution was observed along with a mild exotherm. The solution was heated to reflux overnight and then cooled. The reaction mixture was poured in 10% NH 4 Cl and extracted with CH 2 Cl 2 . The organic extract was dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 50% CH 2 Cl 2 /hexane to afford 262 mg (40%) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine as a colorless oil.
D.
In a 100 ml round-bottomed flask, 262 mg (834 mmol) of 2-(2,6-difluorophenyl)-6-(4-fluoro-2-methylphenyl)pyridine produced in step C was dissolved in 30 ml of anhydrous CHCl 3 forming a clear, colorless solution. Chlorosulfonyl isocyanate (1.0 ml, 11.5 mmol) was added and the light yellow solution was stirred at room temperature overnight. Water (˜30 ml) was added causing a mild exotherm and vigorous gas evolution. After stirring overnight, the organic layer was separated, dried (MgSO 4 ) and evaporated in vacuo to afford a brown oil that was a mixture of the product and starting material. The material was chromatographed on a short column of silica gel using 10% EtOAc/CH 2 Cl 2 . The recovered starting material was re-subjected to the reaction conditions and purified in the same manner to afford a total of 205 mg (69%) of the urea as a white solid.
EXAMPLE 11
Synthesis of Compound 138
Compound 103 (106 mg, 0.25 mmol) was dissolved in THF (0.5 ml) and to this solution was added triethylamine (35 μl, 0.25 mmol) followed by and excess of formaldehyde (37% aqueous solution, 45 mg). The reaction was allowed to stir at room temperature overnight. The reaction mixture was then rotovapped under reduced pressure and the residue was dissolved in methylene chloride and applied to a flash silica gel column. The column was eluted with 2% methanol in methylene chloride to yield pure product (78 mg, 70% yield).
EXAMPLE 12
Synthesis of Prodrugs of Compound 103
A.
Compound 138 (1 equivalent) is dissolved in methylene chloride and to this solution is added triethylamine (1 equivalent) followed by dibenzylphosphonyl chloride (1 equivalent). The solution is stirred at room temperature and monitored by TLC for consumption of starting material. The methylene chloride layer is then diluted with ethyl acetate and washed with 1N HCl, saturated sodium bicarbonate and saturated NaCl. The organic layer is then dried, rotovapped and the crude product is purified on silica gel. The pure product is then dissolved in methanol and the dibenzyl esters are deprotected with 10% palladium on charcoal under a hydrogen atmosphere. When the reaction is monitored as complete, the catalyst is filtered over celite and the filtrate is rotovapped to yield the phosphate product.
B.
Compound 103 (210 mg, 1.05 mmol) was dissolved in THF (2 ml) and cooled to −50° C. under a nitrogen atmosphere. To this solution was added lithium hexamethyldisilazane (1.1 mmol) followed by chloroacetyl chloride (1.13 mmol). The reaction was removed from the cooling bath and allowed to warm to room temperature, after which time the reaction was diluted with ethyl acetate and quenched with water. The organic layer was washed with brine, dried and rotovapped to dryness. The crude product was flash chromatographed on silica gel using 25% ethyl acetate in hexane as eluant to yield 172 mg (70%) of pure desired product, which was used as is in the next reactions.
C.
The chloroacetyl compound is dissolved in methylene chloride and treated with an excess of dimethyl amine. The reaction is monitored by TLC and when complete all volatiles are removed to yield desired product.
EXAMPLE 13
Synthesis of Compounds 34 and 117
A.
The nitrile from Example 5, step A (300 mg, 1.0 mmol) was dissolved in ethanol (10 ml) and to this solution was added thiourea (80.3 mg, 1.05 mmol). The reaction was brought to reflux for 4 hours at which point TLC indicated that all starting material was consumed. The reaction was cooled and all volatiles were removed under reduced pressure, and the residue was dissolved in acetone (10 ml).
To this solution was then added 2,5-difluoronitrobenzene (110 μl, 1.01 mmol) followed by potassium carbonate (200 mg, 1.45 mmol) and water (400 μl). The reaction was allowed to stir at room temperature overnight. The reaction was then diluted with methylene chloride (25 ml) and filtered through a cotton plug. All volatiles were removed under reduced pressure and the residue was flashed chromatographed on silica gel eluting with a gradient from 10%-25% ethyl acetate in hexane to yield the desired product (142 mg, 33%).
B.
The nitrile product from Step A (142 mg, 0.33 mmol) was mixed with concentrated sulfuric acid (2 ml), heated to reflux for 1 hour and then allowed to cool to room temperature. The mixture was then diluted with ethyl acetate and carefully neutralized with saturated potassium carbonate solution (aqueous). The layers were separated and the organic layer was washed with water, brine and dried over magnesium sulfate. The mixture was filtered and evaporated to dryness. The residue was used in the next step without further purification (127 mg, 85% yield).
C.
The amide from the step B (127 mg, 0.28 mmol) was dissolved in THF (3 ml) and to this solution was added dimethylformamide dimethylacetal (110 μl, 0.83 mmol). The reaction was heated to reflux for 5 minutes then cooled to room temperature. All volatiles were removed in vacuo and the residue was flash chromatographed on silica gel eluting with 2.5% methanol in methylene chloride to yield pure desired compound 34 (118 mg, 92%).
D.
A solution of nickel dichloride hexahydrate (103 mg, 0.44 mol) in a mixture of benzene/methanol (0.84 mL/0.84 ml) was added to a solution of compound 34 (100.8 mg, 0.22 mmol) in benzene (3.4 ml) and this solution was cooled to 0° C. To this solution was then added sodium borohydride (49 mg, 1.3 mmol). The reaction was stirred while allowing to warm to room temperature. The reaction was evaporated in vacuo and the residue was flash chromatographed eluting with 2% methanol in methylene chloride to yield pure desired product, compound 117 (21 mg, 25% yield).
EXAMPLE 14
Synthesis of Compounds 53 and 142
A.
The product indicated in the above reaction was synthesized using the procedure in example 1 step B using chloropyridazine (359 mg, 1.21 mmol) and 2,4 difluorothiophenol (176 mg, 1.21 mmol). The product was obtained after flash silica gel chromatography (451 mg, 92%).
B.
The above reaction was carried out as described in Example 1, step C, using 451 mg of starting material and 5 ml of concentrated sulfuric acid to yield the indicated product (425 mg, 90%).
C.
The reaction above was carried out as described in Example 1, step D, using starting amide (410 mg, 0.96 mmol) and dimethylformamide dimethylacetal (3 mmol). The reaction was heated at 50° C. for 30 minutes and worked up as described previously. Compound 53 was obtained (313 mg, 75%).
D.
Compound 34 (213, 0.49 mmol) was dissolved in THF (10 ml), cooled to 0° C. and to this solution was added Borane in THF (1M, 0.6 mmol). The reaction was stirred for 30 minutes quenched with water and diluted with ethyl acetate. The organic layer was washed with water and brine, dried and rotovapped. The residue was purified on silica gel eluting with a gradient of 1% to 5% methanol in methylene chloride to afford compound 142 (125 mg, 57%).
EXAMPLE 15
Cloning of p38 Kinase in Insect Cells
Two splice variants of human p38 kinase, CSBP1 and CSBP2, have been identified. Specific oligonucleotide primers were used to amplify the coding region of CSBP2 cDNA using a HeLa cell library (Stratagene) as a template. The polymerase chain reaction product was cloned into the pET-15b vector (Novagen). The baculovirus transfer vector, pVL-(His)6-p38 was constructed by subcloning a XbaI-BamHI fragment of pET15b-(His)6-p38 into the complementary sites in plasmid pVL1392 (Pharmingen).
The plasmid pVL-(His)6-p38 directed the synthesis of a recombinant protein consisting of a 23-residue peptide (MGSSHHHHHHSSGLVPRGSHMLE, where LVPRGS represents a thrombin cleavage site) fused in frame to the N-terminus of p38, as confirmed by DNA sequencing and by N-terminal sequencing of the expressed protein. Monolayer culture of Spodoptera frugiperda (Sf9) insect cells (ATCC) was maintained in TNM-FH medium (Gibco BRL) supplemented with 10% fetal bovine serum in a T-flask at 27° C. Sf9 cells in log phase were co-transfected with linear viral DNA of Autographa califonica nuclear polyhedrosis virus (Pharmingen) and transfer vector pVL-(His)6-p38 using Lipofectin (Invitrogen). The individual recombinant baculovirus clones were purified by plaque assay using 1% low melting agarose.
EXAMPLE 16
Expression and Purification of Recombinant p38 Kinase
Trichoplusia ni (Tn-368) High-Five™ cells (Invitrogen) were grown in suspension in Excel-405 protein free medium (JRH Bioscience) in a shaker flask at 27° C. Cells at a density of 1.5×10 6 cells/ml were infected with the recombinant baculovirus described above at a multiplicity of infection of 5. The expression level of recombinant p38 was monitored by immunoblotting using a rabbit anti-p38 antibody (Santa Cruz Biotechnology). The cell mass was harvested 72 hours after infection when the expression level of p38 reached its maximum.
Frozen cell paste from cells expressing the (His) 6 -tagged p38 was thawed in 5 volumes of Buffer A (50 mM NaH2PO4 pH 8.0, 200 mM NaCl, 2mM β-Mercaptoethanol, 10% Glycerol and 0.2 mM PMSF). After mechanical disruption of the cells in a microfluidizer, the lysate was centrifuged at 30,000×g for 30 minutes. The supernatant was incubated batchwise for 3-5 hours at 4° C. with Talon™ (Clontech) metal affinity resin at a ratio of 1 ml of resin per 2-4 mgs of expected p38. The resin was settled by centrifugation at 500×g for 5 minutes and gently washed batchwise with Buffer A. The resin was slurried and poured into a colmn (approx. 2.6×5.0 cm) and washed with Buffer A+5 mM imidazole.
The (His) 6 -p38 was eluted with Buffer A+100 mM imidazole and subsequently dialyzed overnight at 4° C. against 2 liters of Buffer B, (50 mM HEPES, pH 7.5, 25 mM β-glycerophosphate, 5% glycerol, 2 mM DTT). The His 6 tag was removed by addition of at 1.5 units thrombin (Calbiochem) per mg of p38 and incubation at 20° C. for 2-3 hours. The thrombin was quenched by addition of 0.2 mM PMSF and then the entire sample was loaded onto a 2 ml benzamidine agarose (American International Chemical) column.
The flow through fraction was directly loaded onto a 2.6×5.0 cm Q-Sepharose (Pharmacia) column previously equilibrated in Buffer B+0.2 mM PMSF. The p38 was eluted with a 20 column volume linear gradient to 0.6M NaCl in Buffer B. The eluted protein peak was pooled and dialyzed overnight at 4° C. vs. Buffer C (50 mM HEPES pH 7.5, 5% glycerol, 50 mM NaCl, 2 mM DTT, 0.2 mM PMSF).
The dialyzed protein was concentrated in a Centriprep (Amicon) to 3-4 ml and applied to a 2.6×100 cm Sephacryl S-100HR (Pharmacia) column. The protein was eluted at a flow rate of 35 ml/hr. The main peak was pooled, adjusted to 20 mM DTT, concentrated to 10-80 mgs/ml and frozen in aliquots at −70° C. or used immediately.
EXAMPLE 17
Activation of p38
P38 was activated by combining 0.5 mg/ml p38 with 0.005 mg/ml DD-double mutant MKK6 in Buffer B+10 mM MgCl2, 2 mM ATP, 0.2 mM Na2VO4 for 30 minutes at 20° C. The activation mixture was then loaded onto a 1.0×10 cm MonoQ column (Pharmacia) and eluted with a linear 20 column volume gradient to 1.0 M NaCl in Buffer B. The activated p38 eluted after the ADP and ATP. The activated p38 peak was pooled and dialyzed against buffer B+0.2mM Na2VO4 to remove the NaCl. The dialyzed protein was adjusted to 1.1M potassium phosphate by addition of a 4.0M stock solution and loaded onto a 1.0×10 cm HIC (Rainin Hydropore) column previously equilibrated in Buffer D (10% glycerol, 20 mM β-glycerophosphate, 2.0 mM DTT)+1.1 MK2HPO4. The protein was eluted with a 20 column volume linear gradient to Buffer D+50 mM K2HPO4. The double phosphorylated p38 eluted as the main peak and was pooled for dialysis against Buffer B+0.2mM Na2VO4. The activated p38 was stored at −70° C.
EXAMPLE 18
P38 Inhibition Assays
A. Inhibition of Phosphorylation of EGF Receptor Peptide
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical IC50 determination, a stock solution was prepared containing all of the above components and activated p38 (5 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. EGF receptor peptide, KRELVEPLTPSGEAPNQALLR, a phosphoryl acceptor in p38-catalyzed kinase reaction (1), was added to each vial to a final concentration of 200 μM. The kinase reaction was initiated with ATP (100 μM) and the vials were incubated at 30° C. After 30 minutes, the reactions were quenched with equal volume of 10% trifluoroacetic acid (TFA).
The phosphorylated peptide was quantified by HPLC analysis. Separation of phosphorylated peptide from the unphosphorylated peptide was achieved on a reverse phase column (Deltapak, 5 μm, C18 100D, part no. 011795) with a binary gradient of water and acteonitrile, each containing 0.1% TFA. IC50 (concentration of inhibitor yielding 50% inhibition) was determined by plotting the % activity remaining against inhibitor concentration.
B. Inhibition of ATPase Activity
This assay was carried out in the presence of 10 mM MgCl2, 25 mM β-glycerophosphate, 10% glycerol and 100 mM HEPES buffer at pH 7.6. For a typical Ki determination, the Km for ATP in the ATPase activity of activated p38 reaction was determined in the absence of inhibitor and in the presence of two concentrations of inhibitor. A stock solution was prepared containing all of the above components and activated p38 (60 nM). The stock solution was aliquotted into vials. A fixed volume of DMSO or inhibitor in DMSO (final concentration of DMSO in reaction was 2.5%) was introduced to each vial, mixed and incubated for 15 minutes at room temperature. The reaction was initiated by adding various concentrations of ATP and then incubated at 30° C. After 30 minutes, the reactions were quenched with 50 μl of EDTA (0.1 M, final concentration), pH 8.0. The product of p38 ATPase activity, ADP, was quantified by HPLC analysis.
Separation of ADP from ATP was achieved on a reversed phase column (Supelcosil, LC-18, 3 μm, part no. 5-8985) using a binary solvent gradient of following composition: Solvent A-0.1 M phosphate buffer containing 8 mM tetrabutylammonium hydrogen sulfate (Sigma Chemical Co., catalogue no. T-7158), Solvent B—Solvent A with 30% methanol.
Ki was determined from the rate data as a function of inhibitor and ATP concentrations. The results for several of the inhibitors of this invention are depicted in Table 6 below:
TABLE 6
Compound
K i (μM)
1
>20
2
15
3
5.0
5
2.9
6
0.4
Other p38 inhibitors of this invention will also inhibit the ATPase activity of p38.
C. Inhibition of IL-1, TNF, IL-6 and IL-8 Production in LPS-Stimulated PBMCs
Inhibitors were serially diluted in DMSO from a 20 mM stock. At least 6 serial dilutions were prepared. Then 4× inhibitor stocks were prepared by adding 4 μl of an inhibitor dilution to 1 ml of RPMI1640 medium/10% fetal bovine serum. The 4× inhibitor stocks contained inhibitor at concentrations of 80 μM, 32 μM, 12.8 μM, 5.12 μm, 2.048 μm, 0.819 μm, 0.328 μm, 0.131 μm, 0.052 μM, 0.021 μM etc. The 4× inhibitor stocks were pre-warmed at 37° C. until use.
Fresh human blood buffy cells were separated from other cells in a Vacutainer CPT from Becton & Dickinson (containing 4 ml blood and enough DPBS without Mg 2+ /Ca 2+ to fill the tube) by centrifugation at 1500×g for 15 min. Peripheral blood mononuclear cells (PBMCs), located on top of the gradient in the Vacutainer, were removed and washed twice with RPMI1640 medium/10% fetal bovine serum. PBMCs were collected by centrifugation at 500×g for 10 min. The total cell number was determined using a Neubauer Cell Chamber and the cells were adjusted to a concentration of 4.8×10 6 cells/ml in cell culture medium (RPMI1640 supplemented with 10% fetal bovine serum).
Alternatively, whole blood containing an anti-coagulant was used directly in the assay.
We placed 100 μl of cell suspension or whole blood in each well of a 96-well cell culture plate. Then we added 50 μl of the 4× inhibitor stock to the cells. Finally, we added 50 μl of a lipopolysaccharide (LPS) working stock solution (16 ng/ml in cell culture medium) to give a final concentration of 4 ng/ml LPS in the assay. The total assay volume of the vehicle control was also adjusted to 200 μl by adding 50 μl cell culture medium. The PBMC cells or whole blood were then incubated overnight (for 12-15 hours) at 37° C./5% CO 2 in a humidified atmosphere.
The next day the cells were mixed on a shaker for 3-5 minutes before centrifugation at 500×g for 5 minutes. Cell culture supernatants were harvested and analyzed by ELISA for levels of IL-1b (R & D Systems, Quantikine kits, #DBL50), TNF-∀ (BioSource, #KHC3012), IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves form which IC50 values were derived.
Results for the kinase assay (“kinase”; subsection A, above), IL-1 and TNF in LPS-stimulated PBMCs (“cell”) and IL-1, TNF and IL-6 in whole blood (“WB”) for various p38 inhibitors of this invention are shown in Table 7 below:
WB
WB
kinase
cell IL-1
cell TNF
WB IL-1
TNF
IL-6
cmpd #
IC50
IC50
IC50
IC50
IC50
IC50
2
+
N.D.
N.D.
N.D.
N.D.
N.D.
3
+
N.D.
N.D.
N.D.
N.D.
N.D.
5
+
N.D.
N.D.
N.D.
N.D.
N.D.
6
++
++
+
N.D.
N.D.
N.D.
7
+
+
+
N.D.
N.D.
N.D.
8
+
+
+
N.D.
N.D.
N.D.
9
+
+
+
N.D.
N.D.
N.D.
10
+
N.D.
N.D.
N.D.
N.D.
N.D.
11
+
+
+
N.D.
N.D.
N.D.
12
++
++
++
+
+
+
13
+
+
+
N.D.
N.D.
N.D.
14
+
++
+
N.D.
N.D.
N.D.
15
+
++
++
N.D.
N.D.
N.D.
16
++
+
++
N.D.
N.D.
N.D.
17
+
+
+
N.D.
N.D.
N.D.
18
+
+
+
N.D.
N.D.
N.D.
19
+
+
+
N.D.
N.D.
N.D.
20
++
+
+
N.D.
N.D.
N.D.
21
++
++
+
N.D.
N.D.
N.D.
22
+
+
+
N.D.
N.D.
N.D.
23
++
++
+
+
+
+
24
++
++
++
+
+
N.D.
25
++
++
+
N.D.
N.D.
N.D.
26
+
+++
++
+
+
+
27
++
+
+
+
+
+
28
++
++
++
N.D.
N.D.
N.D.
29
++
++
++
N.D.
N.D.
N.D.
30
+
+
+
+
N.D.
N.D.
31
+
+
+
N.D.
N.D.
N.D.
32
++
+
++
+
+
+
33
++
++
++
+
+
+
34
+
+
+
N.D.
N.D.
N.D.
35
++
++
+
+
+
+
36
+
+
+
+
+
+
37
++
++
+
+
+
+
38
+++
+++
++
++
++
++
39
++
+
+
N.D.
N.D.
N.D.
40
++
++
+
N.D.
N.D.
N.D.
41
+++
+++
+++
N.D.
N.D.
N.D.
42
+
N.D.
N.D.
N.D.
N.D.
N.D.
43
++
+
+
N.D.
N.D.
N.D.
44
++
+
+
N.D.
N.D.
N.D.
45
++
N.D.
N.D.
N.D.
N.D.
N.D.
46
++
+
+
N.D.
N.D.
N.D.
47
++
++
+
N.D.
N.D.
N.D.
48
++
++
+
N.D.
N.D.
N.D.
49
++
+++
+
+
+
+
50
+
N.D.
N.D.
N.D.
N.D.
N.D.
51
++
N.D.
N.D.
N.D.
N.D.
N.D.
52
++
N.D.
N.D.
N.D.
N.D.
N.D.
53
+++
+++
+++
+++
+++
+++
101
++
+++
+++
+
+
++
102
+++
+++
+++
+
++
++
103
+++
+++
+++
+
++
++
104
++
++
++
+
+
+
105
++
+
+
N.D.
N.D.
N.D.
106
+++
+++
+++
+
++
++
107
++
+
+
N.D.
N.D.
N.D.
109
+++
+++
+++
+
+
++
108
+++
++
+++
++
+++
+++
110
++
+
+
N.D.
N.D.
N.D.
111
++
+
+
N.D.
N.D.
N.D.
112
++
++
+
+
+
+
113
+++
+++
++
+
+
+
114
+++
+++
+++
++
++
+++
115
+++
+++
+++
+
+
+
116
+++
+++
++
+
+
+
117
+++
+++
+++
++
++
+++
118
++
++
++
+
+
+
119
++
N.D.
N.D.
N.D.
N.D.
N.D.
120
N.D.
++
+
+
+
+
121
+++
+++
++
+
+
+
122
++
++
+
+
+
+
123
++
++
++
+
+
+
124
+
+
+
N.D.
N.D.
N.D.
125
+++
+++
+++
+
+
+
126
+
++
+
N.D.
N.D.
N.D.
127
+++
+++
+++
++
++
+++
128
+
+
+
N.D.
N.D.
N.D.
129
+++
+++
+++
++
+
++
130
+++
++
+
N.D.
N.D.
N.D.
131
+++
+++
+++
N.D.
N.D.
N.D.
132
+++
+++
++
N.D.
N.D.
N.D.
133
+++
+++
+++
N.D.
N.D.
N.D.
134
+++
++
+
N.D.
N.D.
N.D.
135
+++
++
+
+
+
+
136
+++
+++
+++
+
+
++
137
+++
+++
++
+
+
++
138
++
+++
++
+
+
+++
139
+++
+++
+
+
+
+
140
+++
+++
+++
++
+
++
141
+++
+++
+++
+
+
+
142
+++
+++
+++
+++
+++
+++
143
+++
+++
++
+
+
+
144
+++
+++
++
+
+
++
145
+++
+++
+++
+++
+++
+++
201
++
+
+
+
+++
+
203
+
N.D.
N.D.
N.D.
N.D.
N.D.
204
+
N.D.
N.D.
N.D.
N.D.
N.D.
205
+
N.D.
N.D.
N.D.
N.D.
N.D.
206
++
+
+
N.D.
N.D.
N.D.
207
+
N.D.
N.D.
N.D.
N.D.
N.D.
208
N.D.
++
N.D.
N.D.
N.D.
N.D.
209
N.D.
+
N.D.
N.D.
N.D.
N.D.
202/
+++
++
++
+
+
+
301
302
+++
+++
++
+
+
+
303
+
+
+
+
+
+
304
+
+
+
+
+
+
305
+++
+++
+
+
+
+
306
++
++
+
+
+
+
307
+++
++
+
+
+
+
308
+
N.D.
N.D.
N.D.
N.D.
N.D.
309
++
++
++
+
+
+
310
++
+
+
N.D.
N.D.
N.D.
311
++
+
+
N.D.
N.D.
N.D.
312
+++
++
+
+
+
+
313
++
+
+
N.D.
N.D.
N.D.
314
+
N.D.
N.D.
N.D.
N.D.
N.D.
315
+
N.D.
N.D.
N.D.
N.D.
N.D.
316
+
N.D.
N.D.
N.D.
N.D.
N.D.
317
+
+
+
N.D.
N.D.
N.D.
318
++
N.D.
N.D.
N.D.
N.D.
N.D.
319
+
N.D.
N.D.
N.D.
N.D.
N.D.
320
+++
++
++
N.D.
N.D.
N.D.
321
+
N.D.
N.D.
N.D.
N.D.
N.D.
322
++
+
+
N.D.
N.D.
N.D.
323
++
++
++
N.D.
N.D.
N.D.
324
++
++
+
N.D.
N.D.
N.D.
325
+++
+++
++
+
+
+
326
+
N.D.
N.D.
N.D.
N.D.
N.D.
327
++
N.D.
N.D.
N.D.
N.D.
N.D.
328
+
N.D.
N.D.
N.D.
N.D.
N.D.
329
++
++
+
+
+
+
330
+
N.D.
N.D.
N.D.
N.D.
N.D.
331
+
N.D.
N.D.
N.D.
N.D.
N.D.
332
++
++
+
+
+
+
333
++
+
+
N.D.
N.D.
N.D.
334
+
N.D.
N.D.
N.D.
N.D.
N.D.
335
++
+
+
+
+
+
336
+
N.D.
N.D.
N.D.
N.D.
N.D.
337
+
N.D.
N.D.
N.D.
N.D.
N.D.
338
+
N.D.
N.D.
N.D.
N.D.
N.D.
339
+
N.D.
N.D.
N.D.
N.D.
N.D.
340
+
N.D.
N.D.
N.D.
N.D.
N.D.
341
++
++
++
N.D.
N.D.
N.D.
342
+
N.D.
N.D.
N.D.
N.D.
N.D.
343
+
N.D.
N.D.
N.D.
N.D.
N.D.
344
+
N.D.
N.D.
N.D.
N.D.
N.D.
345
+
N.D.
N.D.
N.D.
N.D.
N.D.
346
++
+
+
+
+
+
347
+
N.D.
N.D.
N.D.
N.D.
N.D.
348
+
N.D.
N.D.
N.D.
N.D.
N.D.
349
+
++
+
+
+
+
350
+
++
+
N.D.
N.D.
N.D.
351
+
+
+
N.D.
N.D.
N.D.
352
+
+
N.D.
N.D.
N.D.
N.D.
353
++
+
+
N.D.
N.D.
N.D.
354
+
N.D.
N.D.
N.D.
N.D.
N.D.
355
+
N.D.
N.D.
N.D.
N.D.
N.D.
356
+
N.D.
N.D.
N.D.
N.D.
N.D.
357
+
N.D.
N.D.
N.D.
N.D.
N.D.
358
++
+
+
N.D.
N.D.
N.D.
359
+
N.D.
N.D.
N.D.
N.D.
N.D.
360
+
N.D.
N.D.
N.D.
N.D.
N.D.
361
++
++
+
N.D.
N.D.
N.D.
362
+++
++
++
+
+
+
363
+++
+++
++
+
+
+
364
+++
+++
++
+
+
+
365
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
366
+
N.D.
N.D.
N.D.
N.D.
N.D.
367
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
368
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
369
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
370
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
371
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
372
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
373
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
374
++
N.D.
N.D.
N.D.
N.D.
N.D.
375
+++
N.D.
N.D.
N.D.
N.D.
N.D.
376
+++
N.D.
N.D.
N.D.
N.D.
N.D.
377
+++
N.D.
N.D.
N.D.
N.D.
N.D.
378
+++
N.D.
N.D.
N.D.
N.D.
N.D.
379
+++
N.D.
N.D.
N.D.
N.D.
N.D.
380
++
N.D.
N.D.
N.D.
N.D.
N.D.
381
++
N.D.
N.D.
N.D.
N.D.
N.D.
382
+++
N.D.
N.D.
N.D.
N.D.
N.D.
383
+++
N.D.
N.D.
N.D.
N.D.
N.D.
384
++
N.D.
N.D.
N.D.
N.D.
N.D.
385
++
N.D.
N.D.
N.D.
N.D.
N.D.
386
+
N.D.
N.D.
N.D.
N.D.
N.D.
387
+
N.D.
N.D.
N.D.
N.D.
N.D.
388
+++
N.D.
N.D.
N.D.
N.D.
N.D.
389
++
N.D.
N.D.
N.D.
N.D.
N.D.
390
+
N.D.
N.D.
N.D.
N.D.
N.D.
391
++
N.D.
N.D.
N.D.
N.D.
N.D.
392
++
N.D.
N.D.
N.D.
N.D.
N.D.
393
++
N.D.
N.D.
N.D.
N.D.
N.D.
394
+++
N.D.
N.D.
N.D.
N.D.
N.D.
395
+++
N.D.
N.D.
N.D.
N.D.
N.D.
396
+++
N.D.
N.D.
N.D.
N.D.
N.D.
397
+
N.D.
N.D.
N.D.
N.D.
N.D.
398
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
399
+++
N.D.
N.D.
N.D.
N.D.
N.D.
1301
+++
N.D.
N.D.
N.D.
N.D.
N.D.
401
+++
++
++
+
+
+
402
+++
+++
+++
+
+
+
403
+++
+++
+++
+
+
++
404
+++
+++
+++
+
+
+
405
+++
+++
++
N.D.
N.D.
N.D.
406
++
++
+
N.D.
N.D.
N.D.
407
++
++
+
N.D.
N.D.
N.D.
408
+++
+++
++
N.D.
N.D.
N.D.
409
+++
+++
+++
+
+
++
410
+++
+++
+++
++
++
++
411
+++
+++
+++
+
+
+
412
N.D.
N.D.
N.D.
N.D.
N.D.
N.D.
For kinase IC50 values, “+++” represents <0.1 μM, “++” represents between 0.1 and 1.0 μM, and “+” represents >1.0 μM.
For cellular IL-1 and TNF values, “+++” represents <0.1 μM, “++” represents between 0.1 and 0.5 μM, and “+” represents >0.5 μM.
For all whole blood (“WB”) assay values, “+++” represents <0.25 μM, “++” represents between 0.25 and 0.5 μM, and “+” represents >0.5 μM.
In all assays indicated in the table above, “N.D.” represents value not determined.
Other p38 inhibitors of this invention will also inhibit phosphorylation of EGF receptor peptide, and the production of IL-1, TNF and IL-6, as well as IL-8 in LPS-stimulated PBMCs or in whole blood.
D. Inhibition of IL-6 and IL-8 Production in IL-1-Stimulated PBMCs
This assay was carried out on PBMCs exactly the same as above except that 50 μl of an IL-1b working stock solution (2 ng/ml in cell culture medium) was added to the assay instead of the (LPS) working stock solution.
Cell culture supernatants were harvested as described above and analyzed by ELISA for levels of IL-6 (Endogen, #EH2-IL6) and IL-8 (Endogen, #EH2-IL8) according to the instructions of the manufacturer. The ELISA data were used to generate dose-response curves from which IC50 values were derived.
Results for p38 inhibitor compound 6 are shown in Table 8 below:
TABLE 8 Cytokine assayed IC 50 (μM) IL-6 0.60 IL-8 0.85
E. Inhibition of LPS-Induced Prostaglandin Endoperoxide Synthase-2 (PGHS-2, or COX-2) Induction in PBMCs
Human peripheral mononuclear cells (PBMCs) were isolated from fresh human blood buffy coats by centrifugation in a Vacutainer CPT (Becton & Dickinson). We seeded 15×10 6 cells in a 6-well tissue culture dish containing RPMI 1640 supplemented with 10% fetal bovine serum, 50 U/ml penicillin, 50 μg/ml streptomycin, and 2 mM L-glutamine. Compound 6 (above) was added at 0.2, 2.0 and 20 μM final concentrations in DMSO. Then we added LPS at a final concentration of 4 ng/ml to induce enzyme expression. The final culture volume was 10 ml/well.
After overnight incubation at 37° C., 5% CO 2 , the cells were harvested by scraping and subsequent centrifugation, then the supernatant was removed, and the cells were washed twice in ice-cold DPBS (Dulbecco's phosphate buffered saline, BioWhittaker). The cells were lysed on ice for 10 min in 50 μl cold lysis buffer (20 mM Tris-HCl, pH 7.2, 150 mM NaCl, 1% Triton-X-100, 1% deoxycholic acid, 0.1% SDS, 1 mM EDTA, 2% aprotinin (Sigma), 10 μg/ml pepstatin, 10 μg/ml leupeptin, 2 mM PMSF, 1 mM benzamidine, 1 mM DTT) containing 1 μl Benzonase (DNAse from Merck). The protein concentration of each sample was determined using the BCA assay (Pierce) and bovine serum albumin as a standard. Then the protein concentration of each sample was adjusted to 1 mg/ml with cold lysis buffer. To 100 μl lysate an equal volume of 2×SDS PAGE loading buffer was added and the sample was boiled for 5 min. Proteins (30 μg/lane) were size-fractionated on 4-20% SDS PAGE gradient gels (Novex) and subsequently transferred onto nitrocellulose membrane by electrophoretic means for 2 hours at 100 mA in Towbin transfer buffer (25 mM Tris, 192 mM glycine) containing 20% methanol. The membrane was pretreated for 1 hour at room temperature with blocking buffer (5% non-fat dry milk in DPBS supplemented with 0.1% Tween-20) and washed 3 times in DPBS/0.1% Tween-20. The membrane was incubated overnight at 4° C. with a 1:250 dilution of monoclonal anti-COX-2 antibody (Transduction Laboratories) in blocking buffer. After 3 washes in DPBS/0.1% Tween-20, the membrane was incubated with a 1:1000 dilution of horseradish peroxidase-conjugated sheep antiserum to mouse Ig (Amersham) in blocking buffer for 1 h at room temperature. Then the membrane was washed again 3 times in DPBS/0.1% Tween-20 and an ECL detection system (SuperSignal™ CL-HRP Substrate System, Pierce) was used to determine the levels of expression of COX-2.
Results of the above mentioned assay indicate that compound 6 inhibits LPS induced PGHS-2 expression in PBMCs.
While we have hereinbefore presented a number of embodiments of this invention, it is apparent that our basic construction can be altered to provide other embodiments which utilize the methods of this invention. | The present invention relates to inhibitors of p38, a mammalian protein kinase involved cell proliferation, cell death and response to extracellular stimuli. The invention also relates to methods for producing these inhibitors. The invention also provides pharmaceutical compositions comprising the inhibitors of the invention and methods of utilizing those compositions in the treatment and prevention of various disorders. | 2 |
TECHNICAL FIELD
The present invention relates to a method and an apparatus for determining the reaction status of a chemical reaction, in particular a reaction for amplifying nucleic acids.
PRIOR ART/BACKGROUND OF THE INVENTION
It is usually desired in chemical reactions to quantify the result of the reaction by measuring suitable variables or to follow the progress of the reaction by means of such a variable. A well-known example is following the changes in color of a colored indicator which has been added to a reaction mixture.
In a process for amplifying nucleic acids, in contrast to usual chemical reactions, a precursor is not converted into a completely different product, but one part of a molecule is copied with the aid of other precursors. In the specific case of methods for amplifying nucleic acids, especially the polymerase chain reaction (PCR), the result of the reaction is nowadays frequently quantified by staining with ethidium bromide and detecting the fluorescent signal. It has also been proposed to detect the hybridization process itself by fluorescence. Such a method is disclosed in U.S. Pat. No. 6,174,670. The detected fluorescent signal results from a fluorescence resonance energy transfer (FRET) between two fluorophores on excitation of the donor fluorophore with light. The DNA can be genotyped by analyzing specific melting and solidification curves.
Monitoring the progress of a reaction by fluorescence is relatively complicated, because a sensitive optical system must be provided for detection. In addition, such a method is costly to use because of the fluorescence markers necessary therefor.
It is also known to examine the progress of viscosity-altering reactions, e.g. polymerization reactions, by means of viscometry. A reaction is viscosity-altering if the viscosity of the product of the mixture of the products differs from the viscosity of the mixture of the precursors. The viscosity of the mixture will then approach the viscosity of the products as the reaction increasingly advances. Measurement of viscosity then provides a measure of the advancing of the reaction. The viscometers employed for this purpose are, however, ordinarily optimized for industrial production plants and unsuitable for examining small reaction volumes.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method for determining the reaction status of a chemical reaction process in a reaction mixture, where the chemical reaction process includes an amplification reaction for nucleic acids. The method is intended to be simple to carry out and cost-effective. This object is achieved by a method having the features of claim 1 .
The method of the invention includes a determination of the viscosity of the reaction mixture. This can take place with a suitable viscometer, preferably with a dynamic viscometer. However, it is also possible to use another type of viscometer, e.g. a capillary viscometer as known in the art.
It is further intended to provide a method for determining the reaction status of a chemical reaction process in a reaction mixture which is particularly suitable for small sample quantities and can be carried out cost-effectively. This object is achieved by a method having the features of claim 5 . This method is distinguished by the use of a dynamic viscometer and comprises the steps:
provision of the dynamic viscometer which comprises a resonator and at least a first transducer cooperating with the resonator, where the resonator is capable of a mechanical natural vibration with a characteristic frequency, and has a contact surface; contacting the reaction mixture with the contact surface; determining a measure of the viscosity by means of the dynamic viscometer.
It is a further object of the present invention to indicate an apparatus which is particularly suitable for determining the reaction status of a chemical reaction. This object is achieved by an apparatus having the features of claim 9 .
Advantageous embodiments of the invention are indicated in the dependent claims.
In the method according to the present invention, the reaction status, especially the result, of a chemical reaction is determined. The chemical reaction preferably includes at least one reaction step in which an amplification of nucleic acids takes place. The method is distinguished by performing a measurement of the viscosity.
The method of the invention makes it possible to establish, very cost-effectively, whether and the extent to which an amplification has in fact taken place. This is based on the realization that virtually every amplification reaction leads to a viscosity alteration, e.g. a polymerase chain reaction (PCR), a ligase chain reaction (LCR) or a NASBA reaction (nucleic acid sequence based amplification). The corresponding methods are well known in the art.
The method of the invention makes it possible in particular to carry out very cost-effectively methods for screening for the presence of nucleic acids of particular organisms or for the presence of a mutation in the genetic material of an organism, especially of a microbial, plant or animal (including human) organism. For the last-mentioned application, the method preferably includes further analysis steps which allow the presence of a mutation in a nucleic acid to be determined.
In a preferred embodiment, the amplification reaction in this case includes an allele-specific amplification reaction as is well known in the art. An allele-specific amplification is an amplification in which the quantity of the nucleic acid fragments generated by the reaction depends on the absence or presence of the mutation on a target sequence initially present. The further analysis steps then preferably include a step in which the determined measure of the viscosity is compared with a previously measured or calculated reference standard, the result of this comparison enabling a decision to be made about the presence of the mutation.
The reaction process preferably includes at least one reaction step in which nucleic acid fragments are linked together, preferably in a form in which the fragments polymerize together. In a preferred embodiment, the linkage of target nucleic acid fragments takes place by means of linker oligonucleotides. The linker oligonucleotide is designed to hybridize with a first probe region near its 5′ end on a first nucleic acid fragment and to hybridize with a second probe region near its 3′ end on a second nucleic acid fragment. The linker oligonucleotides are preferably themselves linked by means of a ligase subsequent to such a hybridization process. This can take place in the form of an LCR. Before the linkage with the ligase it is optionally possible also for an elongation to take place with a polymerase without 3′→5′ exonuclease activity, as is normally used in a so-called gap LCR. The linker oligonucleotide preferably includes a linker region which includes a repetitive arrangement of bases, e.g. a region of preferably 5 to 20 identical bases, e.g. T bases. The two probe regions, whose nucleotide sequences are preferably substantially complementary to one target sequence in each case, adjoin on both sides of this region. If the linkage of the linker oligonucleotides is to take place allele-specifically on a single nucleotide polymorphism (SNP, exchange of a single base at a mutation site), the linker oligonucleotide is preferably chosen so that a base, which preferably forms the 3′ end of the linker oligonucleotide or is a few, preferably one or two, positions away from the 3′ end, is complementary to the base of the target sequence at the mutation site.
The linker region and the adjoining regions are designed so that substantially no hybridization of both probe regions to a single nucleic acid fragment with the target sequence takes place, but so that preferably each of the probe regions hybridizes to a different nucleic acid fragment having the target sequence. In order for it to be possible for linkage by the ligase to take place, the 5′ end of the linker oligonucleotide is preferably phosphorylated.
Thus, there is here firstly a linkage of target nucleic acid fragments by linker oligonucleotides, and secondly in addition a linkage of the linker oligonucleotides. The linkage may result in a linear macromolecule and/or a network. Concerning the terms “linear macromolecule” and “network”, reference is made to the IUPAC Compendium of Chemical Terminology, 2nd edition (1997). Such an additional polymerization leads to a marked increase in viscosity as long as a sufficient quantity of precursor, i.e. a sufficient number of fragments of the target sequence, is present.
The viscosity is preferably determined using a dynamic viscometer, but can also be determined for example with a known capillary viscometer.
A dynamic viscometer means in connection with this document an apparatus which includes a resonator which is capable of a mechanical natural vibration, preferably a torsional vibration. The resonator has a contact surface which can be brought into contact with a fluid. The resonator, and thus the contact surface, can be stimulated to vibrate by means of a transducer, e.g. a piezo transducer or an electromagnetic transducer. The fluid on the contact surface will damp the vibration. A measure of the viscosity of the fluid can then be derived from the damping of the resonator. A quantitative determination of the viscosity is possible if the density of the fluid is known.
A dynamic viscometer is easy to use, cost-effective to produce and highly sensitive for small viscosity changes. Whereas dynamic viscometers are known per se, the method of the invention is distinguished by using the dynamic viscometer to obtain information about the reaction status through the viscosity. In contrast to methods like those typically employed for monitoring industrial polymerization reactions, the method of the invention is particularly suitable for applications in which the quantity of the reaction mixture is relatively small.
Various embodiments of dynamic viscometers are described in U.S. Pat. No. 4,920,787 and WO 95/24630. Explicit reference is made to the disclosure in these documents for the configuration of a dynamic viscometer.
A great advantage of using a dynamic viscometer in the method of the invention is the high sensitivity which can be achieved with dynamic viscometers. Even small viscosity changes, of the scale of a few percent or less, in small sample volumes can be detected with such a viscometer. The reaction mixture is preferably present in a sample chamber which comprises the contact surface of the resonator and whose volume is less than 1 milliliter, preferably less than 100 microliters, in an advantageous configuration less than 10 microliters. The volume of the sample chamber will ordinarily exceed 1 microliter; however, the volume may be below this value with an appropriate design of the viscometer. In order to enable such small sample volumes to be measured with sufficient sensitivity, the present invention also provides particular configurations of the viscometer.
The sample chamber is preferably at least partly delimited by capillary forces. It is thus very simple, in particular with small sample volumes, to bring an exactly defined region of the contact surface into contact with the reaction mixture, and hold it there during the measurement.
In the method of the invention it is possible for a reaction process to take place while the reaction mixture is present in the sample chamber of the viscometer, or the reaction mixture is introduced into the viscometer only after the reaction has taken place. Advantages accrue if at least part of the reaction process takes place while the reaction mixture is in contact with the contact surface, because elaborate sample transfers can then be omitted. This is an advantage in particular if the reaction process is a reaction for amplifying nucleic acids, because possible contamination is thus avoided and an elaborate manual step in the manipulation can be omitted. It is also possible by periodic measurement of the viscosity to follow the advance of the reaction directly. In this case, the contact surface is preferably formed by the inside of a glass tube, and a temperature-control element, e.g. a heating element or a Peltier element permitting both heating and cooling, is advantageously vapor-deposited on the glass tube.
The invention also relates to an apparatus for determining the reaction status of a viscosity-altering chemical reaction process in a reaction mixture. This apparatus is distinguished by comprising a dynamic viscometer with a torsional vibrator as resonator. In other words, the apparatus includes a resonator which has a contact surface and is capable of a torsional vibration parallel to the contact surface, and at least a first transducer cooperating with the resonator.
It is frequently desired to adjust the temperature of the reaction mixture to a defined value, either to achieve defined measurement conditions, or to induce reactions at elevated temperatures. For this purpose, the viscometer preferably includes a temperature-control element disposed near the contact surface. This may be a pure heating element, e.g. a heating wire, but is preferably an element which enables both heating and cooling, e.g. a Peltier element. The temperature-control element is preferably attached to the resonator. It can be produced by vapor deposition of metal layers on the resonator, especially if the latter comprises a glass tube.
The temperature-control element can, as current-carrying element, simultaneously serve to exert a force or a torque on the resonator through the Lorentz force acting in an external magnetic field. In this function, the temperature-control element may be part of the (electromagnetic) transducer. Conversely, vibration of the resonator in an external magnetic field then leads to induced voltages, which can be used to detect the vibration, in the temperature-control element. In this case, the viscometer preferably includes means for generating a static magnetic field, in particular one or more permanent magnets, in the vicinity of the temperature-control element.
In an advantageous embodiment, the resonator comprises a (mineral) glass tube with an external diameter of 1 millimeter or less. The external diameter is preferably 0.5 millimeter or less. The internal diameter is preferably 0.8 millimeter or less, particularly preferably 0.4 millimeter or less. The wall thickness is preferably between 0.02 millimeter and 0.1 millimeter, particularly preferably about 0.05 millimeter. The glass tube preferably consists of quartz glass. A resonator with such a glass tube has a high sensitivity, inter alia because of the particular mechanical properties of glasses, especially of quartz glass, and because of the low specific mass compared with many metallic materials. In addition, glass is to a large extent chemically inert, thus preventing the resonator material being attacked or chemically altered by the reaction mixture. A glass tube is moreover particularly suitable for vapor deposition of metal regions, thus making it possible to produce a temperature-control element particularly cost-effectively. This is of particular interest if the resonator is designed as a disposable product.
The glass tube is preferably fastened to a first and a second inertial mass whose mass is in each case a multiple (at least ten times) of the mass of the glass tube. Each inertial mass is connected directly or indirectly, e.g. via a weakened region, which acts as spring element, to a housing or holder. For further considerations concerning the inertial mass and connection thereof to the housing or holder, express reference is made to the disclosure in U.S. Pat. No. 4,920,787 and WO 95/24630. The transducer is disposed in the region between the inertial masses close to a vibration antinode (region of maximum amplitude) of a natural vibration of the resonator. The transducer is preferably located in the middle between the inertial masses. The interior of the tube forms the contact surface for the reaction mixture.
The glass tube is preferably detachably fastened to the inertial masses, e.g. by means of a clamp bush. The resonator is thus easily exchangeable, thus enabling it to be easily replaced after each measurement for hygiene reasons. In this case, it is particularly advantageous for current-carrying elements which are part of the transducer and serve to generate a magnetic field to be present on the glass tube.
In a further advantageous development, the resonator has a tube and a contact body. The latter is connected to the tube and has a diameter which is greater than the diameter of the tube, preferably at least twice the diameter of the glass tube. An external surface of the contact body forms the contact surface. The contact body is distinguished by being designed for a direct electromagnetic interaction with a magnetic field generated by the transducer, i.e. it is part of the (electromagnetic) transducer.
In a particular configuration, the contact body includes for this purpose a permanent magnet or is formed by such. The viscometer then comprises at least one pair of electromagnets which are disposed so that they interact magnetically with the permanent magnet. Alternatively, the contact body may also have at least one electromagnet.
In a further configuration, the apparatus includes a dosing device for the reaction mixture, which can be attached to a holder or housing or be formed by the housing itself. The dosing device is disposed close to the contact body and has an orifice in the region of the contact surface. The reaction mixture is introduced through this orifice into a predetermined region between the contact surface and the dosing device. The distance of the dosing device from the contact surface is such that the reaction mixture is kept by capillary forces in this predetermined region. The reaction mixture is thus confined in a defined sample volume.
In this configuration, the resonator preferably also includes a tube with, attached thereto, a contact body of larger diameter. In this case, the orifice is preferably disposed centrally, i.e. substantially concentrically with the tube.
The viscometer is preferably operated with a phase control loop as described in detail in U.S. Pat. No. 4,920,787 or WO 95/24630. For this purpose, the apparatus has a feedback unit which comprises an oscillator driving the first transducer. The feedback unit is intended to stabilize the resonator in the region of a characteristic frequency. For this purpose, an output terminal of the feedback unit is connected at least indirectly to the first transducer which stimulates the resonator to vibrations. The same transducer serves likewise to detect the vibrations, or a second transducer is present for this purpose on the resonator. An input terminal of the feedback device is connected at least indirectly to the first transducer or the second transducer. Operation with such a control loop makes particularly stable, reproducible measurements possible.
In order to make operation possible as disclosed in WO 95/24630, a first switch is present between the output terminal of the feedback device and the first transducer, and a second switch is present between the first or second transducer and the input terminal of the feedback device. The switches may include any suitable electronic means, e.g. transistors. The measurement can then take place in a gated mode without impairing the high frequency stability of the phase control loop.
In an apparatus configured in this way, the step of determining the measure of the viscosity preferably includes the following substeps:
stimulation of the first transducer with a signal generated by the feedback unit for a first pre-determined time interval, with, at least during this first time interval, the connection between the input terminal of the feedback device and the first or second transducer being interrupted; feeding a signal generated by the first or second transducer to the feedback unit during a second pre-determined time interval, with, at least during this second time interval, the connection between the output terminal of the feedback device and the first transducer being interrupted.
This mode of operation has proved to be particularly robust, making it suitable in particular for small sample quantities.
The specific developments mentioned for a dynamic viscometer are, of course, also suitable for other purposes than determining the reaction status of a chemical reaction and display similar advantages therein.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail below with reference to the drawings, which show:
FIG. 1 a diagrammatic representation of a first embodiment of a viscometer of the invention viewed in section from above;
FIG. 2 a diagrammatic representation of the viscometer of FIG. 1 in cross section through plane A-A;
FIG. 3 a diagrammatic representation of a second embodiment of a viscometer of the invention viewed in section from the side;
FIG. 4 a diagrammatic representation of the viscometer of FIG. 3 in cross section through plane B-B;
FIG. 5 a diagrammatic representation of a third embodiment of a viscometer of the invention viewed in section from the side;
FIG. 6 a diagrammatic representation of the viscometer of FIG. 3 in cross section through plane C-C;
FIG. 7 a diagrammatic enlarged partial representation of a variant of the third embodiment viewed in section from the side;
FIG. 8 a diagrammatic side view of a resonator tube;
FIG. 9 a diagrammatic representation of the resonator tube of FIG. 8 in cross section through plane D-D;
FIG. 10 a diagrammatic representation of a variant of the third embodiment of a viscometer of the invention in cross section;
FIG. 11 a diagram to illustrate the position of various nucleotide sequences;
FIG. 12 a diagram with measurements of the viscosity for various samples.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows in highly diagrammatic representation a first embodiment of an apparatus 1 according to the present invention. FIG. 2 shows the apparatus of FIG. 1 likewise highly diagrammatically in cross section seen in the direction A-A. Identical parts are provided with identical reference numbers.
A quartz glass tube 101 which forms the resonator is fastened in the region of each of its two ends to an inertial mass 102 , 102 ′. The inertial masses are connected to a housing 107 , e.g. by bonding. Both ends of the glass tube are accessible from the outside in order to introduce a liquid reaction mixture 110 into the glass tube. For this purpose, a certain region at both ends of the glass tube projects for example in a non-depicted manner out of the inertial masses, and suitable connections for feeding in the reaction mixture are provided. This is depicted for example in FIG. 12 of WO 95/24630. Thus, in operation, the interior of the glass tube serves as contact surface.
Two permanent magnets 103 , 104 are bonded diametrically opposite on the middle of the tube 101 . Two electromagnets 105 , 106 are fastened in the housing 107 adjacent to the permanent magnets. The electromagnets 105 , 106 form together with the permanent magnets 103 , 104 an electromagnetic transducer for stimulating torsional vibrations of the tube 101 and for detecting such vibrations. The mode of functioning of such electromagnetic transducers is well known. In particular, the roles of permanent magnets and electromagnets may be exchanged. For the mode of functioning and configuration of such transducers, express reference is made to WO 95/24630, page 10, line 1 to page 11, line 9. A torque is exerted on the permanent magnets 103 , 104 and thus on the central region of the tube by a current flowing in the electromagnets 105 , 106 via magnetic forces. Conversely, a torsional movement of the tube induces a voltage in the electromagnets 105 , 106 , which can serve to detect torsional vibrations. The transducer thus serves alternately both as actuator for stimulation and as sensor for detection. It is, of course, also possible to provide separate transducers for these purposes.
FIGS. 1 and 2 are to be understood merely as diagrammatic representations. Thus, in particular, the diameter of the glass tube 101 is depicted greatly enlarged for reasons of depictability. In fact, the preferred external diameter of the glass tube is less than 1 millimeter, and is only 0.5 millimeter in a specifically implemented example. The wall thickness of the glass tube is preferably less than 0.1 millimeter, and is only 0.05 millimeter in said example. Thus, the internal diameter in said example is 0.4 millimeter. The length of the glass tube is preferably between about 30 millimeters and 100 millimeters, and is about 80 millimeters in said example. In this example, the volume of the sample chamber present in the interior of the glass tube is about 10 mm 3 , that is 10 microliters. In such a viscometer, therefore, very small amounts of reaction mixture can be investigated.
The material of the glass tube is preferably a quartz glass. This material is preferred because it exhibits a very small internal damping and low density, thus making a high Q factor and a high sensitivity possible. Owing to the low modulus of rigidity of the material it is possible to prevent the boundary layer becoming too small. The resonance frequency of the fundamental vibration is preferably in the range between about 1 kHz and about 100 kHz; in said specifically implemented example it was about 14.7 kHz. The glass tube in this example was a commercially available quartz glass tube as is obtainable for example from VitroCom Inc., Mount Lakes, N.J. (USA).
The damping of the resonator is increased through the reaction mixture being in contact with the contact surface. The viscosity is determined from the measured damping of the resonator. This can take place analytically from the relation between viscosity and damping or through a calibration.
The apparatus is preferably operated as described in WO 95/24630. For this purpose, the electromagnets 105 , 106 of the electromagnetic transducer are connected to a circuit as set forth in FIG. 1 to 8 and on page 4, line 1 to page 9, line 31 of WO 95/24630. Express reference is made to this disclosure for the design of the circuit for operating the apparatus and for the method of operation. The circuit is an example of a feedback circuit in order to stabilize the resonator close to its characteristic frequency. The damping of the resonator is determined by measuring the frequency shift on altering the phase between stimulating signal in the transducer and detected signal in the transducer.
The embodiment of FIGS. 1 and 2 is preferably configured so that all parts coming into contact with the reaction mixture, especially the glass tube 101 , can easily be exchanged. For this purpose, the glass tube 101 is held in the inertial masses 102 , 102 ′ preferably with fastening means which are not depicted in detail and which permit the connection between glass tube and inertial mass to be broken easily. Suitable examples are clamp bushes made of plastic or metal as are well known in the art and which effect a secure connection between glass tube and inertial mass for example by screw tightening. It is important in this case that the connection is sufficiently firm for the glass region held in the fastening means in fact not to be capable of torsional vibrations.
FIG. 3 shows a diagrammatic representation of a second embodiment of an apparatus of the invention, identified by the number 3 . FIG. 4 shows the apparatus of FIG. 3 in cross section looking in the direction B-B. The resonator again includes a quartz glass tube 301 which is fastened by one end in an inertial mass 302 . A cylindrical contact body 303 is placed on the other end. The inertial mass 302 is fastened in a housing 307 . The latter is designed in the vicinity of the contact body to be so cylindrical that it encircles at a constant distance the contact body along its periphery. Opposite the front surface of the contact body there is an orifice 311 in the housing, through which a reaction mixture 310 can be introduced into the region limited by the contact body 303 and the housing 307 . Beneath the contact body, the interior of the housing widens greatly. The orifice 311 likewise widens away from the contact body 303 . These widenings, and the distances between contact body 303 and housing 307 are chosen so that the reaction mixture is held in the intended region by capillary forces. It is additionally possible, by suitable choice of the size of the contact body and of the distances, to reduce the quantity of the reaction mixture very greatly.
In the depicted embodiment, the contact body 303 is in the form of a permanent magnet whose magnetic field runs substantially perpendicular to the long axis of the tube 301 . To prevent corrosion by the reaction mixture, the magnet can be provided with a chemically inert coating. This permanent magnet is suitable for magnetic interactions with two electromagnets 305 , 306 . Contact body 303 and electromagnets 305 , 306 accordingly together form an electromagnetic transducer, and the contact body is itself part of this transducer.
In a specific embodiment, the contact body is formed for example by an Sm—Co permanent magnet which has been hydrophilicized on its surface by known methods in order to ensure good wetting.
Stimulation of the transducer with electrical signals of appropriate frequency stimulates the tube 301 to torsional vibrations, preferably in the fundamental vibration. The vibrations are detected by the same transducer as a sensor. The viscometer of FIG. 3 is operated in substantially the same way as that in FIG. 1 ; the statements made above concerning this accordingly apply analogously. The resonance frequency of the resonator is once again preferably in the range between 1 and 100 kHz.
FIGS. 3 and 4 are once again to be understood only as diagrammatic representations in which, in particular, the size relationships need not correspond to reality.
The statements made about FIGS. 1 and 2 apply in relation to the considerations of the dimensions of the glass tube. The distance between the contact body and the housing is to be chosen to be at least greater than the thickness of the boundary layer, formed during torsional vibration of the resonator, of the reaction mixture. Concerning further dimensions, the skilled worker is aware how these are to be chosen in order to achieve sufficient capillary forces depending on the material of the contact body and of the housing, and the composition of the reaction mixture. In a specific configuration, for example, the contact body has a diameter of 2.0 millimeters and a length of 0.7 millimeter. The internal diameter of the housing surrounding the contact body is 3.0 millimeters, i.e. the gap between contact body 303 and housing 307 has a width of 0.5 millimeter. The total sample volume in such a viscometer is about 15 microliters. It is of course possible for these dimensions to vary within a wide range depending on the specific area of use of the viscometer. One important aspect in the choice of the dimensions of the contact body is the resonance frequency of the resonator, which decreases as the mass of the contact body 303 increases.
The viscometer of FIG. 3 is suitable because of its simple design in particular also as a disposable viscometer whose parts which come into contact with the reaction mixture can simply be thrown away after use. In such a case, the electromagnets 305 , 306 of the transducer are fastened to the housing 307 in an easily removable manner. Housing 307 , inertial mass 302 , tube 301 and contact body 303 form a disposable unit which can be thrown away after use and replaced by a new unit. The electromagnets 305 , 306 and the drive electronics, which are not depicted, are by contrast reused. The housing can in such a case be manufactured cost-effectively from a synthetic material, e.g. polypropylene, in particular in a (precision) injection molding process. The same applies to the inertial mass. The electromagnets may also be held in a separate housing, e.g. a retaining ring, in which case the viscometer housing 307 is for example insertable therein.
FIG. 5 shows a diagrammatic representation of a third embodiment of the apparatus of the invention identified by number 5 . This apparatus is depicted in FIG. 6 in cross section looking in the direction C-C. Once again, the resonator includes a glass tube 501 which is connected at one end to an inertial mass 502 . The inertial mass is inserted into a housing 507 . A contact body 503 is once again attached at the other end of the glass tube 501 . Just as in FIG. 3 , this body is designed as a permanent magnet and interacts magnetically with electromagnets 505 , 506 . It is thus part of an electromagnetic transducer.
Opposite the front surface of the contact body 503 , a dosing element 508 is screwed into the housing 507 . This has a funnel-shaped dosing zone 509 , which opens at the bottom into an orifice 511 , to receive a reaction mixture 510 . The reaction mixture passes through this orifice to the contact surface which is formed by the front surface of the contact body 503 . The reaction mixture is held on this surface by capillary forces. The sample chamber is thus confined to the region between the front surface of the contact body 503 and the dosing element 508 . The distance between contact body and dosing element can be varied for example by means of a fine thread, which is not depicted, on the cylindrical periphery of the dosing element 508 , which cooperates with a corresponding internal thread of the housing 507 . It is thus possible to restrict a reaction mixture to a thin layer whose thickness can be adjusted to the order of magnitude of the boundary layer which forms when the resonator executes torsional vibrations.
FIG. 7 shows a section of a similar viscometer which is constructed according to the principles of FIG. 5 . Only part of the glass tube 501 , the contact body 503 ′ and the dosing element 508 ′ with dosing zone 509 ′ and orifice 511 ′ are depicted, together with the reaction mixture 510 . Whereas the front surface of the contact body 503 ′ is flat, the dosing element 508 ′ has a conical shape in the region opposite the front surface. There is a radial widening of the distance between the contact body 503 ′ and the dosing element 508 ′. This configuration firstly ensures an effective restriction of the reaction mixture by capillary forces to the desired region. Secondly, this configuration ensures that a substantially spatially uniform shear rate (uniform rate gradient along the axial direction) is achieved over the whole reaction mixture. It is possible with this configuration to achieve very small sample volumes, in particular in the region of a few microliters.
The statements made about FIGS. 3 and 4 once again applies to the operation of an apparatus shown in FIG. 5 to 7 .
The viscometers of the present invention can be provided with units for temperature control (heating and/or cooling) of the reaction mixture. FIG. 8 shows as example, diagrammatically and greatly enlarged, a part of a glass tube 101 of a viscometer as shown in FIG. 1 . FIG. 9 depicts the glass tube in cross section looking in the direction D-D. Two metal strips 812 , 813 are vapor-deposited on the glass tube 101 and act as heating wires. The reaction mixture present inside the glass tube 101 can easily be heated therewith. Instead of a layer running in the axial direction, it may also for example be coiled around the glass tube.
It is possible, alternatively or additionally, for a Peltier element as is well known to be disposed in the vicinity of the sample chamber. This makes it possible for the reaction mixture to be optionally heated or cooled. A suitable Peltier element can for example be applied (e.g. bonded) directly to the glass tube, or it can be formed on the glass tube by vapor deposition of two different metals. Depending on the direction of the current, a Peltier element can serve both as heating element and as cooling element.
In a preferred embodiment, the temperature-control element is simultaneously part of the electromagnetic transducer, i.e. a Lorentz force acts on the electrons in the metal of the temperature-control element in a magnetic field and is used to stimulate the resonator and/or to detect the vibrations of the resonator. For this purpose, in addition to the temperature-control element, further metal strips may also be vapor-deposited or applied in another way, e.g. in the form of coils. The temperature-control element acting as part of the transducer, and/or the additional metal strips, may be operated with direct current in a first operating mode. In operation, they then cooperate with an alternating magnetic field which is generated by the electromagnets 105 , 106 in order to stimulate the resonator. Alternatively, they may also be operated with alternating current. In this case, the coils 105 , 106 can be replaced by permanent magnets, and both the stimulation and the vibration detection takes place completely by means of the temperature-control element and/or of the additional metal strips, instead by means of the coils 105 , 106 .
Especially when a Peltier element is part of the transducer it is advantageously operated with alternating current for the purposes of stimulation, so that a negligible cooling or heating effect takes place, because cooling effect and heating effect are substantially canceled over a period of the alternating current.
The metal regions present on the glass tube 101 can be connected in a known manner to electrical supply lines. For this purpose, for example, contact zones are formed near the ends of the glass tube. After the glass tube has been inserted into the inertial masses, these contact zones are in contact with contacts for the electrical supply lines which are provided for example in the borehole of the inertial masses or at another suitable point.
Such a configuration is advantageous especially when the glass tube is configured as a disposable glass tube, i.e. is designed to be removed and replaced after use. It is possible in particular to dispense with the permanent magnets 103 , 104 , leading to a marked saving in costs.
As a further example, FIG. 10 shows a variant of the viscometer of FIG. 4 , in which two heating elements 1012 , 1013 are present on the inner surface of the housing 307 which surrounds the contact body 303 . These may be formed for example from current-carrying pieces of wire or be formed in another known manner.
It is also possible for a plurality of temperature-control elements to be present, making it possible for example to generate temperature gradients. Suitable temperature sensors as are well known in the art (e.g. Pt-100 sensors etc.) are also preferably present.
The presence of one or more temperature-control elements is particularly beneficial especially when a reaction is to be carried out directly in the viscometer, but also has other advantages because the viscosity is usually highly temperature-dependent and a control of the temperature may improve the reproducibility of the measurement. Thus, if a cooling element is present, the reaction mixture can for example be cooled to a temperature close to the solidification point of the reaction mixture, e.g. into the range between 0° C. and 10° C. for dilute aqueous solutions, usually bringing about a significant increase in viscosity, and be stabilized there. Stabilization in a range of, for example ±0.1° C. will often be necessary and can be achieved more quickly and easily with said temperature-control elements than with temperature control of the entire viscometer.
A temperature control is of particular interest when a reaction for amplifying nucleic acid fragments is carried out, especially a PCR or LCR, which often require temperature alterations (temperature cycles). It is possible through the temperature control for the reaction to take place directly in the sample chamber of the viscometer, and the amplification can be followed directly at suitable points in the temperature cycles by means of the change in viscosity. In a method for detecting mutations by means of allele-specific amplification, the reaction can for example be terminated immediately when a change in viscosity indicating the presence of the mutation occurs. If the temperature of the viscometer is not controlled, the amplification is carried out in a separate reaction apparatus for the amplification process initially for a fixed number of cycles. The sample must then be removed from the reaction apparatus and only then transferred into the viscometer. It is obvious that this involves greater expenditure of time and effort.
The use of the method of the invention in a reaction for amplifying nucleic acids is now to be explained by way of example for use for detecting mutations.
Use: Detecting Mutations
Various methods are now normally used to detect mutations of nucleic acids (DNA and RNA). Mutations of the genetic material include the absence of single base pairs (single nucleotide polymorphisms SNPs), the absence of a whole sequence unit (deletion) or the presence of surplus genetic information (insertion). Examples which may be mentioned of the detection of such alterations in genetic material are gel electrophoresis with restriction enzymes, which uses ethidium bromide as staining method. A more modern example is real-time PCR with fluorophores to visualize the reaction. These processes are costly, time-consuming and relatively expensive.
The method of the invention represents a cost-effective alternative with which it is possible to determine a mutation in the genetic material. The method advantageously takes place in the following phases:
isolation of the nucleic acids; amplification of the sequence to be investigated, e.g. by means of a polymerase chain reaction (PCR); linkage of the fragments produced in the amplification reaction by means of a ligase chain reaction (LCR) with probe molecules (allele-specific) specifically designed as linkers; determining the viscosity of the reaction product.
The increase in viscosity in a chemical process such as PCR can in principle be calculated theoretically. In this case, nucleotides are converted into longer, double-stranded products, so that the molecules become larger and water, which previously surrounded the nucleotides, is released. The viscosity will change during this, because polymers are synthesized. The so-called templates produced in the reaction frequently achieve a size of 250 to 500 mer.
However, the amplification process is frequently insufficient on its own for a significant increase in viscosity to be measurable. For this reason, the molecules produced in the amplification are preferably connected together (linear linkage and/or crosslinking). This process is carried out subsequent to the amplification or coupled therewith. The linkage is in this case preferably carried out using an LCR with incorporation of suitable linker molecules.
EXAMPLE
Detection of the “Factor V Leiden” Mutation
The factor V Leiden mutation is a single point mutation (G instead of A) in the human gene sequence, leading to a glutamine residue being replaced by an arginine residue at position 506 in the protein (a clotting factor) encoded by the sequence. Further information on this mutation is to be found for example in R. M. Bertina et al., “Mutation in Blood Coagulation Factor V Associated with Resistance to Activated Protein C”, Nature 369, 64-67 (1994). The entire nucleotide sequence of the factor V gene is described in: R. J. Jenny et al., “Complete cDNA and Derived Amino Acid Sequence of Human Factor V”, Proc. Nat. Acad. USA 84, 4846-4850 (1987). The risk of thrombosis is markedly increased in individuals having the mutation compared with individuals of the wild type, which is, why this mutation is the subject of a laboratory test which is frequently carried out in clinical genetics laboratories.
In the method normally carried out to identify the mutation, the gene segment is amplified by PCR. The amplification product is digested with a restriction endonuclease which cuts only the wild-type sequence, but not the mutant. Wild type and mutant can then be differentiated by gel electrophoresis. This method is time-consuming and requires a large number of manual steps.
An alternative proposal in U.S. Pat. No. 6,174,670 is to monitor the PCR process by means of fluorescence. Although this method is substantially faster it is relatively expensive because of the need for optical components and the use of fluorescence markers.
It is therefore demonstrated hereinafter that mutation of the Leiden V gene can also be examined very cost-effectively, simply and quickly using dynamic viscometry.
Hereinafter, “mutation site” refers to that nucleotide position in the factor V gene where a guanine base in the wild type is replaced by an adenine base in the mutant.
The DNA oligonucleotides indicated in Table 1 were synthesized beforehand (TIB-MOLBIOL, Berlin). FIG. 11 illustrates in this connection how these oligonucleotides correspond to the sequence of the factor V gene. A segment of the double strand of the factor V gene in the vicinity of the mutation site is depicted in the middle of FIG. 11 . The oligonucleotides are designed to hybridize onto the indicated sites on the single strands. In this connection, “probe_for” stands for either “wild type_for” or “mutation_for”, and corresponding “probe_rev” stands for either “wild type_rev” or “mutation_rev”. In a “normal” LCR, the oligonucleotide “probe_for” serves for connection to the oligonucleotide “general_for” which is phosphorylated at the 5′ end, and analogously the oligonuleotide “probe_rev” serves for connection to the 5′-phosphorylated oligonucleotide “general_rev”. The molecules “WT_Linker_for”, “WT_Linker_rev”, “Mut_Linker_for” and “Mut_Linker_rev” are produced by connecting these molecules via a linker of (preferably) nine T bases and are designed to hybridize with their segments on the 5′ side to a first nucleotide and Zenith their segments on the 3′ side to another nucleotide.
TABLE 1
DNA oligonucleotides for analyzing the factor
V Leiden mutation.
Name
Sequence (5′→3′)
ID
Tm
Primer_for
TAATCTGTAA GAGCAGATCC
SEQ ID NO: 1
Primer_rev
TGTTATCACA CTGGTGCTAA
SEQ ID NO: 2
Wild type_for
AGATCCCTGG ACAGGCG
SEQ ID NO: 3
56.1° C.
Mutation_for
CAGATCCCTG GACAGGCA
SEQ ID NO: 4
56.4° C.
General_for
p-AGGAATACAG GTATTTTGTC
SEQ ID NO: 5
55.6° C.
CTTGA
Wild type_rev
CAAGGACAAA ATACCTGTAT
SEQ ID NO: 6
55.6° C.
TCCTC
Mutation_rev
CAAGGACAAA ATACCTGTAT
SEQ ID NO: 7
55.7° C.
TCCTT
General_rev
p-GCCTGTCCAG GGATCTG
SEQ ID NO: 8
53.6° C.
WT_Linker_for
p-AGGAATACAG GTATTTTGTC
SEQ ID NO: 9
CTTGATTTTT TTTTAGATCC
CTGGACAGGC G
WT_Linker_rev
p-GCCTGTCCAG GGATCTGTTT
SEQ ID NO: 10
TTTTTTCAAG GACAAAATAC
CTGTATTCCT C
Mut_Linker_for
p-AGGAATACAG GTATTTTGTC
SEQ ID NO: 11
CTTGATTTTT TTTTAGATCC
CTGGACAGGC A
Mut_Linker_rev
p-GCCTGTCCAG GGATCTGTTT
SEQ ID NO: 12
TTTTTTCAAG GACAAAATAC
CTGTATTCCT T
The letter “p” therein indicates that the respective base is phosphorylated at the relevant 5′ or 3′ end. Tm indicates the melting point calculated by the nearest neighbor method. These oligonucleotides served as primers or probes for the reactions described hereinafter.
The investigation for the presence of the mutation comprised provision of a sample of human DNA which comprised the mutation site, amplification by means of PCR, followed by a “normal” LCR or an allele-specific and specifically adapted LCR, finally followed by a viscosity measurement.
Human genomic DNA (initial DNA) was isolated from whole blood by methods like those well known in the art, see, for example, J. Sambrook et al., “Molecular Cloning: A Laboratory Manual” (2nd edition, 1989), Chapter 9.
The nucleic acid isolate was used initially to carry out a PCR for (non-specific) amplification of the initial DNA as follows: the primers used were the abovementioned oligonucleotides “Primer_for” (SEQ ID NO 1) and “Primer_rev” (SEQ ID NO 2). A PCR was carried out in accordance with the following protocol:
Denaturation: 95° C., 1 s Annealing: 55° C., 10 s Elongation: 72° C., 15 s Cycles: 20 Concentrations: 0.5 micromole of each oligonucleotide Taq polymerase 5 U/microliter, in total 3 microliters MgCl 2 : 3 mM dNTPs: 50 micromole
The PCR was only optionally followed by a “normal” LCR. The LCR was carried out as follows: “Ampligase 1× Reaction Buffer” from Epicentre Technologies (20 mM Tris-HCl (pH 8.3), 25 mM KCl, 10 mM MgCl 2 , 0.5 mM NAD, and 0.01% Triton X-100) was provided. The following were added to 50 microliters of reaction buffer: 50 nmol of each of said probes “Probe_for” (SEQ ID NO 3 or 4), “General_for” (SEQ ID NO 5), “Probe_rev” (SEQ ID NO 6 or 7) and “General_rev” (SEQ ID NO 8), 1.5-5 U of Ampligase (Epicentre Technologies). The Ampligase concentration depends on the type of Ampligase employed. 30 seconds' incubation at 95° C., followed by 30 seconds, incubation at 50° C. for 45 seconds; 35 cycles.
In this case, a normal allele-specific LCR takes place in which the ligase links in each case to forward or reverse probes which are hybridized onto the same nucleotide. The resulting nucleotides thus undergo no further linkage (interlinkage or crosslinking).
Alternatively, a specifically adapted LCR was carried out. The LCR in this case was configured so that crosslinking of the resulting nucleic acid fragments takes place simultaneously. For this purpose, the probes “WT_Linker_for” (SEQ ID NO 9) and “WT_Linker_rev” (SEQ ID NO 10) served as specific bridging molecules which bind between the two ends of each one of the PCR products synthesized by the polymerase. Thus, for example, the probe “WT_Linker_for” (SEQ ID NO 9) includes both the sequence of the probe “General_for” (SEQ ID NO 5) and the sequence “Wild type_for” (SEQ ID NO 3). These are connected by means of a linker region of 9 T bases, it also being possible to choose a different number of bases. Between 5 and 20 bases in the linker region appear to be reasonable, preferably 5 to 10.
During the LCR, the 5′ region of the probe “WT_Linker_for” (SEQ ID NO 8) now hybridizes onto the corresponding region of a first nucleotide, while the 3′ region hybridizes onto the corresponding region of a second nucleotide. If the 5′ end of a further probe molecule is hybridized onto this second nucleotide, the two probe molecules are connected by the ligase. A longer-chain polymer is produced in this way. The production of this polymer leads to a marked rise in viscosity.
However, the ligase linkage will take place only if the sequence of the probe at the 3′ end corresponds exactly to the sequence of the nucleotide. A single base exchange at the 3′ end will therefore inhibit the LCR. The LCR is additionally allele-specific in this way.
The above explanation related to the probe “WT_Linker_for”, but applies analogously also to the probe “WT_Linker_rev”. The reaction is carried out simultaneously on the (+) and (−) DNA strand, in the presence of both probes.
Thus, overall, the LCR is allele-specific and leads simultaneously to polymerization of probe molecules.
The adapted LCR was carried out as follows: “Ampligase 1× Reaction Buffer” from Epicentre Technologies: 50 microliters of reaction buffer, 50 nmol each of said probes “WT_Linker_for”, “WT_Linker_rev”, 1.5-5 U of Ampligase (Epicentre Technologies). The Ampligase concentration depends on the type of Ampligase employed. 30 seconds' incubation at 95° C., followed by 30 seconds' incubation at 50° C. for 45 seconds; 35 cycles.
The product was subsequently examined in a dynamic viscometer as depicted in FIG. 1 (quartz glass tube as resonator, length 80 mm, external diameter 0.5 mm, wall thickness 0.05 mm). In this case, the sample was cooled to 10° C. and the temperature was stabilized in a range of ±0.1° C.
The viscosity of the following samples was determined.
Reference Measurements:
Sample 1 H 2 O (PCR grade)
Sample 6 Buffer solution for PCR (no further additions)
Sample 7 Buffer solution for LCR (no further additions)
Neither a PCR nor an LCR was carried out on these samples.
Control Measurements:
Sample 9 LCR buffer to which a wt sample polymerized previously with linker molecules from a different system was added
Sample 10 PCR buffer with the dye SYBR Green, to which a wt sample polymerized previously with linker molecules from a different system was added
No further PCR or LCR was carried out on these samples either.
The further samples had the composition shown in Table 2. The meanings here are:
Target DNA Target DNA was present as follows: wt=wild type (healthy); mut=homozygous mutation. PCR If yes: a PCR was carried out before the subsequent LCR. LCR conv. If yes: a conventional LCR was carried out with probes of the indicated SEQ ID NO from Table 1, i.e. with probes without linker. LCR linker If yes: an adapted LCR was carried out with the linker probes of the indicated SEQ ID NO from Table 1, i.e. an LCR with simultaneous polymerization of the probe molecules.
TABLE 2
Samples for viscosity measurements
Target
LCR conv.
LCR linker
Number
DNA
PCR
(probes)
(probes)
1
H 2 O, PCR grade
2
wt
no
yes (3, 5, 6, 8)
no
3
wt
no
yes (3, 5, 6, 8)
no
4
mut
yes
yes (3, 5, 6, 8)
no
5
wt
yes
yes (4, 5, 7, 8)
no
6
Buffer for PCR, no other additions
7
Buffer for LCR, no other additions
8
wt
yes
no
yes mut linker
(11, 12)
9
LCR buffer with linked wt sample from a different
system
10
PCR buffer with SYBR Green, with linked wt sample
from a different system
11
mut
yes
no
yes mut linker
(11, 12)
12
wt
no
no
yes, wt linker (9, 10)
13
mut
yes
no
yes, mut linker
(11, 12)
14
mut
no
no
yes, mut linker
(11, 12)
15
wt
yes
no
yes, wt linker (9, 10)
The results are depicted in FIG. 12 . This is a graphical representation of the result of viscosity measurements on the samples indicated in Table 2.
In this case, the symbol n designates the serial number of the measurement, η designates the viscosity. In addition, further control measurements which are not represented were also carried out.
The results showed that detection of a mutation is possible by dynamic viscometry. An increase in viscosity occurs only if the amplification has resulted in sufficient nucleic acid fragments as a product which can serve as templates in the subsequent adapted LCR. The presence or absence of the mutation can thus be concluded from the presence or absence of a change in viscosity in the ligase linkage.
It should be emphasized that the invention is by no means confined to the above examples. Thus, in particular, diverse change in the chemistry design are possible in the method for determining the reaction status of an amplification reaction.
Thus, the number of nucleic acids already present is crucial for the design of the method. If a sufficient number of molecules is present, it is possible for example to dispense with a PCR amplification and to carry out the LCR immediately. For example, to detect DNA from suspensions of bacteria it is possible, as an alternative to PCR with coupled LCR, also to carry out an LCR alone, without PCR. Similarly, to detect thymus DNA it is possible to carry out only a PCR or only an LCR if the amount of nucleic acid is so large that a change in viscosity is measurable by one of these methods alone.
Although the specifically adapted LCR as described herein is advantageous, it is not absolutely essential in all situations. Thus, in some circumstances, solely the increase in viscosity on the basis of a PCR or of a conventional LCR may suffice for detection. If the number of nucleic acid sequences is sufficiently high, it would in particular be possible solely by means of allele-specific amplification to detect an increase in product on the basis of an increase in viscosity, as a type of “real-time PCR”.
In order to be able to detect a point mutation (SNP) by means of an increase in viscosity, the PCR process can also be made dependent on the mutation if the amplification takes place only if the mutation is present. In such a case, only the amplified sequences could then be ligated in the subsequent LCR, i.e. only those of a mutation. No PCR can be carried out on the unmutated ones, and accordingly there is also too little precursor for an LCR which, as a consequence, does not lead to an increase in viscosity either. Such a selective amplification is achieved by means of allele-specific amplification in which a primer is developed for the mutation. Such methods are well known in the art.
A method in which a PCR cycle and an LCR cycle or a so-called ligation detection reaction (LDR) is performed alternately is also conceivable.
A further possibility consists of carrying out a PCR followed by an oligonucleotide ligation assay (OLA) in which the ligation of two neighboring probes is utilized as single detection step.
However, all these methods will have a lower sensitivity than the combination of PCR with the abovementioned specifically adapted LCR, which leads to further interlinkage of the resulting oligonucleotides.
A further very interesting possibility consists of carrying out a gap LCR instead of the PCR or subsequent to the PCR. In a gap LCR, complementary probe pairs are employed with a 3′ extension. After they have hybridized onto the target sequence DNA, there is a gap of one or more bases to the neighboring probe. The thermostable polymerase (for the automation process) without 3′→5′ exonuclease activity, and the appropriate nucleotides (float in solution) are used to couple the gap and the resulting probes with DNA ligase. The use of probe duplexes with non-complementary 3′ extensions prevents the formation of target molecule-independent ligase products (so-called blunt-end ligation). There are studies showing that fewer than 10 molecules per reaction mixture can be detected therewith.
In an alternative experiment, a gap LCR was carried out instead of the PCR. A reaction mixture was made up as follows. “Ampligase 10× Reaction Buffer” from Epicentre Technologies was used as reaction buffer. This contained: 200 mM Tris-HCl (pH 8.3), 250 mM KCl, 100 mM MgCl 2 , 5 mM NAD and 0.1% Triton X-100. The following were added to 50 microliters of reaction buffer: 50 nmol each of suitable probes for the gap LCR, 1.5 U of DNA polymerase without 3′→5′ exonuclease activity (from Thermus flavus) (MBR, Milwaukee, Wis.), 20 mM K + , 1.5-5 U of Ampligase (Epicentre Technologies). The Ampligase concentration depends on the type of Ampligase employed. Definition of the unit U: one unit U catalyzes the ligation of 50% of the cos sites in 1 microgram of lambda-DNA in 1 minute at 45° C. in “1× Ampligase Reaction Buffer”. 1 U of Ampligase DNA ligase is equivalent to at least 15 cohesive end units or nick ligation units as otherwise frequently used in the art. The Ampligase was provided in a storage buffer which had the following composition: 50% glycerol with 50 mM Tris-HCl (pH 7.5), 0.1 M NaCl, 0.1 mM EDTA, 1 mM DTT, and 0.1% Triton X-100. The reaction volume was covered with 50 microliters of mineral oil.
Further evaluation took place as in the above example. The result was comparable with that following a PCR.
An adapted gap LCR in which the probes are designed so that they hybridize with their ends on different nucleic acid fragments, analogous to the adapted LCR described above, is also conceivable.
The proposed methods result in a series of advantages compared with a conventional PCR with fluorescence detection. Of these, the following advantages should be particularly emphasized.
Detection is very cost-effective (up to a factor of 20 more effective than with optical detection). No labeling (dye coupling) is necessary. The synthesis is therefore more cost effective. No specific hybridization probes need to be developed. The reaction can be pooled, i.e. it is possible to test 10, 50, 100 or even more patients simultaneously. If no increase in viscosity occurs, none of the tested samples has a mutation (if the design is for the mutation). If an increase in viscosity is recorded, one or more samples must be mutated. The mutation can be deduced by subsequently dividing the pool. The reaction can be automated: either using a robot pipette or with thermostable ligase. The reaction is multifaceted. There are some subvariants which make application highly interesting, such as, for example, the differentiation of microorganisms. Microorganisms having similar sequences can be differentiated only with difficulty by means of allele-specific amplification. However, such a selection would certainly be possible in a first process. In a following step, the product is then subjected to a sequence-specific crosslinking. This might take place for example with a selective tethering of the molecules in the reaction vessel (well). The coupling and tethering takes place with streptavidin/biotin. The capture probe (complementary) would be able to hybridize the corresponding fragments. In addition, branches which are developed for the sequence differences of the subspecies are now activated, e.g. by means of dendrimers which in turn form a network and thus the viscosity in the event of the presence of a particular sequence and thus species become active and increase the viscosity.
It is generally clear from the above that the method of the invention is generally suitable for determining the reaction status of an amplification reaction, but also for other viscosity-altering chemical reactions, especially when the sample quantities are small.
Diverse variations are also possible in the apparatus of the invention without leaving the scope of the invention, as is evident from the examples described above, and the invention is by no means restricted to these examples.
LIST OF REFERENCE NUMBERS
1 Viscometer (first embodiment)
101 Glass tube
102 , 102 ′ Inertial mass
103 , 104 Permanent magnet
105 , 106 Electromagnet
107 Housing
110 Reaction mixture
A-A Plane of section
3 Viscometer (second embodiment)
301 Glass tube
302 Inertial mass
303 Contact body (permanent magnetic)
305 , 306 Electromagnet
307 Housing
310 Reaction mixture
311 Orifice
B-B Plane of section
5 Viscometer (third embodiment)
501 Glass tube
502 Inertial mass
503 , 503 ′ Contact body (permanent magnetic)
505 , 506 Electromagnet
507 Housing
508 , 508 ′ Dosing insert
509 , 509 ′ Dosing zone
510 Reaction mixture
511 , 511 ′ Orifice
C-C Plane of section
812 , 813 Heating element
D-D Plane of section
1012 , 1013 Heating element
n Measurement number
η Viscosity
Sequence Listing—Free Text
SEQ ID NO 1 Primer for PCR, forward strand
SEQ ID NO 2 Primer for PCR, reverse strand
SEQ ID NO 3 Probe for LCR, wild type-specific, forward strand
SEQ ID NO 4 Probe for LCR, mutation-specific, forward strand
SEQ ID NO 5 Probe for LCR, nonspecific, 5′ end phosphorylated, forward strand
SEQ ID NO 6 Probe for LCR, wild type-specific, reverse strand
SEQ ID NO 7 Probe for LCR, mutation-specific, reverse strand
SEQ ID NO 8 Probe for LCR, nonspecific, 5′ end phosphorylated, reverse strand
SEQ ID NO 9 Linker probe for adapted LCR, wild type-specific, 5′ end phosphorylated, forward strand
SEQ ID NO 10 Linker probe for adapted LCR, wild type-specific, 5′ end phosphorylated, reverse strand
SEQ ID NO 11 Linker probe for adapted LCR, mutation-specific, 5′ end phosphorylated, forward strand
SEQ ID NO 12 Linker probe for adapted LCR, mutation-specific, 5′ end phosphorylated, reverse strand | The invention relates to a method for determining the reactive state of a chemical reaction process in a reaction mixture ( 110 ), in particular an amplification reaction for nucleic acids. The method comprises a viscosity determination, which preferably uses a dynamic viscometer ( 1 ). The invention also relates to an improved dynamic viscometer ( 1 ) for carrying out said method. The viscometer is characterised by an appropriate choice of material for the resonator ( 101 ) and optimised geometric ratios. | 2 |
BACKGROUND
[0001] What is needed is a board game that simulates aspects of Basketball that combines physical skills and luck to create a basketball game experience for children and adults.
BRIEF SUMMARY
[0002] The present invention meets the above-described need by providing a board game that mimics basketball player movements with game pieces requiring that each player rely upon physical skills to play.
BRIEF DESCRIPTION OF PHOTOGRAPHS
[0003] Photo #1): Displays the game board (playing surface) and basketball goals used to simulate regulation basketball court dimensions and lines.
[0004] Photo #2): Displays the game pieces used to simulate basketball players for use with the game.
[0005] Photo #3 and #4): Displays the technique for moving the game pieces used to simulate basketball players during the gaming process.
[0006] Photo # 5 and #6): Displays a technique for simulating a basketball shot during the gaming process.
DETAILED DESCRIPTION
[0007] (Game Board) is designed to imitate/replicate on a smaller scale a regulation basketball court and can be made of wood, plastic, cardboard, rubber, or any other suitable materials. Basketball goals are attached, affixed, or stand alone, either on, or close to the playing surface.
[0008] Other Playing Pieces—
[0009] Playing pieces are constructed of wood, plastic, rubber, cardboard (or any other suitable material) and can be either flat or slightly raised in a variety of shapes sizes and colors. These playing pieces are used to represent basketball players.
[0010] Basketball is designed to simulate a basketball and sized to scale for the basketball goals incorporated into the game design. The basketball material could be plastic, rubber, vinyl or other suitable materials.
[0011] Rules of Play
[0012] Each player chooses a team (recommended the home team uses their lighter colored game pieces, the visiting team uses their darker colored game pieces).
[0013] Determine which team will get the ball first (Home Team, Visiting Team, coin flip, etc.) (See Also “Dropped Ball” in Alternative Rule section).
[0014] Each team alternates offensive series. A series is the movement of all 3 of their players towards the opponent's basket and each eligible player can then take a shot at their opponent's basketball goal.
[0015] The team on defense sets their player pieces on the game court anywhere they choose. Once the defense is set, the offensive player's game pieces are set on their edges, plucking the corner of the game piece, they will spin towards their opponents basket (similar to spinning a coin, hold on its edge with a finger resting on top to keep steady, then with other hand pluck the edge so that the piece spins freely from under your finger towards the opponents goal).
[0016] The offensive players are set on their edges and spun from two possible areas. One area is their own team's baseline (where the ball is inbounded in regulation basketball) and/or any area from their own baseline to the half court line. For every defensive player that is setup in the half of the court closets to their opponent's goal (considered a pressing defense), an offensive game piece must be spun from their own baseline. For every defensive player that is setup in the half of the court closest to the basket they are defending, an offensive player's game piece is spun from any area between their own baseline and the half court line.
[0017] Strategy Note: When the defensive player places his game pieces in their opponents half of the court (press), it forces the offensive player pieces to travel a farther distance, thus potentially creating more difficult shots (or no shots at all, if the offensive piece goes out of bounds or lands on a defensive player piece [FOUL]). When the defensive player places his game pieces back in his own zone, close the the basket he/she is defending, it creates a better opportunity to be “fouled” (when offensive player game piece comes to rest on top of a defensive player's game piece), because they are taking up more space in the area the offensive team is trying to get to and shoot from.
[0018] Once all of the offensive player game pieces have been spun, only those players that remain in bounds; have not committed a foul (landed on opponent's game piece); or landed on their own teammate game piece are eligible to take a shot at the basketball goal. Shots are taken by bouncing the basketball off of the eligible offensive player's game piece and into the basket. Most effective manner is to hold basketball in hand slightly behind and above your player piece (and in a straight line from your hand to the basketball goal) and then gently throw the basketball onto your player piece (will take practice and players skills will develop over time). In order for the basket to count, it must strike the offensive player's game piece.
[0019] NOTE: 1) All eligible offensive player's are allowed to take a shot, regardless of whether a goal has already been made during the series by using another offensive game piece. This means that during an offensive series, the offensive player may score up to 9 points (33 point goals) during his possession. 2) An offensive player is considered out of bounds (not eligible to shoot) if they land anywhere outside of or if any portion of their game piece is touching the out of bounds line (similar to regulation basketball rules). 3) When an offensive player game piece lands on top of (covers any portion of a defensive player game piece) then a foul on that player is called and they are not eligible to shoot. On the 3rd or more foul of any half, the defensive player is allowed to take two free throws (place game piece at foul line and shoot at basket for two shots—each shot=1 point). The defensive player can take more than two foul shots (if more than 1 defensive player is fouled, up to 6 foul shots in one series if all 3 defensive players are fouled). The free throws are shot after any and all eligible offensive players have taken their shots. Once the free throws are attempted, the next series begins and the team, which took the free throws, now gets their regular offensive possession. (4) All made baskets by an offensive game piece is worth 2 points, unless all of that player's game piece is beyond (and not touching any part of) the three point line (similar to regulation basketball), in which case a made basket is worth 3 points. (5) If an offensive player lands on top of another offensive player, then the player on top is removed from action for the series (picked up and placed to the side) and cannot take a shot.
[0020] A series (also called possession) is an offensive player's game piece movement (all three players), shots taken by any and all eligible offensive game pieces, then any free throws by the defense (if 4 th or more fouls in half). Then the possession changes, the player that just took their offensive possession, places his player game pieces into defensive position. Each player should have the same number of possessions during the game, however the number of possessions for each quarter, half, and game can be based on player preferences (we recommend 10 possession per team each half, for a total of 20 possessions per half and 40 total for the game).
[0021] Alternative Rules/Modifications
[0022] The number of possessions (or series) should be predetermined before the start of game play, but can fluctuate to better suit each player.
[0023] The number of fouls before “Free Throws” are taken could be modified to suit player preferences, however basic rules suggest the third foul (in any half) would trigger a defensive players free throws.
[0024] It is recommended that one shot be taken for each eligible player, however before the game it could be determined that the players may take more than one shot at the goal for each eligible player.
[0025] To determine which team gets their offensive possession first, all player game pieces are positioned around the outside of the jump circle (at midcourt) the ball is held over the midcourt circle and dropped, which ever team's game piece the ball strikes first will have the first possession (if no game piece is hit with the ball, continue to drop the ball until a player game piece is struck).
[0026] Enforcing the rule that the ball must strike the eligible offensive player game piece when they are shooting, could be manipulated to simply ensure the ball is not bounced (shot) from a closer or shorter position to the basketball goal. (i.e. as long as the ball is shot from the eligible player or further from the basketball goal, the shot would count). | A basketball board game using a playing board and playing pieces tests a player(s) skill, strategy and luck. The playing board simulates a regulation basketball court and the playing pieces represent basketball players and a basketball. The method of play incorporates physical activity by the game players, combined with strategy and luck to provide a basketball game experience. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to a process for in-situ biodegradation of hydrocarbon contaminated soil, and for containment of the contaminated groundwater to prevent the spread of the contamination. More specifically the invention is an apparatus and process for containing and/or treating groundwater contaminated by an organic compound, such as a petroleum product and for biodegrading in-situ such organic compound, which is contaminating a particulate solid, such as soil.
Under present technologies, ground and groundwater, which are determined to be contaminated by organic compounds such as a petroleum product, are treated through the use of air stripping towers and groundwater withdrawal systems. Generally, a well is drilled into the ground to a depth equal to the vertical extent of contamination. A pump is installed and groundwater is withdrawn from the well and pumped to an above ground air-stripping tower. Pressurized air is pumped into the tower from the bottom and comes into contact with the contaminated water travelling down the tower. The contaminants attach themselves to the air molecules (a function of vapor pressure) and are carried upward into the atmosphere. Treated groundwater is discharged back into the ground for subsequent withdrawal and retreatment or are disposed of off-site. There are two basic disadvantages of air stripping technology.
First, only excessively contaminated soils are typically removed, and residual contamination from the soil can continue to recontaminate the groundwater and prolong air stripping requirements as well as regulatory approvals and delays. Air stripping is only as effective as the ability of the particular soil to release water (and contaminants) from the soil pore spaces, as a result, loose sands can be cleaned with air stripping fairly well, but clays or other loamy sands are not well suited for the air stripping process.
Second, air stripping releases pollutants to the atmosphere, and the pollutant is merely being moved from the water we drink to the air we breathe. Current regulations on air pollution are strengthening due to public pressure. The most obvious air pollutant is smog. When volatiles are released at ground level, sunlight generates photochemical reactions with volatiles and the releases contribute to the formation of smog. Air stripping will require charcoal filtration and liquid recovery in the future as is presently required in California increasing the expense of this technique.
Typical in-situ bioremediation systems, as presently practiced, introduce organisms and/or stimulate indigenous bacteria. This technique can take up to several months depending on the hydrogeological setting. Some of the problems encountered with such bioremediation include following: keeping the bacteria alive until the pollutants reach them, or until they reach the hydrocarbon pollutant which is the food source; the difficulty of controlling oxygen content, nutrient levels and temperature in the field. All three variables are easy to control in the laboratory or in above ground systems, but are difficult to control underground in the field; and monitoring the bacteria degradation rates often becomes difficult. When excess bacteria are introduced, the bacteria become anaerobic and generate methane gas as a waste product. Methane is a combustible gas and large build ups from failed bioremediation attempts have impeded regulatory acceptance to bioremediation.
Bioremediation and biodegradation have been proposed for remediation of hydrocarbon contamination. See, for example, the following U.S. Pat. Nos.: Linn, 3,616,204; Ely et al., 4,765,902; Raymond, 3,846,290; Thirumalachar et al., 4,415,661; Thirumalachar et al., 4,415,662; Lavigne, 4,678,582; Norris et al., 4,849,360; and Hater et al., 4,850,745.
Each of the above mentioned patents suffer from a failure to provide a fully integrated system for the confinement of and reclamation of a hydrocarbon contaminated site.
SUMMARY OF THE INVENTION
The present invention relates to a process for the treatment of hydrocarbon contaminated ground and groundwater to reduce the level of contamination and to contain polluted groundwater. The basic steps of the process are:
(1) Establishing the on-site hydrogeologic characteristics;
(2) Installing veil wells in the direction of flow of the contaminant plume for introduction of hydrocarbon consuming microorganisms, which serve to contain and prevent the further spread of the contaminant plume;
(3) Constructing a land farming area for treating and bioenriching the most severely contaminated soil, i.e. more than 500 ppm of contaminant;
(4) Installing "dead man" devices with gravel packs to be used for the recovery of free floating product if needed due to ground water levels;
(5) Excavating the area of high contamination in a sequential excavation pattern, and placing the excavated material in the land farm area for treatment with bacteria;
(6) Installing horizontal wells for introducing bacteria, water and air into contaminated areas which cannot or will not be excavated;
(7) Installing induction well devices above the water table into the sequential excavation pit for introducing bacteria into areas of contaminated soil and groundwater;
(8) Introducing air pressure into the veil well devices for directing free-floating products toward the dead man devices and/or toward the open checkerboard pit for product recovery with conventional recovery equipment;
(9) Replacing excavated contaminated soils with clean, bioenriched soils generated in the on-site landfarming operation;
(10) "Blowing down" the site by introducing air pressure, bacteria and potable water periodically into veil wells and horizontal wells for continued in-situ degradation; and
(11) Installing monitoring wells for evaluating the effects of treatment.
This process is normally continued until the level of hydrocarbon contamination in the ground and/or groundwater is eliminated or reaches an acceptable level.
The bacteria employed in the present invention is a commercially available high-grease digestant bacteria, such as non-pathogenic bacillus subtilis or ERS Formula 1 which may be obtained from Environmental Bio-Remediation International Corp. The bacteria may be mixed in the field with screenings to assist with the dispersal of the bacteria, in water with a small amount of non-hazardous petroleum product, such as baby oil. The baby oil helps to sustain the viability of the bacteria until it reaches the food source (i.e. the hydrocarbon pollutant). The screenings are by-products of manufacture of aggregate materials. The preferred screenings are light and highly absorbent. The addition of the non-hazardous petroleum product also helps trigger the activity of the bacteria when introduced to the pollutant.
A high degree of hydrocarbon conversion is accomplished in-situ by maintaining adequate supplies of oxygen. Optimum temperatures are accomplished by the introduction of pressurized air through a specially designed well tube and connection fitting. Dry bacteria mix is placed in a veil well to which water is added (approximately 3 to 5 gallons) and air is forced through the tube causing the bacteria to be evenly released. Heat may be generated during the pressurization as a result of the connection fitting which may contain a vibrating reed and a reduction in air line diameter. Oxygen is controlled by the initial burst and subsequent reintroductions of air ("blow downs") into the well pipe.
Methane is controlled by pressure relief valves on the veil wells and induction wells. Methane is a waste product of biodegradation when aerobic bacteria increase to levels where all the available oxygen is consumed. This action causes the aerobic bacteria to be converted to anaerobic bacteria, resulting in a methane by-product being released.
Methane levels are monitored through the veil well. When methane production begins (meaning the point of conversion to anaerobic or the point of high aerobic consumption) a blow down is performed, thereby providing oxygen to stop the conversion of aerobic bacteria to anaerobic bacteria and aerobic degradation continues at a high rate. The introduction of pressurized air through one veil well allows the methane to escape out another veil well on site. Methane levels are thereby kept low and safe, and oxygen levels are kept at an optimum for high degradation.
As will now be recognized, the present invention further overcomes the disadvantages of prior art processes by:
(1) containing the spread of groundwater contamination;
(2) by providing an apparatus and process for recovering floating free product; and
(3) by treating excessively contaminated soil to the extent that it qualifies as bio-enriched clean fill. The clean fill can then be returned back to the area of contamination and excess sold as clean fill.
The reintroduced enriched soil still contains active bacteria and continue the process of site rehabilitation in-situ
Further, for soils which are only moderately contaminated, the apparatus and process of the invention provide for the in-situ treatment of such soils, to minimize excavation and/or to reach areas where excavation is not possible, such as under a building or a major roadway.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a site plan for a typical area contaminated by gasoline, fuel oil or the like showing locations of remediation devices in accordance with the invention;
FIG. 2 is a cross sectional view of soil having a veil well, shown partially cut away, installed therein;
FIG. 3 is a cross sectional view of a landfarm of FIG. 1 prior to depositing of contaminated soil;
FIG. 4 is a cross sectional view of soil having a dead man device installed therein for collection of ground water and product;
FIG. 5 is a perspective view of an excavation of a square of contaminated soil of FIG. 1 showing the ledge procedure;
FIG. 6 is a tine of a rotary tiller used in treating contaminated soil in the landfarm of FIG. 3;
FIG. 7 is a cross sectional view of a building and supporting oil showing a horizontal well installed in the soil;
FIG. 8 is a perspective view of an injection well system installed in an excavation; and
FIG. 9 is a partial and cutaway view of an air manifold used in the process of the invention having a reed for increasing the temperature of air passing therethrough.
DETAILED DESCRIPTION OF THE INVENTION
A typical application of the present invention is in the bioremediation of contaminated soils and groundwater caused by a tank leak of gasoline or other petroleum hydrocarbons at a service station.
The invention will be described with reference to FIG. 1 in a given sequences of steps. Although the procedure described herein is presented in a given sequence, during the actual remediation process, several procedures may be on-going at the same time. Further, depending upon the particular site characteristic, not all steps may be needed.
When contamination from leaking underground storage tank 12 is suspected, an approval and review process for assessing the environmental damage caused from a fuel or other petroleum product discharge is required by the federal government. The procedure is commonly referred to as a contamination assessment. A Contamination Assessment Report is required when a discharge has been discovered or reported.
The first step in a Contamination Assessment Report is to determine if the suspected discharge has in fact occurred and, if so, has it reached the groundwater. To determine this, a monitoring well 13 is installed in the area of the suspected discharge and a water sample is collected. During the drilling process a soil sample can be collected from the cuttings coming up the auger which provides a composite sample over the depth of the well. Alternatively, a split spoon sampling method can be used to collect soil samples from specific depths. The water sample is typically analyzed by conventional means to determine the presence and concentration of a hydrocarbon spill, such as gasoline or diesel fuel. Equivalent conventional tests for soil are also conducted to indicate the presence of a hydrocarbon materials.
If the results of the initial testing indicate the presence of groundwater contamination, the next step is to define the horizontal extent thereof. The term used to define the area of contamination is "plume," and the plume can consist of a free floating fraction on the surface of the groundwater table due to the insolubility of fuel in water and due to the lighter specific gravity, and a dissolved fraction, which is soluble or miscible in water. The floating fraction is referred to as "product."
The two fractions of pollutants will travel at varying rates in the groundwater and both fractions travel as a function of the site specific hydrogeology. To access the hydrogeology and to define the extent of contamination, additional monitoring wells 14 are installed, and the tops of the wells and the horizontal location of the wells are surveyed. Measurements are then made to determine the depth of water from the top of the well casing. The information is used to generate a water contour map 15 which defines the direction and gradient of groundwater flow. After the horizontal extent has been established, a deep monitoring well 16 is then installed, sampled, and analyzed, at one or more locations, to define the vertical extent of contamination.
The analytical data, the flow data and the lithology data are combined with information obtained during on site investigations and research concerning the source and type of discharges. The remaining information needed for a Contamination Assessment Report also concerns regional information such as adjacent land uses, nearby potable water wellfield locations, or surface water bodies and drainage features in the area. All of the information is assembled prior to determining what remedial measures should be taken.
After contamination is verified a plurality of containment wells, referred to as "veil wells" 20 is installed. A veil well 20 is shown in FIG. 2. The veil well 20 is designed with perforations and/or slots 21 and is installed into the unsaturated zone of the soil, just above the water table. Once the extent of contamination has been defined during the assessment process, veil wells 20 are installed down gradient of the plume and on surrounding sides of the plume as required to surround the plume. The locations of the veil well curtain is determined from measurements from monitor wells 16. For example, a measurement of 10 ppm to 50 ppm is considered satisfactory for installation of veil wells.
A bacteria mix is prepared using ERS Formula 1 bacteria mixed with absorbent screenings. The bacteria mix is inserted into veil wells 20 in dry form and water is added to fill veil wells 20. Pressurized air in the range of 15 to 25 psi is then used to force the bacteria into the area down gradient of the contamination.
After the lines of veil wells 20 has been installed and bacteria introduced, a literal curtain of bacteria is created. The curtain serves to keep the contamination plume from migrating away from the original source of contamination and possibly affecting off-site third parties.
The spacing and exact locations of veil wells 20 are determined from simple geometric patterns which result in an even spacing. See FIG. 1. Field instrumentation, such as a Foxboro Organic Vapor Analyzer (OVA) or Drager monitoring device, are used to confirm proper and optimum locations.
After the contamination plume is contained on site the location for an on-side landfarm 22 for treating of excavated soil is determined. The landfarm 22, is constructed in an area not already contaminated, but with monitoring wells 16 in place downgradient from the proposed landfarm location to detect possible leakage from the landfarm.
Once a location has been selected, the area is scraped to an even grade 26 and the landfarm 22 construction is begun. A perimeter berm 23 is constructed to prevent stormwater from coming in contact with contaminated soil stored therein and possibly overflowing the landfarm area.
The landfarm 22 uses clean fill for the base and berm construction. Screenings 23 are placed over the base to a depth of about 12 inches with a plastic liner 24 placed over the screenings 23. The screenings 23 act as a cushion in the landfarm to handle the weight of tilling equipment to be used during soil treatment and also act as an absorbent in the event the liner is breached. The liner material may be overlapped with two foot seams between sections depending upon the size of the landfarm. Another 12 inch lift or thickness of screenings 25 is then placed on top of the liner 24. Excavated contaminated soil is to be placed in the landfarm 22 over the second lift of screenings 25. A leachate collection system 28 is also installed in the base of the landfarm to collect any liquids which may be generated in the landfarm 22. As will be recognized, monitoring well 16-1 is down gradient from landfarm 22. During treatment of contaminated soil in landfarm 22, well 16-1 will be continually monitored to detect any leakage from a possible breach of liner 24.
A dead man 30 is shown in FIG. 4 that is used to remove water and product in downgradient areas from the source of contamination. A 24 to 36 inch culvert pipe 32 with perforations 33 in a lower portion thereof is installed vertically into the ground and extending about three feet into the water table 34, indicated by arrows D. Gravel 36 is placed around dead man 30 to allow for the easy flow of water and free product into and through perforations 33. Three feet of gravel 38 is placed in the center of dead man 30 to allow for water and product flow from below the installation. A cover (not shown) is also placed over dead man 30 to prevent accidental or intentional dumping. Dead man 30 is used to recover free product from the surface of the water table. As will be discussed hereinbelow, free product may be directed toward dead man 30 through the manipulation of the water table contours during blow downs on the site.
As noted from FIG. 1, dead men 30 are installed downgradient from the area of maximum contamination. A series of induction wells 31, similar to veil wells 20, is installed adjacent each dead man 30 approximately five to ten feet away. Induction wells 31 are initially used to draw out and recover free product after first installed. After free product is recovered, the wells 31 are used as a conduit for pressurized air and the introduction of bacteria mix. Air pressure of approximately 500 psi is used in a stripping action, to free contamination products trapped in the soils. The duration of application of air pressure is a function of the pore spaces and pore sizes in the unsaturated zone of the soil. Loose sands will allow for more air pressure at longer durations before the soil becomes saturated and a blow back phenomenon occurs in which water is forced back into the well 31.
The air pressure forces the bacteria mix into the surrounding soil to produce the desired bio-degradation of contaminants. The pressure also moves free product and water in the soil toward dead men 30, permitting recovery therefrom.
After the soil is saturated and the air pressure in soil has reached equilibrium, additional air can be introduced to move additional water and product to dead men 30.
After air injection into wells 31 has been completed and free product recovered from dead man 30, the highly contaminated region is excavated for treatment of the soil. The present invention contemplates that a systematic excavation pattern will be followed and testing done throughout the excavation. In the preferred embodiment a checkerboard excavation pattern 40 is used, as shown in FIG. 1.
A single bucket-wide hole 41 is excavated downgradient of the area of contamination as determined by hydrogeological characters. The purpose of the excavation 41 is to recover free product from the directly contaminated area and to permit organic vapor analyzer (OVA) sampling on the sidewalls of the excavation to be performed.
When the OVA registers 500 ppm (parts per million) hydrocarbon or greater, the soil is deemed excessively contaminated. Such excessively contaminated soils with 500 ppm or more are excavated and are processed in the landfarm 22. Soils with lower levels are treated by use of well injections of bacteria mix as discussed hereinafter.
The single bucket wide excavation 41 with OVA testing of the side walls, downgradient of the land farm is performed prior to construction of landfarm 22 and is used to estimate the quantities of soil to be excavated and thus, to determine the size and capacity of the landfarm 22. The OVA testing is also done to determine the number of monitoring well 16 installations, and amount of sampling and analysis required.
The initial excavation is preferably performed in an upgradient square of checkerboard pattern 40, such as square 42. Excavating upgradient of the tank farm is an optimal process for all sites because bacteria mix introduced upgradient flows into the area of contamination prior to the excavation of the source of contamination.
The preferred method of removing heavily contaminated soil in square 42 is shown in FIG. 4, termed a ledge type of excavation, and avoids dewatering the area of excavation. In the ledge excavation process, a large square 43 of about 20 feet by 20 feet is excavated to produce sidewalls 44 of approximately three feet. The next level of excavation 46 is dug to just above the water table 47 and is approximately 15 feet by 15 feet. The optimum size and depth of the excavation is dependent on the level of contamination and site specific characteristics.
The soil excavated from square 42 is deposited in landfarm 22 for treatment when the excavated soil is spread within berm 23, the surface is coated with bacteria mix dissolved in water, and tilled by a specially designed rotary tiller. The tiller has tines 50, as seen in FIG. 5, having flattened back bars 52. This tiller design produces a fluffing of the soil, increasing its absorbance of the liquid bacteria. The action of the bacteria quickly reduces the contamination to the 10 ppm to 20 ppm range.
The cleaned soil from landfarm 40 is then used to construct a dike between the excavation 43 and the next square to be excavated.
Once the second level 46 of ledge excavation is complete on the first excavation 43 and while excavation of a second sequential excavation of square 51 is proceeding, the floor of the first sequential excavation 43 is graded until it is completely level. A six inch layer or lift of screenings is placed on the bottom of excavation 43 followed by a six inch lift of 3/4 inch rock. The floor is leveled with a grade stick. The leveling of the floor of the excavation is critical to the process to prevent any particular area from being inundated with too much bacteria during treatment of the excavation.
Next, about ten pounds of dry bacteria mix is distributed over the excavation floor and sprayed with water from a hose. Immediately thereafter, a 12 inch lift of clean fill is placed on top of the rock lift. This procedure traps the victory and starts to create heat, necessary for optimum action of the bacteria.
The above excavation and treatment procedure is continued for a row of squares in area 40 on either side of tank 12. After completion of these squares, tank 12 may be removed.
When the area of contamination is adjacent to a building, such as building 10, it is evident that soil beneath the building will have a high level of contaminants. This soil is treated by the use of low, horizontally disposed wells 54 shown in the cross sectional view of FIG. 7.
Horizontal wells 54 may be installed in the area under building 10. Horizontal wells 54 can treat soils up to 800 ppm of hydrocarbon with adequate success. Beyond 800 ppm more bacteria is required and degradation rates slow considerably. A culvert pipe 58 has a plurality of perforations 61 in its side wall. A horizontal section of tubing 57 is inserted in pipe 58 and surrounded by rock 59. An end section 63 includes perforations 62. A vertical section of tubing 56 includes an air lined fitting 53.
Horizontal section 57 preferably has a 10 degree drop from horizontal. For use under a building, the perforations 61 are placed in the bottom and top of the horizontal pipe. No holes are placed in the sides of the horizontal well under a building, in order to prevent the hole from collapsing and creating voids under the building. Additionally, when the horizontal well is in place, a concrete collar (not shown) is set into place around the pipe. Rebar is set into the concrete to further hold horizontal well 54 in place during the air injection process.
Dry bacteria is placed into horizontal wells 54 in dry form. A horizontal well 54 is filled with water and 500 psi of air pressure is introduced in a single burst to introduce the water, air and bacteria mix. The process is repeated when a blow back occurs. Repeating the process tends to tamp the soil around the horizontal well so more bacteria can be introduced under lower pressures. It is critical that water be used when introducing air pressure into the horizontal well to prevent the pipe from backing out of the hole as the water forms ducts through the soil. Although the horizontal well 54 has been described relative to treating soil under buildings and the like, it may also be used for soil surrounding pattern 40 which may have OVA levels below 500 ppm.
For a horizontal well 54 radiating out laterally from the sequential excavation pattern 40, perforations are placed in the bottom, sides and top of the pipe 61. Where OVA readings are less than 500 ppm less bacteria is required, and lower pressure can be used. The amount of bacteria mix used will depend on the degree of contamination of the site.
An air line fitting 53 is provided at the upper end of tube 56. To treat soil with horizontal well 54, fitting 53 is removed and dry bacteria mix inserted into tube 56. The well 54 is filled with water and air under pressure is introduced via fitting 53. The compressed air is supplied to all wells in the system via a special manifold 65 shown in partial cutaway view in FIG. 9. A body 68 is connected to the source of compressed air. A thin, metallic reed 66 is interposed in the air flow such that fingers cut into reed 66 vibrate causing a significant increase in the air temperature. The heated air exits manifold 65 via a fitting and hose 67 of reduced diameter, increasing the velocity and temperature. Advantageously, the higher temperature accelerates the remediation action of the bacteria.
Horizontal wells 54 are also used in areas which have contamination below 500 ppm which is not economical to excavate. For example, wells 54 are shown in FIG. 1 inserted in the outside walls of excavated squares in pattern 40.
After installation of respective horizontal wells 54 in the excavation areas, and treatment of each excavation as described above, a special bacteria injection device 70, shown in perspective view in FIG. 8, is used. The device 70 is fabricated from polyvinyl chloride pipe (PVC) and includes input fittings 75 and valves 74. A bacteria injection array 72 may be in the form of a square of PVC pipe having holes 73 along the sides thereof. Array 72 is fed by a pair of vertical pipes connected to valves 74.
The device 70 is lowered into an excavated square of pattern 50 after the described leveling and treatment of the floor. Array 72 is covered with a 12 inch lift of 3/4 inch drainfield rock followed by a 12 inch lift of screenings. This allows for good movement of groundwater through the area, allowing the bacteria to move freely through the site. Bio-enriched fill from landfarm 22 is then placed over the screenings up to subgrade level. Bacteria, mix and water are introduced and air, via a manifold 68, previously described, is used to inject bacteria into the contaminated areas for treating any remaining contamination. The second inlet 75 serves to control the pressure in the system, and acts as a relief mechanism. The device 70 is left permanently in the area. If monitoring wells indicate excessing levels of contamination in the future, additional treatment can be provided at minimum cost as discussed below.
As discussed above, when excessively contaminated soils are removed from the area of contamination, they are placed in the onsite landfarm 22 for treatment. The landfarm 22 is being operated concurrently with free product recovery operations, and sequential excavations of area 40. An OVA meter or similar instrument is used to determine when soil is ready to be removed from landfarm 22. When 10 ppm or less is registered on the OVA, the soil is considered to be clean fill. The bio-enriched soil is placed back into the sequential excavation pits. Surplus soil may be sold as clean fill. Commercially, the bio-enriched soil is very good for plant growth, but more importantly the soil is able to be sold and/or reused instead of being hauled and burned.
When bio-enriched soil at 10 ppm to 20 ppm from the landfarm is stockpiled, the bacteria continues to work, and cleans the soil to less than 10 ppm. Potable water is added to keep the pH neutral (7.0) during the landfarming operation.
At the point in the remediation of the site of FIG. 1 when the sequential excavations of pattern 40 have been brought up to subgrade with bio-enriched fill, and closed, the site may be covered with asphalt or concrete and normal business operations can begin on the site again.
Monitoring wells 16 are left located in strategic positions to monitor the effectiveness of the remediation. The bacteria will continue working in the ground to clean the soils and groundwater. Available oxygen is being consumed by the aerobic bacteria left in the ground. When the levels of oxygen get too low, the aerobic bacterial convert to anaerobic bacteria and methane is produced.
Because the wells are still in place and methane is being monitored, air can be introduced as needed to continue the site rehabilitation process and methane is controlled by pressure relief valves on the wells. The air which is introduced may still be heated and if monitoring data warrants, more bacteria mix and water may be added.
While this invention has been described in detail with respect to the preferred embodiment, it will be apparent to one skilled in the art that changes and modifications may be made therein without departing from the scope thereof. | A process for bio-remediation of soil contaminated with organic compounds and containment of the contamination, utilizes a group of veil wells disposed along the limits of the contamination and downgradient of groundwater flow. Contamination consuming bacteria and water are injected into the soil to form a curtain of bacteria for presenting spread of contamination. Areas of heavy concentration of contaminants are excavated, bio-remediation of areas of lower concentrations of contaminants by injection of bacteria and water under pressure. Dead man wells are provided for recovery of contaminated ground water and the organic compounds. | 1 |
TECHNICAL FIELD
The present invention relates to a medicine comprising a mixture of a prostaglandin compound and a nitric oxide (hereinafter referred to as “NO”) donating compound that is effective in the treatment of ocular hypertension and glaucoma.
BACKGROUND ART
Presently, eye drop solutions and internal medicines are principally used for reducing ocular tension in the treatment of ocular hypertension and glaucoma. As examples of eye drop solutions, β-blockers such as timolol maleate, carteolol hydrochloride, befunolol hydrochloride, and betaxolol hydrochloride, sympathetic nerve stimulants such as epinephrine and dipivefrine hydrochloride, parasympathetic nerve stimulants such as pilocarpine hydrochloride and carbachol, α-blockers such as bunazosin, αβ-blockers such as nipradilol, and prostaglandin derivatives such as isopropyl unoprostone and latanoprost can be given. As examples of internal medicines, carbonic anhydrase inhibitors such as acetazolamide, methazolamide, and diclofenamide can be given.
In many cases, the use of only one of these medicines cannot sufficiently control ocular tension. Therefore, the combined use of two or more of these medicines has increased. However, there are cases where the combined use of these medicines does not significantly reduce ocular tension, thereby making the selection of these medicines very difficult.
Accordingly, an object of the present invention is to provide a medicine that significantly reduces ocular tension resulting from ocular hypertension and glaucoma, in particular, a medicine that effectively reduces ocular tension in cases where the combined use of conventional medicines is not effective.
DISCLOSURE OF THE INVENTION
To achieve the above object, the present inventors have conducted extensive research of a medicine comprising a prostaglandin compound and a NO-donating compound.
Of the above medicines, prostaglandin compounds are already known to be effective in reducing ocular tension when used alone. However, the action mechanism of this effect has not yet been fully understood. It is commonly believed that this effect is due to the increased uveoscleral flow rate and there are several opinions regarding the reason. One opinion is that prostaglandin F 2 α causes secretion of MMP. MMP degrades the extracellular matrix of the smooth muscle fibers of the ciliary body (uveoscleral outflow pathway) thereby decreasing outflow resistance and increasing outflow (Lutjen-Drecoll E. and Tamm E., Exp. Eye. Res 47, 761-769, 1988). Another opinion is that the smooth muscle fibers of the ciliary body become relaxed and the cell spacing expands thereby decreasing outflow resistance and increasing outflow (Poyer J F., Inv. Opht. Vis. Sci. 36, 2461-2465, 1995).
The inventors of the present invention paid particular attention to the following reports on prostaglandin. As a result of combining a prostaglandin compound (a derivative of prostaglandin F 2 α. in particular) with a prostaglandin receptor, phospholipase A 2 is stimulated, thereby causing arachidonic acid to be produced and released from the biomembrane phospholipid. This arachidonic acid is converted into prostaglandin G 2 by the action of cyclooxygenase then converted into various types of endogenic prostaglandin. In this instance, prostaglandin E 2 and prostaglandin F 2 α are produced and cause the ciliary muscle to become relaxed thereby increasing the uveoscleral flow rate, and as a result, the ocular tension is reduced (Y. K. Sardar, Exp. Eye. Res. 63, 305, 1996 and the like).
The ocular tension reducing effect of NO donating compounds has already been known in the art. The nitric oxide released by the NO donating compound activates the guanylate cyclase, which increases the amount of cyclic GMP (S. A. Waldman et al, J. Biol. Chem 259, 14332, 1984), and results in reduced ocular tension (J. A. Nathanson Eur. J. Pharmacol. 147, 155, 1988).
In general, the combination of several components effective in reducing ocular tension does not greatly improve the overall effect. However, the inventors of the present invention conducted research based on the assumption that a mixture of a prostaglandin compound and an NO donating compound could significantly reduce ocular tension, wherein the nitric oxide released by the NO donating compound not only activates guanylate cyclase but also activates cycloxygenase (D. Salvemini, et al, Proc. Natl. Acad. Sci. USA 90, 7240, 1993) thereby enhancing the conversion of arachidonic acid in the ocular tension reducing mechanism of the prostaglandin compound. As a result, the inventors have discovered that this combination is in fact highly effective in reducing ocular tension, thereby completing the present invention.
Accordingly, the present invention provides a medicine comprising a prostaglandin compound and an NO donating compound.
The present invention also provides a method for treating and/or preventing ocular hypertension or glaucoma using the above medicine.
Since ocular hypertension and glaucoma can be very difficult to treat, there are many cases where these disorders cannot be completely cured using conventional medicines for reducing ocular tension. Experimented use of various combinations of these medicines, which resulted in either no improvement or only a slight improvement in effect, could not achieve a significant improvement in the treatment of these disorders.
In the medicine of the present invention comprising the combination of a prostaglandin compound and an NO donating compound, the nitric oxide is released from the NO donating compound and enhances the conversion of the arachidonic acid in the ocular tension reducing mechanism of the prostaglandin compound, thereby exhibiting a synergistic effect of the two compounds of significantly increasing the ocular tension reducing effect. Thus, the medicine is not only effective in regular ocular hypertension and glaucoma patients but is also effective in those patients wherein the combined use of several conventional medicines does not significantly reduce ocular tension.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As the prostaglandin compound used in the medicine of the present invention, all pharmaceutically acceptable prostaglandin compounds, derivatives, and analogues thereof can be given, wherein the derivatives include pharmaceutically acceptable esters and salts thereof.
As examples of the prostaglandin compound, naturally occurring prostaglandins such as prostagladin (hereinafter referred to as “PG”) D 1 , PGE 1 , PGE 2 , PGE 3 , PGF 1 α, PGF 2 α, PGF 3 α, PGG 2 , PGH 2 , PGI 2 , and PGI 3 , thromboxane A 2 , latanoprost, isopropyl unoprostone, PGF 2 α 1-isopropyl ester, salt of PGF 2 α 1-isopropyl ester-15-propione, and 15-deoxy PGF 2 α can be given without any limitations. These prostaglandin compounds may be used singularly or in combination of two or more.
Of those given above, prostaglandin F 2 α derivatives are preferably used as the prostaglandin compound in the medicine of the present invention, with PGF 2 α, latanoprost, and isopropyl unoprostone being particularly preferable.
In the medicine of the present invention, the prostaglandin compound is preferably used in an amount of 0.0001-0.05 w/v %, and particular preferably 0.001-0.01 w/v % of the total amount of the medicine.
As the NO donating compound used in the medicine of the present invention, those that release NO (nitric oxide) in vivo can be given. Examples of the NO donating compound include, but are not limited to, nipradilol, nitroglycerine, isosorbide dinitrate, sodium nitroprusside, N-nitrosoacetyl penicillamine, 3-morpholino-sydnonimine hydrochloride, S-nitroso-N-acetyl-DL-penicillamine (SNAP), S-nitrosoglutathione, 4-phenyl-3-furoxanecarbonitryl, arginine, and sodium nitrite. These NO donating compounds may be used singularly or in combination of two or more.
Of the above NO donating compounds, nipradilol is particularly preferable. In addition to releasing NO, nipradilol is known to be effective in α,β blocking, which adds an increased effect to the treatment of ocular hypertension and glaucoma.
In the medicine of the present invention, the NO donating compound is preferably used in an amount of 0.01-5 w/v %, and particular preferably 0.1-1.0 w/v % of the total amount of the medicine.
The medicine of the present invention may be used in the form of an eye drop solution and the like, wherein the prostaglandin and NO donating compounds may be combined into a single preparation or each compound may be separate preparations and administered in order in the form of a medicine kit or the like.
In the medicine of the present invention, the use of a single preparation comprising both compounds is advantageous in view of convenience. On the other hand, the use of each compound in separate preparations is also advantageous because the method of administration can be determined and the amount of each compound administered can be controlled.
The medicine of the present invention is preferably used in the form of an eye drop solution. This eye drop solution may comprise the prostaglandin compound and the NO donating compound in separate containers or both the prostaglandin compound and NO donating compound in the same container.
In the preparation of the above medicine, commonly used base materials, dissolution agents, solubilizers, solvents, wetting agents, emulsifiers, excipient, adhesives, viscous agents, binders, preservatives, antioxidants, stabilizers, surfactants, antiseptics, pH adjustors, and the like may be appropriately used in accordance with the form of the preparation.
EXAMPLES
The present invention will be described in more detail by the way of examples, which should not be construed as limiting the present invention.
Example 1
100 ml of an aqueous solution containing 0.25 w/v % of nipradilol and 100 ml of an aqueous solution containing 0.005 w/v % of latanoprost were prepared separately and combined into a single package to prepare a medicine kit.
Example 2
100 ml of an aqueous solution containing 0.1 w/v % of sodium nitroprusside and 100 ml of an aqueous solution containing 0.005 w/v % of latanoprost were prepared separately and combined into a single package to prepare a medicine kit.
Examples 3 and 4
The medicines of Examples 3 and 4 were prepared using the ingredients and amounts shown in Table 1.
TABLE 1
Example 3
Example 4
nipradilol
0.25 g
nitroprusside
0.10 g
Na
latanoprost
0.005 g
latanoprost
0.005 g
purified
appropriate amount
purified water
appropriate amount
water
total amount
100 mL
total amount
100 mL
Test Example 1
Domesticated rabbits intravenously administered with 100 μl of a 5 w/v % hypertonic saline solution were used as ocular hypertension models. After intravenously administering the hypertonic saline solution, 50 μl of each of the eye drop solutions were administered and the ocular tension was measured 60 and 120 minutes thereafter.
A physiological saline solution, a 0.005 w/v % latanoprost aqueous solution (latanoprost), a 0.25 w/v % nipradilol aqueous solution (nipradilol), a combination of latanoprost and nipradilol (Example 1), and a combination of a 0.5 w/v % indomethacin aqueous solution (indomethacin), latanoprost, and nipradilol were used as the eye drop solutions.
When nipradilol and latanoprost were used in combination, nipradilol was administered first and latanoprost was administered five minutes thereafter. Furthermore, when indomethacin was used, the indomethacin was administered five minutes before the administration of nipradilol. The results are shown in Table 2, wherein the ocular tension change (mmHg), the change in ocular tension after administration, is shown as the mean value±the standard error.
TABLE 2
No. of
Ocular tension change (mmHg)
Eye drop solution
specimens
60 minutes
120 minutes
Physiological saline
6
24.8 ± 1.7
16.2 ± 1.6
solution
Latanoprost
6
22.7 ± 1.2
9.8 ± 1.9
Nipradilol
6
14.7 ± 1.7*
7.3 ± 1.6*
Nipradilol + Latanoprost
6
5.3 ± 3.3** ♯♯b
1.7 ± 2.7** ♯
(Example 1)
Indomethacin +
6
13.3 ± 3.7* ♯
8.2 ± 1.7*
Nipradilol + Latanoprost
*p < 0.05,
**p < 0.01 (Dunnett's multiple comparison test, comparison with physiological saline solution)
♯ p < 0.05,
♯♯ p < 0.01 (Dunnett's multiple comparison test, comparison with latanoprost solution)
b p < 0.05 (Dunnett's multiple comparison test, comparison with nipradilol)
Test Example 2
Domesticated rabbits intravitreously administered with 100 μl of a 5 w/v % hypertonic saline solution were used as ocular hypertension models. After intravitreously administering the hypertonic saline solution, 50 μl of each of the eye drop solutions was administered, and the ocular tension was measured 60 and 120 minutes thereafter.
A 0.1 w/v % sodium nitroprusside aqueous solution (sodium nitroprusside), a combination of the sodium nitroprusside and a 0.005 w/v % latanoprost aqueous solution (latanoprost) (Example 2) and a combination of a 0.5 w/v % indomethacin aqueous solution (indomethacin), latanoprost, and sodium nitroprusside were used as the eye drop solutions.
When sodium nitroprusside and latanoprost were used in combination, sodium nitroprusside was administered first and latanoprost was administered five minutes thereafter. Furthermore, when indomethacin was used, the indomethacin was administered five minutes before administration of sodium nitroprusside. The results are shown in Table 3, wherein the ocular tension reduction (mmHg), the change in ocular tension after administration, is shown as the mean value±the standard error.
TABLE 3
No. of
Ocular tension reduction (mmHg)
Eye drop solution
specimens
60 minutes
120 minutes
Sodium nitroprusside
5
18.0 ± 2.4
9.4 ± 2.5
Sodium nitroprusside +
5
4.8 ± 3.9
−2.8 ± 1.3**
latanoprost (Example 2)
Indomethacin + sodium
5
22.8 ± 2.9 ##
12.4 ± 6.3 ##
nitroprusside +
latanoprost
**p < 0.01 (Dunnett's multiple comparison test, comparison with sodium nitroprusside)
## p < 0.01 (Dunnett's multiple comparison test, comparison with sodium nitroprusside + latanoprost solution)
The results of the above Test Examples 1 and 2 show that the combination of the NO donating compound and prostaglandin compound significantly suppresses an increase in ocular tension when compared with the case where these compounds are individually used. The effect of this combination disappeared with the addition of indomethacin. This suggests that the effect of preventing an increase in ocular tension possessed by the combination of the NO donating compound and latanoprost is a result of cycloxygenase activation. The strengthened production of various endogenic prostaglandins resulting from a synergistic effect of the endogenic arachidonic acid derivative produced by the activation of phospholipase A2 by latanoprost and the activation of cycloxygenase by NO is believed to have stimulated production of PGE 2 , which is known to be effective for ocular tension reduction in domesticated rabbits.
INDUSTRIAL APPLICABILITY
A medicine comprising a combination of a prostaglandin compound and NO donating compound significantly suppresses an increase in ocular tension when compared to the compounds used individually.
Therefore, the medicine of the present invention is effective in treating persons affected by ocular hypertension and glaucoma. | It is intended to provide medicines having a higher ocular tension-lowering effect on ocular hypertension and glaucoma. Because of showing an excellent effect of lowering ocular tension, medicines comprising a combination of a prostaglandin compound with an NO-donating compound are useful in treating ocular hypertension and glaucoma. | 0 |
FIELD OF THE INVENTION
[0001] The invention generally relates to an energy recovery device of the positive displacement type that can be used to transfer energy from a first fluid at a higher pressure to a second fluid at a lower pressure. The invention specifically relates to the use of such an energy recover device in the process of desalination by reverse osmosis, where the device is used to transfer a portion of the energy from rejected brine to the incoming feed. Other applications include the use of the device as a fluid driven pump or a hydraulic compressor.
BACKGROUND
[0002] This invention relates to energy recovery devices, and particularly to those used in the desalination of seawater by the reverse osmosis method. The recovery problem is of vital importance in desalination by reverse osmosis. Fluid pressure energy recovered from high pressure rejected brine is utilized for the pressurization of the feed flow. Prior art energy recovery devices used in reverse osmosis systems may be classified as mechanical assistants, hydraulic driven boosting pumps and work exchangers.
[0003] A mechanical assistant commonly has the prime pump, motor and energy recovery turbine mounted on a common shaft. The turbine can either be a Pelton type or a reverse running centrifugal pump (Francis turbine). The overall efficiency of such devices is of the order of 60%.
[0004] A hydraulically driven boosting pump, sometimes called a turbocharger, is usually mounted on the same line as the primary pump in order to carry a portion of the required load. The rotating member in these devices comprises a turbine impeller fixedly coupled to a pump impeller within a common housing. This scheme has an estimated overall efficiency between 60-70%.
[0005] A work exchanger uses the rejected brine to positively pressurize an approximately equal amount of brackish feed water. One subset of this type employs a number of stationary cylinders with floating pistons and a control mechanism for synchronizing the opening and closing of valves. A second subset uses a spinning rotor with a multiplicity of channels. Work exchangers have an estimated overall efficiency between 80%-90%.
[0006] The mechanical assistants and hydraulic booster pumps involve the conversion of hydraulic energy into mechanical energy, which is then converted back to hydraulic energy. Work exchangers, on the other hand, directly transfer the hydraulic energy of one fluid (rejected brine) to hydraulic energy of the second fluid (feed), and are hence more efficient. The present invention falls within this category, i.e. a positive displacement, or work exchanger, energy recovery device. Examples of prior art devices of this sort include one taught in U.S. Pat. No. 3,791,768 which uses opposed piston/diaphragm pumps. The primary drawback of these devices is a restriction in the amount of fluid that can be handled, which renders such devices best suited to relatively small installations. Other energy recovery devices employing pistons of different areas with connecting rods are shown in U.S. Pat. No. 3,558,242 and in U.S. Pat. No. 6,017,200. Still another device of this sort uses a system of cylinders with freely moving pistons synchronized by a complex system of valves, and is shown in U.S. Pat. No. 5,797,429.
[0007] The main drawback of prior art work exchange devices is that they require a complex mechanism to control the opening and closing of valves as well as a mechanism for synchronizing various piston movements.
[0008] In addition to the energy recovery devices discussed above, there is also a class of devices in which pressure exchange takes place through direct contact between two fluid flows. Arrangements of this sort are shown in U.S. Pat. Nos. 5,988,993, 5,338,158 and 4,887,942 to Hauge. These devices have a cylindrical rotor comprising a plurality of open-ended axial channels spinning in a housing that is connected at both ends to intake and discharge ports of the differently pressurized fluids.
[0009] The main drawbacks of the prior art direct contact systems include uncontrollable internal mixing between the two flows, uncontrollable rotor speed, a complex water lubrication arrangement, axial alignment problems, lack of flexibility to deal with varying loads, and constraints on overall dimensions.
SUMMARY OF THE INVENTION
[0010] A preferred embodiment of the present invention accomplishes energy recovery through a positive displacement rotary device. In a preferred embodiment of this device, a small portion of the high pressure energy fluid is diverted through a nozzle to impinge on blades externally attached to the cylindrical rotor block, causing it to rotate. The bulk of the high pressure fluid is conveyed to axial channels within the block in order to pressurize the low pressure fluid within those channels. In some embodiments the two fluids are physically separated by freely sliding piston elements; in others no sliding elements are used and the pressure exchange is made through direct contact of the two fluids. The preferred axial channels are closed at both ends and have radially inward directed openings, one adjacent each end. Each of these openings alternately registers with axially aligned intake and discharge ports within a central stationary member so that at any given instant a single channel communicates with an intake port of one fluid and a discharge port of a second fluid. The sliding elements are arranged to freely reciprocate in respective channels in response to the alternate registering of the inward openings at the ends of the axial channels with intake and discharge ports in a central stationary member providing fluid connections for exchanging fluid flows. Each sliding element performs two strokes in the course of one complete revolution of the cylindrical block. Each stroke of the double acting sliding element comprises an intake of one fluid and a discharge of the second fluid. Alternatively, where no sliding elements are used, a fluid interface separating the two fluids acts as a sliding element.
[0011] A principal object of the present invention is to provide a device for use in a reverse osmosis desalinization plant to recover energy from waste brine flows and to deliver that energy to the feed flow.
[0012] One object of the present invention is to provide a hydraulically driven energy recovery device that does not require a separate driving means such as a motor.
[0013] Another object of the present invention is to provide an energy recovery device that does not require either a valve system or the associated electro-mechanical control mechanism needed to synchronize the opening and closing of valves.
[0014] Another object of the present invention is to provide an energy recovery device that can be used over a wide range of installation capacities.
[0015] Another object of the present invention is to provide an energy recovery device that minimizes the mixing of the two fluid flows.
[0016] Another object of the present invention is to provide an energy recovery device in which the speed of a rotating member is controlled manually by adjusting the flow rate of a fluid in a nozzle connected to an external valve.
[0017] Another object of the present invention is to provide an energy recovery device that is less costly to manufacture, easy to maintain and install in existing reverse osmosis systems than are prior art devices.
[0018] Still another object of the present invention is to provide an energy recovery device characterized by low fluid flow pulsation and vibration.
[0019] These and other objects and advantages of the present invention will be apparent from the following detailed description and the appended claims. It will be recognized that the foregoing description is not intended to list all of the features and advantages of the invention. Various embodiments of the inventions will satisfy various combinations of the objects of the invention and some embodiments of the invention will provide fewer than all of the listed features and satisfy fewer than all the listed objectives.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 is an exploded isometric view of a rotary work exchanger device of the invention.
[0021] [0021]FIG. 2 is a partly cut-away isometric view of the rotor assembly of the rotary work exchanger device of FIG. 1.
[0022] [0022]FIG. 3 is a partly cut-away isometric view of the rotary work exchanger device.
[0023] [0023]FIG. 4 is an end elevation view of the rotary work exchanger device of FIG. 1.
[0024] [0024]FIG. 5 is a sectional view taken along line 5 - 5 of FIG. 4.
[0025] [0025]FIG. 6 is a sectional view, taken along line 6 - 6 of FIG. 4, of a work exchanger comprising sliding elements.
[0026] [0026]FIG. 6 a is a sectional view, taken along line 6 - 6 of FIG. 4, of a work exchanger that has no sliding elements.
[0027] [0027]FIG. 7 is a side elevation view of the rotary work exchanger device of FIG. 1.
[0028] [0028]FIG. 8 a is a sectional view taken along line 8 a - 8 a of FIG. 7.
[0029] [0029]FIG. 8 b is a sectional view taken along line 8 b - 8 b of FIG. 7.
[0030] [0030]FIG. 9 is a sectional view taken along line 9 - 9 of FIG. 7.
[0031] [0031]FIG. 10 is a schematic diagram of a work exchanger of the invention used in a reverse osmosis desalinization system.
[0032] [0032]FIG. 11 is a schematic diagram for an alternative flow arrangement for the work exchanger used in a reverse osmosis desalinization system.
[0033] [0033]FIG. 12 is a schematic diagram for yet another work exchanger arrangement used in a reverse osmosis desalinization system.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In FIGS. 1 - 9 of the drawing, the principles of this invention are illustrated through its application as a work-exchanger device for recovering pressure energy from a high pressure fluid flow and transferring that energy to a low pressure fluid flow. Although a device of this sort is most commonly used for pressure exchange in reverse osmosis (“RO”) systems, where the high and low pressure fluid flows respectively comprise the rejected brine outflow and the sea or brackish water feed, the device may also be employed as a turbocharger in internal combustion engines, a hydraulically driven pump, or a compressor.
[0035] A preferred rotary work exchanger device 10 comprises a housing defining a generally cylindrical interior comprising a middle portion that may be horizontally split into mating halves 12 a, 12 b fixed together at side flange portions 71 a and 71 b by suitable fixture means (not shown). The preferred middle portion is closed at both ends by end plates 14 a and 14 b attached to it by other suitable fixture means (not shown). The preferred housing comprises a medially disposed, tangentially positioned nozzle 17 for receiving an impelling fluid through an inlet 16 . The nozzle may be regulated by a screw adjustable pin 27 fixed to a dial wheel 25 within a pipe fixture 18 . In a preferred embodiment the internal peripheral wall of the housing comprises a recess portion 68 axially aligned with the nozzle for directing the spent jet fluid to a drainage outlet 70 . The housing end plates may include centrally inwardly projecting core portions 42 a and 42 b, where each core portion comprises a respective pair of inlet and outlet passageways ( 52 a, 54 a ) and ( 52 b, 54 b ) connected to respective peripheral port pairs ( 48 a, 50 a ) and ( 48 b, 50 b ). Each pair of ports comprises a pair of angularly adjacent cutout openings defined within a transverse plane, and each cutout preferably encompasses substantially a 180-degree angular displacement on the peripheral surface of the cylindrical projection. The disposition of ports is made so that one pair of ports, defined in one transverse plane, is 180 degrees out of phase with a second pair of ports defined in a second transverse plane, and so that one inlet port of the first pair communicates, through a plurality of conduits 26 , with an outlet port in the second pair. A fluid distributor 60 , comprising an inlet line 62 a and an outlet line 64 a, may be fixedly attached to an outer wall of the end plate 14 a by means of a flange portion 66 a and a mating flange portion 44 a. A similar fluid distributor comprising an inlet line 62 b and an outlet line 64 b may be fixedly attached to an outer wall of the end plate 14 b by means of a flange portion 66 b and a mating flange portion 44 b. Each of the projecting portions 42 a, 42 b preferably comprises a respective stepped wall portion for mounting a respective bearing 58 a, 58 b.
[0036] A preferred rotor assembly 20 , as shown in FIG. 2, comprises a cylindrical block 22 having two centrally disposed end bores 38 a and 38 b. These bores rotatably enclose the projecting wall portions 42 a and 42 b and include internally recessed wall portions 36 a and 36 b for mounting respective bearings 58 a, 58 b. Furthermore, the preferred rotor assembly includes a multiplicity of axial conduits 26 disposed symmetrically about the axis of rotation of the assembly. Each of the preferred conduits 26 is closed at both ends by respective plates 24 a, 24 b that are attached by suitable fixture means (not shown). Radially inward openings 32 a, 32 b are respectively disposed proximal to each end of each conduit and open to the two respective central bores. Each opening is preferably axially aligned with the respective peripheral pair of intake and discharge ports in the centrally projecting end wall portion. Furthermore, each conduit may include a freely sliding piston element, such as a ball element 34 , used to divide the conduit into two variable-volume working conduit elements. The outer peripheral wall of a preferred rotor block also comprises a circular array of blades 30 within a recess wall portion 28 , where each blade 30 is axially aligned with a centerline of the nozzle.
[0037] The preferred rotary work exchanger device can work in at least two modes. One employs a system of freely sliding elements in respective conduits to physically separate the two fluids, as shown in FIG. 5 and FIG. 6. A second mode allows direct contact of the two fluids, as shown in FIG. 6 a. In operation of a preferred apparatus, a portion of the high-pressure fluid is diverted to the nozzle line 16 and the flow rate is adjusted by means of a screw adjustable pin 27 used to vary the nozzle 17 flow area, through which the emerging impelling fluid jet impinges on the blade elements 30 to cause the rotation of the rotor assembly.
[0038] The operation of the preferred work exchanger, as shown in FIG. 5 through FIG. 8 b, comprises two stroke phases. A pressurizing stroke phase, during which the rotor assembly advances through the first half of the cycle, is followed by a reverse depressurizing stroke phase during which the rotor assembly advances through the second half of the cycle. During each stroke a sliding element or, alternately, a moving interface, traverses a distance within the conduit corresponding to a stroke length. Adjusting the rotational speed of the rotor assembly by regulating the jet flow through nozzle 17 may control this stroke length. The pressurization stroke phase occurs when a conduit 26 has one of its end openings registered with an inlet port of the high pressure energy fluid and the other end opening registered with an outlet of the low pressure energy fluid. For example, this may involve a conduit 26 having one end inward opening 32 a registering with one end inlet port 48 a communicating with the high energy pressure fluid and a second end opening 32 b registering with the second end outlet port 50 b. During the pressurization phase, pressure energy is transferred from the high-pressure energy fluid to the low-pressure energy fluid across a sliding element, or alternately through direct fluid contact across a fluid interface traversing a stroke length. During the pressurization phase, the high-pressure fluid displaces the low-pressure fluid, thereby executing a simultaneous intake of high-pressure fluid and discharge of the low-pressure fluid as the sliding element or fluid interface moves a stroke length.
[0039] The depressurization stroke phase occurs when the conduit 26 has one of its end openings registered with an outlet port of the high pressure energy fluid and the other end opening registered with an inlet port of the low pressure energy fluid. For example, a conduit 26 having one end inward opening 32 a registering with one end outlet port 50 a, communicating with the high energy pressure fluid, and a second end opening 32 b registering with the second end inlet port 48 b of the low pressure energy fluid. During the depressurization phase, the low-pressure fluid displaces the depressurized high-pressure fluid, thereby executing a simultaneous intake of low-pressure fluid and discharge of the depressurized high-pressure fluid during which the sliding element or fluid interface traverses a reverse stroke length.
[0040] This alternate alignment of axial conduits with intake and discharge ports provides the inflow and outflow at both ends of axial conduits while the sliding elements or alternately, the fluid interface between the two fluids, axially reciprocates with respect to the axial conduits as the rotor rotates. As the rotor assembly makes one revolution, the sliding elements or fluid interface complete two stroke phases, a forward pressurization and a backward depressurization phase stroke.
[0041] In addition to operating as a work exchanger device for transferring fluid pressure from one fluid to another, the present invention can serve as a fluid driven pump in which the pressure energy of one high-pressure fluid is used to pressurize and pump another lower pressure energy fluid. Still another application is a hydraulic compressor in which the pressure energy of a high-pressure liquid is used to pressurize and compress another, gaseous, fluid by means of direct contact or, alternately, by means of freely sliding elements. Still another application is a turbocharger in internal combustion processes in which the exhaust gases of the combustion process are used partly to drive the rotor assembly and partly to compress the inlet air prior to its introduction into the combustion chamber.
[0042] [0042]FIG. 10 depicts a schematic arrangement for a reverse osmosis desalination plant system 80 using the work exchanger device 10 shown in FIG. 1. The overall plant comprises the actual reverse osmosis membrane module 74 , a main feed pump 72 , a booster pump 76 and a work exchanger device of the present invention. In this arrangement, a portion, which may be on the order of 40% of the total capacity, of a low pressure feed source, which may be seawater at a pressure of 2 bar, is conveyed through a line 88 to the main pump which increases the pressure to a higher value, which may be on the order of 60 bar. The remaining 60% of the low pressure fluid is diverted through a line 86 to the low pressure intake line 62 a of the work exchanger device where it is pressurized to a pressure of 56 bar, discharged from an outlet 64 a, and conveyed through a line 94 to a booster pump 76 for further pressurization to the feed pressure of 60 bar. In the reverse osmosis membrane module 74 the feed stream is converted to a low salinity stream, i.e., fresh water, that is output through a first output line 96 and a remainder, comprising an outflow of high salinity rejected brine, that is output through another line 82 . The exiting spent brine accounts for 60% of the feed volume and usually has a high pressure; say 54 bar, which is conveyed to the work exchanger for energy recovery. A small portion of the spent brine, say 2%, is conveyed to the nozzle 16 through line a 78 to impart rotation to the rotor assembly. The rest of this fluid is conveyed to the high pressure intake 62 b. The high-pressure rejected brine transfers its pressure energy to the low pressure feed stream and exits through an outlet 64 b connected to the line 84 for disposal. The rejected brine portion used for driving the rotor assembly leaves the work exchanger through an outlet 70 and another line 92 .
[0043] Alternative schemes can be configured using an alternative fluid source for driving the rotor assembly. For example, FIG. 11 depicts an alternative arrangement of a reverse osmosis plant 90 in which a small portion of the high pressure feed from the main discharge line 94 from the main pump is conveyed through a line 78 to a nozzle 16 of the work exchanger device in order to impart rotation to the rotor assembly. Yet another alternative arrangement, depicted in FIG. 12, comprises a reverse osmosis plant 100 in which a portion of the low pressure source feed, initially input through a line 86 , is diverted to a line 78 connected to the nozzle 16 and used to impart rotation to the rotor assembly.
[0044] As will be understood by those skilled in the art, various embodiments other than those described in detail in the specification are possible without departing from the scope of the invention will occur to those skilled in the art. It is, therefore, to be understood that the invention is to be limited only by the appended claims. | An energy exchanger device can be used for exchanging pressure energy from one fluid to another, or may act as a hydraulic compressor or fluid driven pump. A preferred device uses a jet nozzle to rotate a cylindrical rotor block having a number of axially oriented conduits within it. As the rotor turns, one end of each of the conduits is alternately connected, through a first set of ports, to either an inlet for a high pressure fluid, or an outlet for the high pressure fluid from which the energy has been extracted. Correspondingly, the other end of each of the conduits is alternately connected to either an inlet for a low pressure fluid or an outlet for the fluid to which the energy has been transferred. A freely sliding element, such as a ball, may be placed in each of the conduits to isolate the two fluids from each other. | 1 |
FIELD OF THE INVENTION
The present invention relates to a system for a combustion engine. The present invention more particularly relates to the reduction of harmful emissions from a diesel engine which is fitted with a system for recirculating the exhaust gases to the inlet of the engine, known as an EGR (exhaust gas recirculation) system.
BACKGROUND OF THE INVENTION
For vehicles powered by diesel engines there is a general desire to reduce, to the greatest possible extent, the emission of harmful pollutants in the exhaust gases from the engine. These emissions consist mainly of nitrous oxide pollutants (NO x ), carbon monoxide (CO), hydrocarbons (HC) and soot. A number of different measures can be taken in order to reduce these emissions. For example, it is known that the design of the combustion chamber in the cylinders of the engine and the timing of injecting fuel into the engine can be adapted to minimize the emissions. In those cases where the diesel engine is fitted with a turbo unit, the emission of NO x pollutants can also be reduced by cooling the air fed into the engine (known as intercooling.)
For engines running on gasoline, cleaning of the exhaust gases is normally carried out using an exhaust catalyser as part of the exhaust system. Because a diesel engine is run with an excess of air, the normal type of three-way catalyser cannot be used to reduce the NO x pollutants from diesel engines.
As a result of environmental requirements and expected future legislation, it has become increasingly desirable to reduce the emission of NO x pollutants in particular from diesel engines. A known way of achieving this is to delay the combustion in the cylinders. However, if combustion takes place too late, it reduces the efficiency of the engine in question. Another way of reducing the emissions of NO x pollutants from a diesel engine is to provide it with a known EGR (exhaust gas recirculation) system, by which a certain amount of the exhaust gases can be recirculated from the exhaust pipe of the engine to the inlet of the engine. The formation of NO x pollutants in a diesel engine is mainly exponentially proportional to the local maximum temperature in the combustion chamber, and by using an EGR system the temperature during combustion can be reduced by dilution with the exhaust gases, which in turn leads to a reduced formation of NO x .
A diesel engine can be designed with an EGR system by means of a special pipe which is connected between the exhaust pipe of the engine and a point in connection with the engine's fresh air intake. Along this pipe there is fitted a controllable valve, which in turn is connected to a control unit. This control unit is arranged so that, depending upon the current operation of the engine, in particular as regards its rotational speed and load, it determines a suitable degree of opening for the valve. The setting of the valve in turn controls the amount of EGR gases that are recirculated to the inlet of the engine. If the pressure of the EGR gases at the exhaust side of the engine is higher than the pressure at the intake side this creates a driving force which urges the EGR gases to the inlet side of the engine.
Where a diesel engine with an EGR system is used together with a turbo system and an intercooler, it is not appropriate to recirculate the EGR gases to a point on the inlet side of the engine which is upstream of the turbo system's compressor and intercooler, as this can lead to unwanted fouling of the intercooler, and to high a temperature in the compressor. For this reason such an EGR system is preferably arranged so that the EGR gases are fed from a point on the exhaust side which is upstream of the turbo unit's turbine and to a point on the inlet side which is downstream of the intercooler.
Where an EGR system is used in the manner described above, a problem arises however, in that in most parts of the system there is a higher pressure from the turbo unit's compressor (that is at the point in the engine's intake pipe where the incoming fresh air is fed to the engine) than at the exhaust outlet of the engine. This means in turn that there is no driving force from the exhaust side of the engine to the intake side. For this reason no flow of EGR gases can be recirculated to the engine. It is already known that this problem can be solved by designing the turbo unit with variable turbine geometry. In this manner a sufficiently high pressure can be built up on the exhaust side of the engine. This solution has, however, the disadvantage that it results in deterioration of the engine's heat balance, which in turn makes the engine less efficient.
There is therefore a need for an engine system comprising an EGR system and an exhaust gas system with a turbo unit which provides a sufficient driving force for the EGR gases and which gives a minimal deterioration of the heat balance. This can be provided by the EGR system arranged in such a way that the EGR gases are taken from only one cylinder in the engine. By means of such a system the back-pressure can be increased for only one cylinder (whereby there is only a relatively small deterioration of the heat balance) so that a sufficient driving force is obtained. This can, in turn, be achieved by using a shunt valve which also works as a metering valve controlling the amount of EGR gases required at that particular point of the system. This also means that the exhaust gases from this one cylinder which are not directed to the EGR flow are directed to the turbine in the conventional way together with the exhaust gases from the other cylinders.
A problem that can arise in connection with a system which uses EGR gases from only one cylinder results from the fact that the exhaust gases are emitted from this one cylinder in pulses, which gives a correspondingly pulsating flow of EGR gases to the inlet side. This, in turn, means that the EGR gases are not distributed evenly to the cylinders at the inlet side of the engine, but that there are different levels of EGR gases to the different cylinders. If there is too great a range in the amount of EGR gases fed to the different cylinders, there will be an insufficient reduction of the formation of NO x caused by combustion in the cylinders with low EGR gas content. In addition, there is a danger of a considerable (and unwanted) build-up of smoke and soot in the exhaust gases from the cylinders with high EGR content.
An object of the present invention is to provide an improved system for reducing harmful emissions from a combustion engine, in particular a diesel engine with an EGR system and an exhaust system with a turbo unit, which in particular provides a sufficient driving force for the EGR gases and an even distribution of the EGR gases between the different engine cylinders.
SUMMARY OF THE INVENTION
In accordance with the present invention, this and other objects have now been realized by the invention of an internal combustion engine comprising at least two cylinders, each of the at least two cylinders including an inlet port, an air inlet manifold for providing air to the at least two cylinders, the air inlet manifold including a connection point, at least two outlets for emitting exhaust gases from the at least two cylinders, a recirculation conduit for reducing harmful emissions in the exhaust gases, the recirculation conduit extending from one of the at least two outlets for recirculating the exhaust gases from the one of the at least two outlets to the connection point thereby defining a first volume from the one of the at least two outlets to the connection point, the air inlet manifold being divided into at least two further volumes defined by the distance between the connection point to each of the at least two inlet ports, at least one energy recovery member for recovering energy from the emitted exhaust gases, and a compressor for compressing air for supply to the air inlet manifold, the first volume and the at least two further volumes being dimensioned such that the recirculated exhaust gases are substantially equally distributed between each of the at least two cylinders. In a preferred embodiment, the air inlet manifold includes a partition for dividing the air inlet manifold into at least two air inlet manifold sections for defining the at least two further volumes. In accordance with a preferred embodiment, the at least two cylinders comprise at least two pluralities of cylinders, and the at least two air inlet manifold sections are disposed so as to supply the air and the recirculated exhaust gases separately to the at least two pluralities of cylinders.
In accordance with one embodiment of the internal combustion engine of the present invention, the partition extends from a point upstream of the connection point. Preferably, the partition includes an opening for reducing pulses in the gas mixture fed into the air inlet manifold.
In accordance with another embodiment of the internal combustion engine of the present invention, the recirculation conduit recirculates the exhaust gases from only one of the at least two cylinders, whereby the pressure in the recirculation conduit exceeds the pressure in the air inlet manifold.
In accordance with another embodiment of the internal combustion engine of the present invention, the engine includes a cooler disposed in the recirculation conduit for cooling the exhaust gases recirculated to the air inlet manifold.
In accordance with another embodiment of the internal combustion engine of the present invention, the at least one energy recovery member comprises a turbine.
In accordance with another embodiment of the internal combustion engine of the present invention, the engine includes a controllable valve disposed in the recirculation conduit for controlling the amount of the exhaust gases recirculated therein. Preferably, the controllable valve comprises an electronically controllable shunt valve which is continuously adjustable between open and closed positions.
In accordance with another embodiment of the internal combustion engine of the present invention, the controllable valve comprises an on/off valve.
The system according to the present invention is intended for a combustion engine which comprises at least two cylinders, an inlet for the supply of air, an outlet for the output of exhaust gases, an additional pipe for recirculating exhaust gases from at least one cylinder in the engine to the inlet for the reduction of harmful emissions from the engine, and at least one energy-recovery unit comprising a device for recovering energy from the exhaust gases, and a device for compressing air for the inlet. The present invention is characterized by the inlet being designed with a volume calculated from the connection of the pipe to the inlet and up to the inlet port of the respective cylinder which is so dimensioned that the exhaust gases which are recirculated from the cylinder are distributed substantially equally between the different cylinders of the engine. By means of this even distribution the conditions are favorable for optimal reduction of NO emissions from the engine.
The present invention can, for example, be used with a six-cylinder diesel engine and according to a preferred embodiment of the present invention the inlet can then consist of an inlet manifold which is divided into two halves or partial volumes for three cylinders each. In addition, there is preferably recirculation of EGR gases from only one engine cylinder, which means that the back-pressure is only increased for that cylinder. This results in a minimal deterioration of the gas exchange work of the engine.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in greater detail in the following detailed description, which, in turn, refers to the attached figure, in which:
FIG. 1 is a top, elevational, diagrammatic representation of the system of the present invention.
DETAILED DESCRIPTION
Referring to the drawing, FIG. 1 shows diagrammatically a system according to the present invention which in particular can be used for a combustion engine 1 of the diesel type. According to a preferred embodiment the diesel engine 1 is intended to be used in a vehicle and comprises six cylinders, 2 a , 2 b , 2 c , 2 d , 2 e and 2 f . However, the present invention is not restricted to a certain number of cylinders, a certain cylinder configuration or a certain type of fuel.
In a known manner, the engine 1 is designed with an inlet manifold 3 to which air is fed from the atmosphere through an inlet pipe 4 . As will be described in detail below, the air supplied is distributed between the different cylinders, 2 a - 2 f . In addition, fuel is supplied to the cylinders, 2 a - 2 f , through a corresponding number of fuel injection devices, 5 a , 5 b , 5 c , 5 d , 5 e and 5 f , which are arranged in association with the respective cylinders, 2 a - 2 f , and which are each connected to a central control unit 6 by means of electrical connections 7 . The control unit 6 , which is preferably computer-based, is arranged, in a known manner, to control the injection devices, 5 a - 5 f , so that at any moment a suitable fuel/air mixture is provided for the engine 1 , that is to say so that the mixture provided at any time is adjusted to suit the current operating conditions. The injection device can also be of conventional mechanical type.
The cylinders, 2 a - 2 f , are provided with an exhaust gas outlet, 8 a , 8 b , 8 c , 8 d , 8 e and 8 f , which together form a branched exhaust gas pipe. The three exhaust gas outlets, 8 a - 8 c , which lead out from the three first cylinders 2 a - 2 c are connected to a first exhaust gas pipe 9 , while the three exhaust gas outlets, 8 d - 8 f , which lead out from the fourth, fifth and sixth cylinders, 2 d - 2 f , are connected to a second exhaust gas pipe 10 . The first exhaust gas pipe 9 and the second exhaust gas pipe 10 pass through a turbo unit, 11 which is principally conventional. Thus, the turbo unit 11 comprises a device for recovering energy from the exhaust gases in the form of a turbine 12 which is rotated by the exhaust gases which flow through the two exhaust gas pipes, 9 and 10 . The exhaust gases which have passed through the turbine 12 are then led out into the atmosphere through an outlet 15 which, in turn, is preferably fitted with a (not shown) silencer.
Instead of a conventional turbo unit, a known Comprex charger can, in principle, be used as an alternative device for recovering energy from the exhaust gases and supplying compressed air to the inlet of the engine.
As an alternative to the embodiment shown in the figure, which is designed so that the exhaust gas outlets, 9 and 10 , are arranged in two groups with two pipes leading to the turbine 12 (known as a twin inlet), the exhaust gas outlets, 9 and 10 , can instead join into a single exhaust gas pipe (known as a single inlet).
According to another alternative to the embodiment shown in the figure, the exhaust gas outlet can be divided into two or more groups by which the exhaust gases are fed to a corresponding number of separate turbo units.
The turbine 12 is arranged on an axle 13 on which a compressor is also arranged. The energy which is recovered from the flow of exhaust gas by the turbine 12 is transferred in this way to the compressor 14 which is arranged to compress air flowing in through an inlet 16 and to feed this air to the inlet pipe 4 . By this means, in a known manner an increased amount of fuel can be delivered to the engine 1 , whereby its power can be increased.
The engine 1 is equipped with a system for recirculating a certain amount of exhaust gases to the inlet side of the engine 1 . By way of introduction, such an EGR (exhaust gas recirculation) system is already known. According to the present invention an additional exhaust gas pipe in the form of an EGR pipe 17 is therefore connected to, for example, the first exhaust gas outlet 8 a , that is the outlet which takes exhaust gases from the first cylinder 2 a . The EGR pipe 17 is connected to the first exhaust gas outlet 8 a by means of a special EGR valve 18 , which preferably consists of an electrically regulated shunt valve. As is shown in the figure, the EGR valve 18 is positioned upstream of the turbine 12 and also upstream of the point where the first exhaust gas outlet 8 a is connected to the second exhaust gas outlet 8 b . In addition, the EGR valve 18 is connected to the control unit 6 by means of an additional electrical connection 19 .
The control unit 6 is arranged to set the valve 18 in a closed, open or partially open position, depending upon the current operating conditions. Dependent upon the state of the valve 18 , a corresponding flow of exhaust gases will thus be recirculated to the inlet manifold 3 through the EGR pipe 17 . At the same time a corresponding reduction is obtained in the flow of exhaust gases from the first cylinder 2 a to the first exhaust gas pipe 9 . By means of the recirculating of EGR gases to the inlet manifold 3 , a reduction in temperature is achieved during combustion in cylinder 2 , whereby the NO x formation in cylinder 2 is reduced.
To control the valve 18 , the control unit 6 is arranged to determine the rotational speed and load (torque) of the engine 1 and to calculate from these parameters the amount of EGR gases required to be recirculated to the inlet manifold. This amount of EGR gases is mainly determined in the control unit 6 by utilizing a stored table which gives the required amount of EGR gases for optimal reduction of NO x pollutants as a function of the rotational speed and load. Dependent upon the calculated value for the amount of EGR gas, the valve 18 is then set in a corresponding position by means of a signal from the control unit 6 .
The NO x formation in cylinder 2 is dependent upon the temperature and for this reason it is desirable to reduce to the greatest possible extent the temperature of the gas fed into the engine 1 (which is made up of air and recirculated EGR gases). For this reason, the EGR pipe 17 is equipped with a cooler 20 which is designed for cooling the EGR gases recirculated to the inlet manifold 3 . For this purpose, the cooler 20 comprises a loop 21 through which a suitable cooling medium is passed. This cooling medium preferably consists of the ordinary coolant used in the engine 1 , but as an alternative air can be used for this cooling. The EGR gases can be cooled by means of the cooler 21 , which further contributes to a reduction in the amount of NO x pollutants which are created.
Along the inlet pipe 4 there is an intercooler 22 which is used to cool the compressed air which is fed to the engine by means of the compressor 14 . This also contributes to a reduction in the amount of NO x pollutants which are created in the engine 1 . This second cooler 22 is preferably designed for cooling by air, which is indicated diagrammatically by the reference 23 .
According to the present invention, the inlet manifold 3 is designed in a manner which is intended to provide an even distribution of the recirculated EGR gases to the cylinders 2 a - 2 f . For this purpose, the inlet manifold 3 is preferably divided into a first inlet section 3 a and a second inlet section 3 b which are separated by means of a partition 24 . This is shown in the figure, in which the actual inlet manifold 3 is shown in cross section. In addition the EGR pipe 17 is arranged so that it divides downstream of the EGR cooler 20 and goes to a first pipe section 17 a and a second pipe section 17 b . The first pipe section 17 a opens into the first inlet section 3 a by means of a first calibrated opening 25 , while the second pipe section 17 b opens into the second inlet section 3 b by means of a second calibrated opening 26 . The first opening 25 is designed with a first predetermined area A 1 , while the second opening 26 is designed with a second predetermined area A 2 .
The first pipe section 17 a and the second pipe section 17 b open into an EGR mixer 27 which consists of a primarily pipe-shaped element, which comprises a connection between the inlet manifold 3 and the inlet pipe 4 . In this EGR mixer 27 there is a primarily homogenous mixing of the charging air fed through the inlet pipe 4 and the EGR gases recirculated from the first cylinder 2 a and fed through the first pipe section 17 a or the second pipe section 17 b . For this purpose the EGR mixer 27 is divided in two so that the EGR gases in the first pipe section 17 a are mixed with charging air in the inlet pipe 4 separately from the mixing of the EGR gases from the second pipe section 17 b with charging air. The mixture of charging air and EGR gases is then fed to the first three cylinders, 2 a - 2 c , through the first inlet section 3 a and to the other three cylinders, 2 d - 2 f , through the second inlet section 3 b.
The term “homogenous mixing” is used to describe the fact that homogenous mixing takes place in the EGR mixer 27 principally across the direction of flow of the air. However, there are variations in this mixing during a particular operation cycle along the direction of flow of the air. These variations are due to the exhaust gases being supplied in pulses from the first cylinder 2 a while the charging air mainly flows evenly during the said operation cycle.
As shown in the figure, the partition 24 passes through both the inlet manifold 3 and the EGR mixer 27 , that is upstream of the point where the EGR gases are fed into the EGR mixer 27 . Consequently, due to the partition 24 there is a division of the flow of gas between the two inlet sections, 3 a and 3 b , before it reaches the EGR mixer 27 .
According to the present invention, pressure is built up in the first exhaust gas outlet 8 a during operation of the engine 1 , which pressure is higher than the pressure on the intake side of the engine 1 . In this manner, a sufficient driving force is obtained for recirculating the EGR gases to the inlet manifold 3 , without appreciable reduction in heat balance and without any appreciable deterioration in the efficiency of the engine 1 .
A basic principle underlying the present invention is that the volume of the inlet manifold 3 and the volumes of the two inlet sections, 3 a and 3 b , are calculated in order to provide a principally equally large flow of EGR gases to each of the cylinders, 2 a - 2 f . The inlet sections, 3 a and 3 b , consist in turn of determined partial volumes which extends between the branching-off positions defined by the openings, 25 and 26 , for EGR gases and the inlet port (not shown) for each of the cylinders, 2 a - 2 f . In particular, the volumes of the inlet sections, 3 a and 3 b , are determined so that the volumes which are created between the EGR valve 18 and each of the cylinders, 2 a - 2 f , enable the periodically recurring amounts of EGR gas from the first cylinder to pass along the inlet sections, 3 a and 3 b , and be distributed evenly between the cylinders, 2 a - 2 f , when their respective inlet valves (not shown) are open.
In the figure the reference V EGR refers to the volume which is created between the exhaust gas valve (not shown) of the first cylinder 2 a and the openings, 25 and 26 , that is comprising the volume which extends through the valve 18 , the pipe 17 , the EGR cooler 20 and the pipe sections, 17 a and 17 b . In addition, the reference V 1 refers to the volume between the EGR mixer 27 and the inlet port of the first cylinder 2 a , in particular the volume between a first imaginary plane 28 which extends across the longitudinal direction of the EGR mixer 27 , at the opening of the first pipe section 17 a , and up to a further imaginary plane 29 which extends across the inlet manifold 3 , at the first cylinder 2 a . In a corresponding manner, the volume V 2 is defined as the volume between the plane 29 at the first cylinder 2 a and the inlet port of the second cylinder 2 b , whereby the latter is defined by a further transverse plane 30 . In addition, the volume V 3 is defined as the volume between the plane 30 at the second cylinder 2 b and the inlet port of the third cylinder 2 c , which is defined by a further plane 31 .
The volume V 4 is defined as the volume between the EGR mixer 27 , that is the plane 28 , up to the inlet port of the fourth cylinder 2 d , which is defined by a further transverse plane 32 . In addition, the volume V 5 is defined as the volume between the plane 32 and the inlet port of the fifth cylinder 2 e , which is defined by a further transverse plane 33 .
According to the embodiment shown in the figure the first pipe section 17 a and the second pipe section 17 b are arranged along the same plane, that is along the plane 28 . In an alternative embodiment, these two pipe sections, 17 a and 17 b , can, however, also open out at different points along the EGR mixer 27 .
According to this embodiment, the partition 24 is designed with an opening 34 , that is a connection between the first inlet section 3 a and the second inlet section 3 b . The opening 34 is positioned downstream of the third cylinder 2 c and is designed with an opening area A 3 . This opening 34 can reduce pulses in the flow of gas fed through the inlet manifold 3 , which would otherwise impair the gas exchange work in the engine 1 .
According to the present invention, the dimensions of the respective volumes, V EGR and V 1 -V 5 , are selected so that the flow of EGR gases through the pipe 17 is distributed principally equally between the six cylinders, 2 a - 2 f . The size of the opening areas A 1 -A 3 is preferably also selected in a way that contributes to this equal distribution. The EGR gases that are fed through the EGR pipe 17 periodically in the form of pulses of exhaust gas from the first cylinder 2 a , are taken past the inlet ports of the six cylinders, 2 a - 2 f . By means of the setting of the volumes, V 1 -V 3 , according to the present invention it is ensured that a certain amount of EGR gases is fed in to the first cylinder 2 a when the inlet valve (not shown) of the first cylinder 2 a is open, that an essentially equally large amount is fed in to the second cylinder 2 b when the inlet valve (not shown) of the second cylinder 2 b is open and that essentially equally large amount is fed into the third cylinder 2 c when the inlet valve (not shown) of the third cylinder 2 c is open. In a corresponding manner, by means of the setting of the volumes V 4 -V 5 it is ensured that an essentially equally large amount of EGR gases is fed in to the fourth, fifth and sixth cylinder, 2 d - 2 f , when the inlet valves (not shown) of these cylinders, 2 d - 2 f , are open.
The design of the volumes, V EGR and V 1 -V 5 , and the areas, A 1 -A 3 , can be determined by practical trials or by means of simulations using theoretical models. The flow and the distribution of EGR gases to each of the cylinders, 2 a - 2 f , is a complex process involving for example the pressure, temperature, speed and composition of the EGR gases in each of the volumes, V EGR and V 1 -V 5 . The settings can therefore be worked out by computer simulation. For such a design an appropriate operating state can be taken as the starting point, for example medium rotational speeds and loads, whereby an even EGR distribution between the cylinders is obtained in normally occurring operating states of the engine. For a standard six-cylinder engine of the diesel type with a compression ratio of the order of 12:1, the volumes, V EGR and V 1 -V 5 , and the areas, A 1 -A 3 , are preferably selected as follows:
V EGR
V 1
V 2
V 3
V 4
V 5
A 1
A 2
A 3
4.8
2.4
0.8
0.7
4.6
0.9
1.9
2.1
5.0
In the table above the volumes are given in dm 3 and the areas in cm 2 . The present invention provides for an even distribution of EGR gases to the cylinders, which in turn makes possible a considerable reduction in the NO x emissions from the engine.
The size of the volume extending from the plane 33 up to the inlet of the sixth cylinder 2 e is of no great significance, as practically the whole amount of EGR gas which is fed as far as this volume will be drawn in to the sixth cylinder 2 e.
The different volumes and areas are set according to a particular operating state which is determined in advance. In those cases where it is desirable to adapt the present invention to suit some alternative operating state, other values for the volumes and areas are obtained. According to the present invention, the volumes and areas can also be set, for example, according to the power of the engine 1 or according to what type of turbo unit 11 is used.
The present invention is not restricted to the embodiment described above, but can be varied within the framework of the following claims. For example, the number of cylinders in the engine can vary. In addition the valve 18 can alternatively be of the type that has an on/off setting, that is it can be set only in an open position or a closed position.
In addition, the control unit 6 can be arranged to control, for example, the timing of injection for the injection devices, 5 a - 5 f , in order to further reduce the emission of NO x pollutants.
The inlet manifold can be divided into two inlet sections with three cylinders each (as shown in the figure) or can alternatively be divided into three inlet sections with two cylinders each, or some other combination which can be selected, for example, depending upon the number of cylinders in the engine for which the present invention is used. In addition, the inlet manifold can also in principle be designed as a single volume, particularly in engines which have fewer than six cylinders.
In principle, any one of the engine's cylinders can be used to supply the EGR gases to be recirculated to the inlet of the engine. In order to make the installation of the EGR pipe and the EGR valve simpler, however, the first or sixth cylinder should preferably be selected for this purpose (provided that a straight six-cylinder engine is used). In principle EGR gases can also be taken from more than one cylinder.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | An internal combustion engine is disclosed including at least two cylinders, each including an inlet port, an air inlet manifold for providing air to the cylinders, at least two outlets for emitting exhaust gases from the cylinders, a recirculation conduit for reducing harmful emissions from the exhaust gases and extending from one of the outlet for recirculating the exhaust gases from an outlet to a connection point in the air inlet manifold thereby defining a first volume from the outlet to the connection point, the air inlet manifold being divided into at least two further volumes defined by the distance between the connection point to each of the inlet points, at least one turbine for recovering energy from the exhaust gases, and a compressor for compressing air supplied to the air inlet manifold, the first volume and the further volumes being dimensioned such that the recirculated exhaust gases are substantially equally distributed between each of the cylinders. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a slip forming process and to the monolithic, reinforced concrete structures produced in accordance with this slip forming process of this invention. More specifically, this invention relates to a process for slip forming reinforced concrete road structures, wherein the resulting slip formed structures have exposed reinforcing bars (“rebars”), which are partially embedded in and extend from within a slip formed, reinforced concrete structure. in one of the preferred embodiment of this invention, this slip forming process utilizes a “tunnel mold assembly” for forming a coping for bridge construction, wherein the coping is preferably formed concurrent with a slip formed concrete road bed pad. In this preferred embodiment of the invention, this slip formed coping includes both rebars embedded therein and exposed reinforcing bars extending from within the formed/finished coping. These exposed reinforcing bars are suitable for subsequent reinforcement and integration with additional in situ cast concrete structures. so as to further integrate such additional in situ cast concrete structures with the reinforced concrete road structures produced by this process.
2. Description of The Prior Art
Slip forming of concrete structures is a well-known technique for preparation of structural concrete elements for various industrial and public works (road, conduit, etc.) projects. Slip forming is a construction method in which concrete is poured into a continuously moving form. Slip forming is used for tall structures (such as bridges, towers, buildings, and dams), as well as horizontal structures, such as roadways. Slip forming enables continuous, non-interrupted, cast-in-place “flawless”, (i.e. no joints), concrete structures which have superior performance characteristics to piecewise construction, using discretely formed elements. Slip forming relies on the quick-setting properties of concrete, and requires a balance between quick-setting capacity and workability, Concrete needs to be workable enough to be placed into the form and consolidated. (via vibration), yet quick-setting enough to emerge from the form with strength (also “self supporting strength” or “green strength”). This green strength is needed because the freshly set concrete must not only permit the form to “slip” upwards/forward. but also support the freshly poured concrete above it (“vertical slip forming”) and/or the freshly poured concrete in front of it (“horizontal slip forming”).
in vertical slip forming, the concrete on may be surrounded by a platform on which workers stand. placing steel reinforcing rods into the concrete and ensuring a smooth pour. Together. the concrete form and working platform are raised by means of hydraulic jacks. Generally, the slip-form rises at a rate which permits the concrete to harden (develop green strength) by the time it emerges from the bottom of the form. In horizontal slip forming for pavement and traffic separation walls. concrete is laid down, vibrated, worked, and settled in place, while the form itself slowly moves ahead. This method was initially devised and utilized in Interstate Highway construction initiated by the Eisenhower administration during the 1950s.
The following is a representative (and not exhaustive) review of the prior art in this field:
U.S. Pat. No. 3,792,133 (to Goughnour issued Feb. 12, 1974) describes a method and an apparatus for concrete slip forming a highway barrier wall of varying transverse cross-sectional configuration for accommodating different grade levels on opposite sides of the wall, and wherein variations in the wail cross-sectional configuration may be readily accomplished during wail formation without requiring stopping, realignment or other interruptions in the screed movement during wall forming.
U.S. Pat. No. 4,266,917 (to Godbersen issued Mar. 12, 1981) describes a method for the efficient slip forming of highway median barrier wails of differing, size (adjustable height) and shape having any arrangement of linear and curved sections and while the machine is being advanced in a single direction. The lateral adjustability of opposite side walls of the form, relative to the top wall, permits the use of the side walls with top wails of varying widths. The relative vertical adjustment of the top wall and side walls provides for a wide variation in the vertical height of a barrier will particularly where a glare shield is to be formed on the barrier wall top surface. The slip forming of the glare shield takes place simultaneously and continuously with the slip forming of the barrier wall and over any selected portion of the wail while the machine is being advanced in a single direction. At any adjusted position of the slip form, the skirt member associated with each side wall is adjustable to prevent any flow of concrete from between the ground or highway surface and the form.
U.S. Pat. No. 4,084,948 (to Petersik issued Apr. 18, 1978) describes an improved barrier forming apparatus and method whereby a barrier is formed continuously over a surface, the barrier having continuous reinforcing rods extending the length of the barrier and having cagereinforced standard supports at predetermined intervals along the length of the barrier. The Petersik improved barrier forming assembly comprising a concrete forming member having a form cavity extending there through; a concrete passing member having a concrete delivery opening for passing concrete or the like to the fibrin cavity; and a positioning assembly comprising a support shaft and a door Member pivotally supported at a forward end of the concrete forming member, the barrier being extrudable continuously via the form cavity forom a rearward end of the concrete forming member. The door member selectively is positionable to partially seal the form cavity at the forward end of the concrete forming member and has rod clearance channels through which the reinforcing rods pass through the door member into the harm cavity when the door member is so positioned to seal the form cavity. The rod clearance channels permit ie door member to clearingly pass the reinforcing rods to open the form cavity at the forward end of the concrete forming member to allow the free passage of the barrier forming assembly over the cage reinforced standard supports.
U.S. Pat. No. 5,290,492 (to Belarde, issued May 1, 1994) describes a system for continuously forming a concrete Structure (a) having a predetermined cross-sectional configuration, (b) which extends along an elongate path, and (c) includes art outer surface haying a textured pattern comprising concave or convex portions which extend other than just parallel to the elongate path. The system includes a frame, a first form assembly, a second form assembly, a drive system, and a support assembly.
As is evident from the above, there are number of alternatives for the slip forming of structures for use in road and bridge construction, The numerous alternative systems have their proponents and their detractors. In the context of selection of the more appropriate and efficient system, for example, for construction of retainer/barrier walls and/or glare shield concrete structures, time is money and often is reflected in the bidding process. More specifically, the bid letting on highway construction projects routinely include both penalty provisions for tardy completion and/or bonus payments thr early completion. Accordingly, efficiencies Which advance project completion, generally translate into cost saving. Thus, there is continuing efforts to automate, where possible, the fabrication of structural concrete components in highway construction; and, to standardize the process for the fabrication of roadway components and thereby simplify the bid letting on such proiects, particularly federally funded highway construction projects,
As is evident from the foregoing, and need not be belabored, the slip forming of structural concrete structures, including, concrete structures for highway construction, is well-known, Invariably, such slip formed highway structures are integrated into roadbeds, used as dividers for road beds and as components for bridges or overpasses for such road beds. The specifications for these concrete structures have and continue to become more uniform and/or have basic specifications in common, because of the advancements in construction methods, and the use of federal funds for such highway construction projects. For example, the specification for a concrete bridge coping must include exposed rehars for the integration into both the road bed, or with a barrier wall, which is to be erected thereupon, and integrated therewith.
Up to now, the standard or generally accepted techniques for the fabrication of bridge coping for an overpass on the highway, have required either the use of a pre-cast coping element (fabricated off-site),, and/or the manual casting of a coping on-site, utilizing traditional forms and concrete casting techniques. In the case of a pre-cast concrete coping element, the road bed of the overpass requires special preparation since the pre-cast element does not readily conform to the angle of incline or grade of a ramp or overpass and, therefore, imperfectly abut one another upon placement on the incline of the bridge overpass. Accordingly, additional installation expense is required to insure the connection of abutting pre-cast copings to one another to insure the formation of a unitary coherent structure.
Alternatively, the casting of an overpass/bridge coping, using the a manual process for forming the coping, specifically, traditional forms and concrete casting techniques, is preferably to the pre-cast coping, because the resulting coping is structurally continuous, and better conforms to the incline/grade of the ramp or overpass. Notwithstanding, the on-site casting, of a bridge coping, by traditional concrete casting technique, is very labor intensive and does not. without an inordinate amount of man power, lend itself to rapid fabrication and accelerated completion schedules. In each of the foregoing alternatives, the coping is formed with extending rebars for the later integration of the coping into a road bed pad and/or the attachment to a retaining wall. which can be later formed on the top of the coping.
Accordingly, there continues to exist the need to both simplify the on-site fabrication of a bridge coping, minimize the manual labor requirements, permit/accommodate accelerated construction schedules, and yet produces a structure which is both coherent (e.g. monolithic structure), and faithfully conforms to the angle of incline or grade of a road overpass, without additional extensive on-site preparation.
OBJECTIVES OF THIS INVENTION
It is the object of this invention to remedy the above, as well as related deficiencies, in the prior art.
More specifically, it is the principle object of this invention to provide a process for slip forming a monolithic, concrete structure having both partially embedded, rebar reinforcement and partially exposed (extending). rebar.
It is another object of this invention to provide a process ter slip forming a monolithic, reinforced concrete structure, which includes a formed. bridge coping, having exposed rebars.
it is yet another object of this invention to provide a process for the slip forming of a monolithic, reinforced concrete structure, which includes a formed road bed pad and a formed bridge coping having exposed rebars
It is still yet another of object of this invention to provide a process, which utilizes a tunnel mold assembly, for slip forming a. monolithic, reinforced concrete structure, which includes a formed bridge coping having both partially embedded and partially exposed (extending) exposed rebars.
Additional objects of this invention include a tunnel mold assembly equipped slip forming machine for slip forming a monolithic concrete structure with exposed rebars; and, a tunnel mold for use in the slip forming of a monolithic concrete structure with exposed rebars.
SUMMARY OF THE INVENTION
The above and related objects are achieved by providing a process for the on-site slip forming of a monolithic concrete structure having both partially embedded and partially exposed (extending) rebars. This process is particularly well-suited for the on-site fabrication of a monolithic concrete structure on uneven terrain (ramp) and/or an overpass/bridge grade. This process utilizes an improved slip forming process, in combination with equipment designed specifically for use in this improved slip forming process. In brief, this process combines slip forming with a unique tunnel mold assembly, which is adapted to produce a monolithic, rebar reinforced concrete structure having both partially embedded and partially exposed rebars. These exposed rebars, which extend from within the slip formed, concrete coping, produced in accord with this invention, enable the further integration and union of the slip formed coping, with a concrete retaining wall or other (preferable) concrete structure, or with a guard rail assembly.
The slip forming machinery which is used in the process of the invention includes the traditional concrete handling conveyances, and a unique tunnel mold assembly for forming a reinforced concrete structure with exposed rebars. This tunnel mold assembly includes:
(a) a tunnel mold having at least one channel therein which permits the passage of a rebar through the mold without being encased in concrete.
(b) auger means for essentially uniform distribution of unset concrete within the mold cavity of the tunnel mold and
(c) a plurality of vibration means, strategically positioned within the mold cavity of the tunnel mold, for consolidating the unset concrete within the mold cavity and thereby eliminating any voids or lack of continuity within the resultant slip formed structure.
This tunnel mold of this assembly is unique in that it is provided with one or more passages, or channels, which extend through the mold cavity, from the leading/front mold surface to the trailing/rear mold surface of the mold. The dimensions of these channels within the mold cavity is sufficient to accommodate the width and height of exposed rebars, during the in situ fabrication of a slip formed, reinforced concrete structure, such as a the slip formed bridge coping. More specifically, the dimensions of such channels within the mold cavity mold, permits the slip forming of a rebar, reinforced concrete coping, wherein a only a portion of the reinforcing rebars are partially embedded within a slip formed concrete coping, and a portion of the reinforcing rebars remain exposed, (free of concrete), and extend front the slip formed bridge coping, for later integration into a companion structure. The size and number of passages or channels of this tunnel mold is limited, to some extent, by practical constraints—the shape/dimensions of the coping—and engineering factors which dictate the thickness of the concrete which occupies the formed structure which surrounds these exposed rebars.
In the preferred embodiments of this invention, these passages or channels within the tunnel mold, are open at the base of the mold, and correspond in the placement and the extension of the rebars, which are only partially embedded within the slip formed coping. The relative viscosity/rheological properties of the concrete fed into the mold cavity of the tunnel mold (a) limits the configuration of the channels within the mold cavity, and (b) controls/limits the extent to which the concrete can flow from within the mold cavity into these channels. The tunnel mold of the slip forming assembly effectively restricts the extent to which concrete can flow from the mold cavity into these channels, and thereby such channels are maintained essentially concrete free, to accommodate passa rebars through the tunnel mold and remain concrete free.
In another of the preferred embodiments of this invention, the improved process is suitable for concurrent slip forming of multiple structural concrete components, as a monolithic structure. in this preferred embodiment of this invention, the process can be used to concurrently slip form both a bridge coping and a road bed pad, in a single pass of the slip forming equipment, thus, further minimizing the steps and time required for completion of a highway construction project.
In yet an of the preferred embodiments of this invention, the bridge coping, (which is formed in accordance with invention), is further modified, as appropriate, with additional rebar reinforcement, and a slip formed concrete structure, (e,g. noise wall, visual barrier, wall cap, etc.), formed on the top thereof, so as to integrate a latter formed concrete with the slip formed bridge coping, Insofar as the exposed rehar extending from the coping is also thereby integrated into this latter slip formed concrete structure, this latter concrete structure becomes integral with the bridge coping.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a perspective view of an inclined road bed, which has yet to be prepared for the addition of a concrete coping or concrete road pad.
FIG. 2 depicts a perspective view of the custom fabricated forms used in the on-site framing of a coping and road bed pad preliminary to the manual casting of a coping and road bed pad by traditional concrete casting techniques,
FIG. 3(A) depicts a perspective view of the iron work array on an inclined road bed, prior to the concurrent slip forming of a bridge coping and road bed pad.
FIG. 3(B) depicts a perspective view of the tunnel mold assembly of this invention. in relation to the iron work array of FIG. 3(A) .
FIG. 3(C) depicts slip forming machinery of this invention in relation to an iron work array Fig, 3 (A),
FIG. 4(A) depicts an enlarged view, oot a tunnel mold assembly of this invention, when viewed from above.
FIG. 4(B) depicts an enlarged view, in partial section, of a tunnel mold assembly of this invention of FIG. 4(A) , when viewed from the rear.
FIG. 4(C) depicts art enlarged view in partial section, of a tunnel mold assembly of this invention of FIG. 4(B) .
FIG. 5(A) depicts a perspective view of a tunnel mold assembly and slip formed bridge coping and road bed pad, when viewed from the rear of the tunnel mold.
FIG. 5(B) depicts a perspective view of a slip formed bridge coping and road bed pad. when viewed from side of an MSE retaining wall.
FIG. 6(A) depicts a perspective view of a slip formed bridge coping and road bed pad wherein the extended rebars are physically joined to additional rebars.
FIG. 6(B) is an enlarged view the extended rebars, from a slip formed bridge coping, physically joined to additional rebars
DESCRIPTION OF THE INVENTION
INCLUDING PREFERRED EMBODIMENTS
As understood within the context of this invention, the following terms and phrases are intended to have the following meaning unless otherwise indicated.
The phrase “slip forming”, or “horizontal slip forming”, is intended, and used herein, to describe a construction method in which concrete is poured into a continuously moving form. Slip forming is used for tall structures (such as bridges, towers, buildings, and dams), as well as horizontal structures, such as roadways. Slip forming enables continuous, non-interrupted, cast-in-place “flawless” (i.e. no joints) concrete structures, which have superior performance characteristics to piecewise construction using discrete form elements. Slip forming relies on the quick-setting properties of concrete, and requires a balance between quick-setting capacity and workability. Concrete needs to be workable enough to be placed into the form and consolidated (via vibration), yet quick-setting enough to emerge from the form with strength, (also “green strength”), sufficient to be self- supporting because the freshly set concrete must not only permit the form to “slip” forward but also support the freshly poured concrete which now abuts it, as the form continues to move forward.
The term “coping” or “bridge coping” is intended, and used herein, to describe and connote the structural element which is affixed and preferably integral with the top of a retaining wall of an elevated roadway. Within the context of this invention, “coping” and “bridge coping” are fabricated by the improved process of this invention, and have rebars extending from within and partially embedded within the slip formed coping, The slip formed coping prepared in accordance with the process of this invention is thus unique in terms of its fabrication history.
The phrase “road pad” is intended, and used herein, to describe a slip formed concrete slab, which is preferably formed concurrent with the bridge coping. The road pad is used to delineate the lateral margins of the road bed, and is subsequently integral with the road bed. The phrase “tunnel mold” is intended, and used herein, to describe a slip forming compatible assembly, having a one or more channels or passages through the mold cavity and extending from the front (leading edge) to back (trailing edge) of the mold. Each of these channels or passages also have an open end along the base of the mold, which opening extends from the front (leading edge) to back (trailing edge) of the mold, and is of a sufficient height to accommodate the passage of extending rebars, as the they pass through these passages or tunnels, from the front to the back of the tunnel mold, and yet remain concrete-free, as the mold advances forward in the process of slip forming a reinforced concrete structure. The structure which emerges from the tunnel mold has both embedded rebars and concrete free rebars, which extend from rebars embedded in slip formed concrete structure.
The term “rebar” (short for “reinforcing bar”), is intended, and used herein, to describe a steel bar that, is commonly used as a tension device in reinforced concrete, and in reinforced masonry structures, to strengthen and hold the concrete in compression. It is usually in the form of carbon steel bars or wires, and the surfaces may be deformed for a better bond with the concrete.
The abbreviation “MSE” is intended, and used herein, to describe Mechanically Stabilized Earth, constructed with artificial reinforcing MSE walls stabilize unstable slopes and retain the soil on steep slopes and under crest loads. The wall face is often of precast, segmental blocks, panels or geocells, that can tolerate some differential movement. The walls are in-filled with granular soil, with or without reinforcement, while retaining the backfill soil. Reinforced walls utilize horizontal layers typically geogrids The reinforced soil mass, along with the facing, forms the wall. in many types of MSE's, each vertical fascia row is inset, thereby providing individual cells that can be in-filled with topsoil and planted with vegetation to create a green wall.
In the description of the preferred embodiments of this invention, as illustrated in accompanying patent drawings, where an element or feature in one or more Figures is common to more than one of the accompanying patent drawings. it is assigned the same reference numeral for ease of understanding and simplicity of expression.
FIG. 1 is a perspective view of an inclined road bed ( 2 ) for an overpass. As is evident from this illustration, the angle of incline, and decline, of the road bed can vary with the grade, and, thus, the preferred method for the fabrication of structural components associated with such inclined road bed are best resolved with on-site fabrication of the structural bridge and road elements. Within the context of this invention, the focus is upon the integration of the structural components for a roadway by means which minimize labor intensive manual labor, and provide for the sequential formation of bridge and overpass components by means of slip forming. The road bed ( 2 ) shown in this FIG. 2 has an which has been stabilized by MSE retaining wall ( 4 ). The MSF retaining wall ( 4 ) shown in FIG. 2 has an unfinished top edge ( 6 ), which needs to be integrated into the road bed ( 2 ). This integration typically requires the formation of a coping or a comparable structural element, along the unfinished top edge ( 6 ) of the MSE retaining wall ( 4 ), which, in turn, is further integrated into the finish road bed (not shown).
FIG. 2 is a perspective view of the traditional, manual on-site preparation for casting of a bridge coping and road pad onto a road bed ( 2 ) by conventional concrete casting techniques. In the manual on-site casting of a bridge coping and road pad, extensive manual preparation is required to initially frame a series of forms ( 14 ). These forms ( 14 ) are used to confine a concrete pour onto an array of iron work reinforcing steel ( 16 ). After the cast concrete sets up, the worker thereafter breakdown the forms; and, this manual process repeated for an additional length of coping, until the job is completed. In a typical road construction environment, this process is labor intensive, time consuming, inefficient and very slow because the typical road crew can only fabricate about 40 to 50 feet of traditionally cast product per day. Obviously, the employment of additional manpower on the job will advance the construction schedule somewhat, but be prohibitively expensive and uncompetitive.
FIG. 3(A) depicts a perspective view of the layout of the iron work array ( 16 ) for the slip forming of coping and road bed pad on a similar inclined road bed ( 2 ) as in FIG. 2 , As is evident, the preparation for the slip farming of a coping a road bed pad does not require the use of the tradition series of forms ( 14 ). It is emphasized, that the placement of the ironwork array ( 16 ) is arrange along the road bed ( 2 ) proximate to the MSE retaining wall ( 4 ) without structure defining elements (forms). The ironwork array ( 16 ) can, and is often fabricated on-site; and, its placement determined by a series of surveyor/reference lines (not shown).
FIG. 3(B) depicts placement of a tunnel mold ( 18 ) preliminary to the slip forming of a coping and road bed pad upon the ironwork array ( 16 ) of FIG. 3A . FIG. (B) shows the iron work array ( 16 ), in respect to the MSE retaining wall ( 4 ), and a platform ( 20 ) which has been erected along the outside (exposed side) of MSE retaining wall ( 4 ) to allow for worker oversight of the slip funning process, and to provide a support ( 22 ) for a coping along the top of the MSE retaining wall ( 4 ), it is noted that the platform ( 20 ) is positioned, relative to the iron work array ( 16 ), and to the top of tile MSE retaining wall ( 4 ), so as to provide a base for a coping, which is to extend over the top of the MSE retaining wall ( 4 ), in this FIG. 3(B) , the tunnel mold ( 18 ) is shown to have an open form cavity ( 23 ) and an auger ( 24 ).
FIG. 3(C) depicts the tunnel mold ( 18 ) in combination with slip forming support assembly ( 19 ) typically associated therewith. In FIG. 3(C) , ready mix concrete is conveyed from a cement mixer to a slip forming support assembly ( 19 ), A workman is shown dispensing the relatively fluid concrete mix into the form cavity ( 23 ) of the tunnel mold ( 18 ). The assembly includes both well-know means for guidance of the assembly relative to the iron work arrays: and, for modulation of the speed of the assembly.
FIG. 4 (A) is an isolated and enlarged view of the tunnel mold ( 18 ) of FIGS. 3(B) & (C). In FIG. 4(A) , the auger ( 24 ) is disposed within the form cavity ( 23 ) of the tunnel mold ( 18 ) along with a series of vibrators ( 26 ). Upon the dispensing of a ready mix concrete into the form cavity ( 23 ) of the tunnel mold ( 18 ), it gradually fills the form cavity ( 23 ) until it completely covers the auger ( 24 ). The auger ( 24 ) is driven by a drive motor (not shown), which rotates an auger drive shaft ( 27 ), and thereby effects rotation of the auger and distribution of the concrete across the width of form cavity ( 23 ). in practice and operation of the slip forming process, the tunnel mold ( 18 ) is progressively advanced over ironwork array ( 16 ) of FIG. 3A (from left to right), as a slip formed, concrete coping and a road bed pad are formed upon the iron work array ( 16 ), A series of vibrators ( 26 ) within the form cavity ( 23 ) of tunnel mold assembly ( 18 ) effectively consolidates the unset concrete within the form cavity ( 23 ), and thereby eliminate any voids or lack of continuity within the resultant slip formed structure. This consolidation of the concrete is essential to the green strength of the formed structure and the continuous forward movement (slipping) of the tunnel mold assembly over the iron work array.
FIG. 4(B) is an isolated and enlarged view of the tunnel mold ( 18 ) of FIGS. 3(B) & (C).), when viewed from the rear. in FIG. 4(B) , the tunnel mold ( 18 ) is shown to have two open slots or channels ( 28 , 29 ), for accommodating the passage a pair of rebars ( 30 , 31 ), through the tunnel mold ( 18 ), without embedding rebars ( 30 , 31 ) in the concrete, which is dispensed into the form cavity ( 23 ) of the tunnel mold ( 18 ). Each of channels ( 28 , 29 ) are further provided with fins ( 32 , 33 ), which extend from the tunnel mold ( 18 ), into the concrete corresponding to the coping ( 10 ), to provent/minimizing the flow of unset concrete from the area of the tunnel mold ( 18 ), corresponding to coping ( 10 ), into channes ( 28 , 29 ), and thereby permitting the formation of a coping ( 10 ) with exposed rebars ( 30 , 31 ). and within the define a hollow insert-like member, which projects into the tunnel mold ( 18 ), which extend from the ironwork array ( 16 ).
FIG. 4(C) depicts a partial cutaway of the tunnel mold ( 18 ) of FIG. 4(B) . The fins ( 32 , 33 ) are preferably asymmetrical, having greater/deeper extension into the concrete of a formed coping at the forward or leading portion of the tunnel mold ( 18 ), and tapering gradually toward the rear of the mold cavity, ultimately withdrawing from the concrete of the formed coping as the tunnel mold ( 18 ) progressively moves forward over ironwork array ( 16 ) of FIGS. 3A & 3B .
FIG. 5(A) depicts a coping ( 10 ) and road pad ( 12 ), which have been formed with the tunnel mold ( 10 ) of FIG. 3(A) to FIG. 3 (F), in accordance the slip forming process of this invention. As is evident in FIG. 5(A) , the coping ( 10 ) and road pad. ( 12 ) have been slip harmed as a monolithic structure; and, the coping ( 10 ) fully engages the top of the MSE retaining wall ( 4 ), so as to mechanically couple the MSE retaining wall ( 4 ) to the road (road pad ( 12 )). The coping ( 10 ) includes extending rebars ( 30 , 31 ) which can be used to further integrate the coping ( 10 ) with other structural road elements.
FIG. 5(B) depicts a slip formed coping, ( 10 ) and road pad ( 12 ), when viewed from the side of the MSE retaining wall ( 4 ). In FIG. 5(B) , the coping ( 10 ) extends over the top and down the outside of the MSE retaining wall ( 4 ), to the platform., which had been constructed along the side of the MSE retaining wall ( 4 ). In this FIG. 5(B) , the platform ( 20 ) is Shown to have served as a support/form for the base of vertical extension ( 11 ) of coping ( 10 ), and thereby, the position of the platform ( 20 ) relative to the top of the MSE retaning wall ( 4 ), defines the length of the vertical extension ( 11 ) of the coping ( 10 ) proximate to MSE retaining wall ( 4 ).
FIG. 6A depicts a perspective view of the layout of an iron work array ( 50 ) for a retaining wall/barrier wall which has been placed on top of the slip formed bridge coping illustrated in FIG. 5(A) and FIG. 5(B) The extending rebars ( 30 , 31 ) from the slip formed coping ( 10 ) and road pad ( 12 ), having which have been physically connected to iron work array ( 50 ) for retaining wall/barrier wall. FIG 6 B is an enlarged view of the extending rebars ( 30 , 31 ) which have been physically connected to additional reinforcing steel rods. In order to accommodate their physical connection, rebar ( 31 ) has been bent prior to the connection to additional reinforcing steel rods. Accordingly, upon Slip, forming of retaining wall/barrier, it shall be structurally reinforced with both exposed rebars ( 30 , 31 ) from the coping ( 10 ), and the iron work array ( 50 ) intended for its reinforcement. Thus, the retaining wail/barrier wall, once formed, shall be integrated into the slip formed coping ( 10 ).
the foregoing invention has been described m reference to a number of the preferred embodiments of this process for use in the in situ fabrication of concrete structures for highway and bridge construction; and, the resultant concrete structures formed in this process. Both time and space does not permit inclusion all of the potential applications of this process for the formation of monolithic reinforced structures, nor is the invention limited to the concrete and/or rebar reinforcement, Clearly, this process has potential application to the slip formation of reinforced structural shapes having both an embedded reinforcing member and an exposed component Of such reinforcing member. Thus, the scope of this invention is not limited by what has been explicated illustrated and described, but rather defined in the following claims. | A process for slip forming of concrete structures, specifically, concrete structural components, for road and bridge construction. This process has particular application for slip forming of monolithic structures having multiple component/functional parts, wherein the resultant slip formed monolithic, structure has exposed rebars bar the later integration with additional concrete structures arid/or mechanical structural elements, c,g. noise walls, barricades, guard rails and the like. This invention also includes a system adapted for the formation of these unique, monolithic slip formed structures with exposed rebars, including the tunnel mold assembly, which is utilized in this slip forming process; and, the resultant to slip molded monolithic structural component with exposed rebus. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present disclosure is related to copending U.S. application for Letters Patent titled “Thermo-Electro-Acoustic Engine And Method Of Using Same”, Ser. No. 12/533,839, filed on the same filing date and assigned to the same assignee as the present application, and further which, in its entirety, is hereby incorporated herein by reference.
BACKGROUND
[0002] The present disclosure is related to thermoacoustic devices, and more specifically to a thermoacoustic device employing an acoustic energy converter and electrical impedance network in place of selected portions of an acoustic impedance network.
[0003] The Stirling cycle is a well-known 4-part thermodynamic process, typically operating on a gas, to produce work, or conversely to effect heating or refrigeration. The 4 parts are: isothermal expansion, isochoric heat extraction, isothermal compression, and isochoric heat addition. The process is closed, in that the gas remains within the system at all times during the cycle.
[0004] One device that takes advantage of the Stirling cycle is the Stirling refrigerator. A typical Stirling refrigerator has one or more mechanical pistons, which control the heating/expansion and cooling/contraction of a contained gas as part of the Stirling cycle. Expansion of the gas as part of the Stirling cycle serves to cool a load. An element, typically called a regenerative heat exchanger or regenerator, increases the refrigerator's thermal efficiency. Devices of this type are often complex, involve seals, pistons, etc., and require regular maintenance.
[0005] Related types of refrigeration devices are thermoacoustic refrigerators. These devices share some fundamental physical properties with Stirling refrigerators, namely a contained gas which approximates a Stirling cycle. However, a thermoacoustic refrigerator differs from a Stirling refrigerator in that acoustic energy drives a temperature differential for extracting heat from the load. Unlike conventional Stirling refrigerators, the gas within a thermoacoustic refrigerator does not travel significantly within the body structure. Rather, the pressure wave propagates through the gas and the Stirling cycle takes place locally inside the regenerator.
[0006] Thermoacoustic refrigerators may operate with either substantially standing wave or traveling wave acoustic phasing in the regenerator. Standing-wave devices are known to be less efficient than traveling-wave devices.
[0007] FIG. 6 is a cross-sectional representation of one example 30 of known traveling-wave thermoacoustic refrigerator designs, known as an orifice pulse-tube refrigerator. As is typical, device 30 comprises a hollow, tubular, body structure 32 having a regenerator 34 located therein. Regenerator 34 is often simply a metal mesh or matrix. Regenerator 34 is proximate a first heat exchanger 36 , generally a “hot” or “ambient” exchanger often at room temperature, at a first end thereof and a second heat exchanger 38 , generally a “cold” exchanger, at the opposite end thereof. A third heat exchanger 39 , generally at hot or ambient temperature, is typically present. An acoustic impedance network 40 is provided at one end of body structure 32 . A motor and piston 42 is provided at the end of body structure 32 opposite acoustic impedance network 40 . A pressurized gas is sealed within body structure 32 . Acoustic energy in the form of a pressure wave generated by motor and piston 42 subjects the gas to periodic compression and expansion within regenerator 34 . Under favorable conditions, the gas effectively undergoes an approximate Stirling cycle in the regenerator. This induces a temperature differential across the regenerator, i.e., between the hot and cold heat exchangers. Heat transfer may then be obtained between the gas and the heat exchangers, such that heat may be removed from the “cold” heat exchanger.
[0008] The acoustic impedance network 40 sets the relative phasing between the pressure and velocity waves so that the gas in contact with the regenerator approximates a Stirling cycle. This creates the thermal gradient between the “cold” and “hot” heat exchangers. However, in a pulse-tube refrigerator, no power is recovered in the gas expansion portion of the cycle. Therefore, the theoretical maximum efficiency of typical pulse-tube refrigerators is limited in comparison with that of Stirling refrigerators.
[0009] There are numerous other examples of Stirling and thermoacoustic refrigerators known in the art. U.S. Pat. No. 7,263,837 to Smith, U.S. Pat. No. 7,240,495 to Symko et al., and U.S. Pat. No. 6,804,967 also to Symko et al. illustrate several examples. Each of these U.S. patents is incorporated herein by reference. However, each of these examples presents its own set of disadvantages. One disadvantage of certain prior art devices is the dissipation of power in the acoustic impedance network, limiting their maximum theoretical efficiency. As the relative amount of power lost is greater with higher cold temperatures, this has inhibited the usefulness of thermoacoustic refrigerators for near-room-temperature applications. Another disadvantage of some prior art devices is the relatively large size of the acoustic impedance network. The size is a disadvantage for many applications, where a compact device is required.
SUMMARY
[0010] Accordingly, the present disclosure is directed to an efficient traveling wave thermoacoustic refrigerator. One characteristic of the refrigerator disclosed herein is that the device recovers the acoustic power at the cold heat exchanger. Another characteristic is the use of electromechanical elements and electrical circuitry to effect this recovery and the reuse of the recovered energy to improve the efficiency of the device.
[0011] The refrigerator consists of a body housing a regenerator, two heat exchangers with one on each side of the regenerator, two electroacoustic transducers with one on each end of the body opposite one another relative to the regenerator, and an external electrical network which serves to control the motion of the two transducers. Thus, useful thermal energy can be coupled to/from a load. The refrigerator may also contain a third heat exchanger separated from the cold heat exchanger by a length of the body.
[0012] According to one aspect of the disclosure, acoustic energy is introduced to the device by an electroacoustic transducer, referred to herein as the “acoustic source.” A portion of this energy is used to thermoacoustically cool a load, as is described below. The acoustic energy that remains drives a second electroacoustic transducer, the “acoustic energy converter,” and is converted to electrical energy. This energy is fed back through an electrical impedance network to help drive the acoustic source.
[0013] According to this aspect, an electrical impedance network replaces the acoustic impedance network and, in addition, effects power recovery. For this reason, the device disclosed herein is referred to as a thermo-electro-acoustic refrigerator. The electrical impedance network may take a variety of forms, and comprise a variety of passive and/or active elements.
[0014] The acoustic source drives a pressure wave within a closed body structure containing a gas. The closed body structure further contains a regenerator, and first and second heat exchangers, through which the pressure wave may travel. Located opposite the acoustic source relative to the regenerator is the acoustic energy converter, which converts the remaining pressure wave to an electrical signal. The third heat exchanger, if present, serves to control the temperature of the gas at a distance from the cold heat exchanger.
[0015] The electrical energy provided by the acoustic energy converter is output from the refrigerator and fed back to the acoustic source, subjected to an appropriate phase delay and impedance such that power transfer to the acoustic source is maximized. Furthermore, the electrical network, in combination with the electroacoustic transducers and acoustic elements, sets the impedance and phasing of the acoustic waves in the region of the regenerator.
[0016] Accordingly, a portion of the acoustic energy within the body is converted to electrical energy and fed back to the acoustic source to generate additional acoustic energy. At least a portion of this captured acoustic energy is energy that would otherwise be lost in a prior art acoustic impedance network.
[0017] The gas in the region of the regenerator is subjected to an approximate Stirling cycle, creating a thermal gradient in the regenerator. This thermal gradient results in heat addition to a “hot” heat exchanger adjacent the regenerator on a first side thereof, and extraction of heat from a “cold” heat exchanger adjacent the regenerator on a second side thereof opposite said first side.
[0018] The above is a summary of a number of the unique aspects, features, and advantages of the present disclosure. However, this summary is not exhaustive. Thus, these and other aspects, features, and advantages of the present disclosure will become more apparent from the following detailed description and the appended drawings, when considered in light of the claims provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] In the drawings appended hereto like reference numerals denote like elements between the various drawings. While illustrative, the drawings are not drawn to scale. In the drawings:
[0020] FIG. 1 is a schematic illustration of a first embodiment of a thermo-electro-acoustic refrigerator according to the present disclosure.
[0021] FIG. 2 is a schematic illustration of an impedance circuit for use in thermo-electro-acoustic refrigerator of FIG. 1 .
[0022] FIG. 3 is a graph of pressure versus volume illustrating the Stirling cycle as approximated by the gas in the thermo-electro-acoustic refrigerator of FIG. 1 .
[0023] FIG. 4 is a schematic illustration of a power combiner for use in the thermo-electro-acoustic refrigerator of FIG. 1 .
[0024] FIG. 5 is a schematic illustration of a series arrangement of a thermo-electro-acoustic engine and refrigerator according to one embodiment disclosed herein.
[0025] FIG. 6 is an illustration of a thermoacoustic refrigerator of a type known in the art.
DETAILED DESCRIPTION
[0026] With reference to FIG. 1 , there is shown therein a first embodiment 10 of a thermo-electro-acoustic refrigerator according to the present disclosure. Refrigerator 10 comprises a generally tubular body 12 . The material from which body 12 is constructed may vary depending upon the application of the present invention. However, body 12 should generally be thermally and acoustically insulative, and capable of withstanding pressurization to at least several atmospheres. Exemplary materials for body 12 include stainless steel or an iron-nickel-chromium alloy.
[0027] Disposed within body 12 is regenerator 14 . Regenerator 14 may be constructed of any of a wide variety of materials and structural arrangements which provide a relatively high thermal mass and high surface area of interaction with the gas but low acoustic attenuation. A wire mesh or screen, open-cell material, random fiber mesh or screen, or other material and arrangement as will be understood by one skilled in the art may be employed. The density of the material comprising regenerator 14 may be constant, or may vary along its longitudinal axis such that the area of interaction between the gas and wall, and the acoustic impedance, across the longitudinal dimension of regenerator 14 may be tailored for optimal efficiency. Details of regenerator design are otherwise known in the art and are therefore not further discussed herein.
[0028] Adjacent each lateral end of regenerator 14 are first and second heat exchangers 16 , 18 , respectively. Heat exchangers 16 , 18 may be constructed of any of a wide variety of materials and structural arrangements which provide a relatively high efficiency of heat transfer from within body 12 to a transfer medium. In one embodiment, heat exchangers 16 , 18 may be one or more tubes for carrying therein a fluid to be heated or cooled. The tubes are formed of a material and sized and positioned to efficiently transfer thermal energy (heating or cooling) between the fluid therein and the gas within body 12 during operation of the refrigerator. To enhance heat transfer, the surface area of the tubes may be increased with fins or other structures as is well known in the art. Tubes 52 , 54 permit the transfer of fluid from a thermal reservoir or load external to refrigerator 10 to and from the first and second heat exchangers, respectively. Details of heat exchanger design are otherwise known in the art and are therefore not further discussed herein.
[0029] Optionally, a third heat exchanger 19 may be disposed within one end of body 12 , for example such that heat exchanger 18 is located between third heat exchanger 19 and regenerator 14 . Third heat exchanger 19 may be of a similar construction to first and second heat exchangers 16 , 18 such as one or more tubes formed of a material and sized and positioned to efficiently transfer thermal energy (heating or cooling) between a fluid therein and the gas within body 12 during operation of the refrigerator. Tube 56 permits the transfer of fluid from a thermal reservoir or load external to refrigerator 10 to and from the third heat exchanger 19 .
[0030] An acoustic source 20 is disposed at a first longitudinal end of body 12 , and an acoustic converter 22 is disposed at a second longitudinal end of body 12 opposite to said acoustic source 20 relative to said regenerator 14 . Many different types of devices may serve the function of acoustic source 20 . A well-known moving coil, piezo-electric, electro-static, ribbon or other form of loudspeaker may form acoustic source 20 . A very efficient, compact, low-moving-mass, frequency tunable, and frequency stable speaker design is preferred so that the cooling efficiency of the refrigerator may be maximized.
[0031] Likewise, many different types of devices may serve the function of acoustic converter 22 . A well-known electrostatic, electromagnetic, piezo-electric or other form of microphone or pressure transducer may form acoustic converter 22 . In addition, gas-spring, compliance elements, inertance elements, or other acoustic elements, may also be employed to enhance the function of converter 22 . Again, efficiency is a preferred attribute of acoustic converter 22 so that the cooling efficiency of the refrigerator may be maximized.
[0032] A driver 26 is connected to inputs k, l of a combiner 28 (of a type, for example, illustrate in FIG. 4 ). Driver 26 is an audio driver capable of driving acoustic source 20 at a desired frequency and amplitude, as discussed further herein. Outputs of combiner 28 form inputs to a impedance circuit Z 1 , such as circuit 24 , illustrated in FIG. 2 . The outputs a, b of impedance circuit Z 1 form the inputs to acoustic source 20 . Outputs e, f of a second impedance circuit Z 2 , such as circuit 24 , illustrated in FIG. 2 are connected as inputs g, h to combiner 28 . Outputs c, d, from acoustic converter 22 are provided as inputs to the impedance circuit Z 2 . The role of impedance circuits Z 1 , Z 2 , are to match the system impedances so as to drive acoustic source 20 efficiently at a desired frequency and phase. A phase delay circuit (φ(ω) may also be employed to achieve the desired phasing as is well understood in the art.
[0033] With the basic physical elements and their interconnections described above, we now turn to the operation of refrigerator 10 . Initially, a gas, such as helium, is sealed within body 12 . An acoustic wave is established within the gas by acoustic source 20 . This acoustic wave causes the gas to undergo acoustic oscillations approximating a Stirling cycle. This cycle, illustrated in FIG. 3 , comprises a constant-volume cooling of the gas as it moves in the direction from the hot heat exchanger to the cold heat exchanger at stage 1 , isothermal expansion of the gas at stage 2 , constant-volume heating of the gas as it moves in the direction from the cold heat exchanger to the hot heat exchanger at stage 3 , and consequent isothermal contraction of the gas at stage 4 , at which point the gas cools again and the process repeats itself. Remaining energy in the acoustic wave is converted into electrical energy by converter 22 , and fed back as an additional input to acoustic source 20 .
[0034] A temperature gradient is therefore established in regenerator 14 . First heat exchanger 16 becomes a “hot” heat exchanger in that heat energy is extracted from the gas in the refrigerator 10 and rejected by the hot heat exchanger to the fluid therein. Likewise, second heat exchanger 18 becomes a “cold” heat exchanger in that heat energy is extracted from the fluid therein and transferred to the gas contained in refrigerator 10 , and the fluid exits refrigerator 10 colder than it arrived. Cold fluid is thereby available at the output of that heat exchanger, which may be used for extracting heat external to refrigerator 10 . Regenerator 14 serves to store heat energy and greatly improves the efficiency of this heat energy conversion process.
[0035] After the cooling process, a portion of the acoustic energy remains and is incident on converter 22 , which converts a portion of that energy into electric energy. This electric energy is fed back to and helps drive acoustic source 20 via impedance circuits Z 1 and Z 2 . With reference again to FIG. 2 , the values of the electrical components (e.g., R 1-4 , L 1-3 , and C 1-3 ) are chosen such that in conjunction with the mechanical and acoustic components, positive feedback is established to maintain the oscillations at a desired phase, amplitude, and frequency and to maximize power transfer from the converter 22 to the source 20 .
[0036] One benefit of the present disclosure is that the power recovery greatly improves the efficiency of the refrigerator. A further benefit is that electrical components can be more easily tuned than acoustic elements, increasing the simplicity and flexibility of optimization of the device.
[0037] With reference now to FIG. 5 , there is shown therein a system 100 comprised of a combined thermo-electro-acoustic engine portion 102 and thermo-electro-acoustic refrigerator portion 104 operating in series. A combiner 106 provides inputs to a first impedance circuit Z 1 that in turn provides electrical input to an acoustic source of engine portion 102 . A second impedance circuit Z 2 receives the electrical output of a converter of engine portion 102 , and provides same to splitter 108 . Engine portion 102 , combiner 106 , impedance circuits Z 1 and Z 2 , and splitter 108 may be, for example, substantially as described in the aforementioned copending U.S. patent application Ser. No. 12/533,839. A combiner 110 provides electrical input to an impedance circuit Z 5 which in turn provides electrical input to an acoustic source of refrigerator portion 104 . An impedance circuit Z 6 receives the electrical output of a converter of refrigerator portion 104 . An optional splitter 112 may receive the output of impedance circuit Z 6 . Refrigerator portion 104 , combiner 110 , impedance circuits Z 5 and Z 6 , and splitter 112 may be, for example, substantially as described herein above. Impedance circuits Z 3 and Z 4 as well as phase delay φ(ω) 1 condition the electrical output of splitter 108 such that it is input to combiner 110 with a desired frequency, amplitude, and phase. Likewise, impedance circuits Z 7 and Z 8 as well as phase delay φ(ω) 2 condition the electrical output of splitter 112 (or optionally the output directly from the converter of refrigerator portion 104 ) such that it is input to combiner 106 with a desired frequency, amplitude, and phase. Impedance circuits Z 3 , Z 4 , Z 7 , and Z 8 may be such as illustrated in FIG. 2 , circuit 24 .
[0038] In operation, system 100 uses a thermal gradient established within the regenerator of engine portion 102 to create an acoustic wave within engine portion 102 . A portion of that wave is converted into electrical energy by the converter of engine portion 102 , as described in more detail in the aforementioned U.S. patent application Ser. No. 12/533,839. At least a portion of that electrical energy is provide by splitter 108 to impedance circuits Z 3 and Z 4 as well as phase delay φ(ω) 1 and ultimately forms the input driving energy for the acoustic source of refrigerator portion 104 . Refrigerator portion 104 is operated as described above such that heat is extracted from the fluid within the “cold” heat exchanger. A cold fluid is thereby available at the output of that heat exchanger, which may be used for extracting heat external to refrigerator portion 104 . Excess electrical energy is converted by the converter of refrigerator 104 , and provided via an impedance circuit Z 6 , splitter 112 , impedance circuits Z 7 and Z 8 , and phase delay φ(ω) 2 to the input of combiner 106 , and ultimately provides input energy to the acoustic source of engine portion 102 to amplify the acoustic wave therein, as described in the aforementioned U.S. patent application Ser. No. 12/533,839. In addition, electrical energy can be provided to system 100 , for example to drive engine portion 102 and/or refrigerator portion 104 , from a source external to system 100 , by applying same at combiners 106 , 110 respectively, as described herein and in the aforementioned U.S. patent application Ser. No. 12/533,839. Furthermore, electrical energy can be extracted from system 100 , for example to do work external to system 100 , by tapping same at splitters 108 , 112 respectively, as described herein and in the aforementioned U.S. patent application Ser. No. 12/533,839.
[0039] As an alternative to system 100 , the output of a thermo-electro-acoustic refrigerator, for example system 10 as described above, may receive as its inputs k, l, the output from a post-converter splitter of a thermo-electro-acoustic engine of the type described and disclosed in the aforementioned U.S. patent application Ser. No. 12/533,839. In one embodiment of this alternative, the thermo-electro-acoustic refrigerator receives no other electrical input.
[0040] No limitation in the description of the present disclosure or its claims can or should be read as absolute. The limitations of the claims are intended to define the boundaries of the present disclosure, up to and including those limitations. To further highlight this, the term “generally” may occasionally be used herein in association with a claim limitation (although consideration for variations and imperfections is not restricted to only those limitations used with that term). While as difficult to precisely define as the limitations of the present disclosure themselves, we intend that this term be interpreted as “to a large extent”, “nearly”, “within technical limitations”, and the like.
[0041] Furthermore, while a plurality of preferred exemplary embodiments have been presented in the foregoing detailed description, it should be understood that a vast number of variations exist, and these preferred exemplary embodiments are merely representative examples, and are not intended to limit the scope, applicability or configuration of the disclosure in any way. For example, the above description is in terms of a tubular structure with coaxially arranged elements. However, other physical arrangements may be advantageous for one application or another, such as a curved or folded body, locating either or both source and converter non-coaxially (e.g., on a side as opposed to end of the body), etc., and are contemplated by the present description and claims, Thus, various of the above-disclosed and other features and functions, or alternative thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications variations, or improvements therein or thereon may be subsequently made by those skilled in the art which are also intended to be encompassed by the claims, below.
[0042] Therefore, the foregoing description provides those of ordinary skill in the art with a convenient guide for implementation of the disclosure, and contemplates that various changes in the functions and arrangements of the described embodiments may be made without departing from the spirit and scope of the disclosure defined by the claims thereto. | A thermo-electro-acoustic refrigerator comprises a sealed body having a regenerator, hot and cold heat exchangers, an acoustic source, and an acoustic energy converter. A first drive signal drives the acoustic source to produce an acoustic pressure wave in the region of the regenerator. The converter converts a portion of the acoustic pressure into a second drive signal which is fed back to and further drives the acoustic source. The pressure wave produces a thermal gradient between the cold and hot heat exchangers, permitting heat extraction (cooling) within at least one of the heat exchangers. The resonant frequency of the refrigerator can be controlled electronically, and is not limited by the physical structure of the refrigerator body and its elements. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application No. 60/550,955, filed Mar. 4, 2004. The entire disclosure of that application is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
This invention relates to fabrics.
BACKGROUND OF THE INVENTION
Accurate measuring, marking, and cutting of fabric is important for many applications, including upholstery of furniture and the fabrication of garments, draperies linens and quilts. Factors which need to be considered include the grain of the fabric (lines parallel to the selvedge being referred to as lengthwise straight of grain, and lines at right angles to the selvedge being referred to as crosswise straight of grain), and, in appropriate fabrics, the position and repeat of decorative patterns, and the up-down direction, particularly the nap direction.
Modern garment cutting patterns are generally supplied with instructions, e.g. directional arrows on the pattern, how the cutting pattern should be positioned on the fabric, for example relative to the straight of grain. In present practice, in order to identify the straight of grain at any point on a conventional fabric, one must either reference the selvedge, and measure and mark the straight of grain at that point, or, if there is no selvedge, find another way of determining the straight-of-grain. Identification of other fabric characteristics, e.g. a nap or lay direction, or the position and repeat of a decorative pattern, similarly requires careful and repetitive work. As a result, a significant percentage of sewn items arrive on the market with visible problems resulting from failure to correctly account for fabric characteristics such as grain, nap, decorative pattern and repeat of decorative pattern.
U.S. Pat. Nos. 4,869,726 (Linda et al) and 6,839,971 (Schafer et al) describe attempts to mitigate the problems outlined above.
SUMMARY OF THE INVENTION
This invention relates to a fabric having a procedure map thereon, the procedure map comprising at least one set of machine-make markings which identifies one or more of certain fabric characteristics, namely lengthwise straight of grain, crosswise straight of grain, true bias, position of a decorative pattern, repeat of a decorative pattern, up-down direction (e.g. nap direction), fabric width measured perpendicular to a selvedge, and fabric length measured parallel to a selvedge.
In a first preferred aspect, this invention provides a roll of woven fabric, the fabric having two selvedges and a procedure map thereon, the procedure map comprising at least one set of machine-made markings which
(a) is at many points across the breadth and throughout the length of the fabric, (b) identifies at least one characteristic of the fabric, said at least one characteristic being selected from the group consisting of lengthwise straight of grain, crosswise straight of grain, true bias, position of a decorative pattern, repeat of a decorative pattern, up-down direction, fabric width measured perpendicular to a selvedge, and fabric length measured parallel to a selvedge, (c) directly contacts fibers of the fabric, and (d) is not part of a decorative pattern.
In a second preferred aspect, this invention provides a method of producing a roll of woven fabric according to the first aspect of the invention, the method comprising the steps of
(A) using a machine to impart the procedure map to a run of the fabric; and (B) after step (A), rolling up the run of fabric having the procedure map thereon.
In one embodiment of the second preferred aspect of the invention, the procedure map is imparted to the fabric as part of a continuous process which includes weaving the fabric. In one example of such an embodiment, the procedure map is woven into the fabric at the same time as the fabric is being woven. In another example of such an embodiment, the fabric is woven and the procedure map is imparted to the woven fabric immediately thereafter. In another embodiment of the second preferred aspect of invention, the run of fabric is provided by unrolling an existing roll of fabric.
In a third preferred aspect, this invention provides a method of detecting a characteristic of a fabric, the method comprising
(A) providing a roll of fabric according to the first preferred aspect of the invention; (B) unrolling a run of fabric from the roll; and (C) inspecting the run of fabric with a machine which detects one or more of said at least one set of machine-made markings.
In one embodiment of the third preferred aspect of the invention, the method further comprises, simultaneously with step (C), or after step (C),
(D) using a machine to cut a relatively small piece of fabric from the run of fabric, the cutting being carried out according to a cutting pattern which is referenced to the procedure map on the run of fabric.
In a fourth preferred aspect, this invention provides a method of cutting a length of fabric from a roll of fabric, the fabric
(a) being a woven fabric having two selvedges, and (b) having on it a procedure map comprising at least one set of machine-made markings which (i) are on one of the selvedges, (ii) identify fabric length along the selvedge, and (iii) are sequentially numbered;
the method comprising cutting the length of fabric from the roll of fabric according to a cutting pattern which is referenced to the sequentially numbered markings.
In a fifth preferred aspect, this invention provides a fabric which has a procedure map thereon, the procedure map comprising at least one set of machine-made markings which
(a) is at many points across the breadth and throughout the length of the fabric, (b) identifies at least one characteristic of the fabric, said at least one characteristic being selected from the group consisting of lengthwise straight of grain, crosswise straight of grain, true bias, position of a decorative pattern, repeat of a decorative pattern, up-down direction, fabric width measured perpendicular to a selvedge, and fabric length measured parallel to a selvedge, (b) directly contacts fibers of the fabric, (c) is not part of a decorative pattern;
said at least one set of machine-made markings comprising a set of markings selected from the group consisting of
(1) a set of markings which are invisible to the naked eye, (2) a set of markings which can be removed by washing, (3) a set of markings which comprise magnetic or magnetized threads, (4) a set of markings comprising a pigment or thread visible only under ultraviolet light, (5) a set of lengthwise straight of grain markings which are equally spaced from each other, (6) a set of crosswise straight of grain markings which are equally spaced from each other, (7) on a fabric having a bias, a set of markings which identifies the true bias of the fabric, (8) on a fabric having an up-down direction, a set of markings which identifies the up-down direction of the fabric, (9) on a fabric having a decorative pattern, a set of markings which identifies the position and/or the repeat of the decorative pattern, (10) on a fabric having two selvedges, a set of lengthwise straight of grain markings which identify fabric widths perpendicular to a selvedge, at least one of the markings identifying a position halfway across the width, or a position quarter-way across the width or a position one third-way across the width, and (11) on a fabric having two selvedges, a set of markings which (i) are on at least one of the selvedges, (ii) identify fabric length along one of the selvedges, and (iii) are sequentially numbered.
In preferred embodiments, this invention can provide one or more of the following functions:—
(a) a reduction in the time involved in determining the straight-of-grain at virtually any point on the fabric; (b) a reduction in waste in the production of garments, draperies, linens, upholstery, quilts, and other sewn goods by providing immediate reference for the straight-of-grain and other orientation marks; (c) the production of a higher quality finished product through precision grain orientation; (d) a reduction in the need for hand measuring, and marking, by providing pre-measured markings already on the fabric, thus saving time; (e) providing a means for accurate bias orientation consistently available to assure the proper drape by allowing the adjustment of the degree of bias desired; (f) manual or automatic detection of straight-of-grain and other markings, depending on the use of the fabric; (g) provision of an accurate cutting line through a grid of lengthwise and crosswise straight-of-grain lines, thus saving time at the retail level, and helping customers visually estimate yardage; (h) increasing the efficiency of fabric use by enabling the use of fabric not having a selvedge; (i) determination of the lay or nap orientation in the manual or automatic use of fabric via directional markings to benefit those working with fabric such as velour or velvet and the like which have a nap orientation, or those fabrics with an unidirectional decorative pattern; and (j) enabling the scaling up and down of a grid of lengthwise and crosswise straight of grain markings to aid in the processes of quilting, by either enlarging or narrowing the distance between markings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 show a fabric having a procedure map thereon, with FIG. 1 showing one part of the procedure map and FIG. 2 showing the other part of the procedure map.
DETAILED DESCRIPTION OF THE INVENTION
The form of the various markings can be the same or different. For example, each of the markings in a particular set of markings (for example the straight of grain markings) can be a continuous line or a line which is discontinuous (e.g. a line made up of dashes or dots); or can be a number of arrows (e.g. to identify the nap or lay direction, in which case the precise positioning of the arrows may not be important); or can be a number of aligned symbols (e.g. to identify the position and/or repeat of a decorative pattern). In preferred embodiments, the markings directly contact fibers of the fabric. In some embodiments, the markings are at many points across the breadth and throughout the length of the fabric and/or cover substantially the whole of the fabric. In some embodiments, the straight of grain markings are equally spaced from each other. The fabric optionally comprises a decorative pattern. When the fabric comprises a decorative pattern, the markings are not part of the decorative pattern.
Specific examples of sets of markings include one or more of the following:—
(1) a set of markings which are invisible to the naked eye, (2) a set of markings which can be removed by washing, (3) a set of markings which comprise magnetic or magnetized threads, (4) a set of markings comprising a pigment or thread visible only under ultraviolet light, (5) a set of lengthwise straight of grain markings which are equally spaced from each other, (6) a set of crosswise straight of grain markings which are equally spaced from each other, (7) on a fabric having a bias, a set of markings which identifies the true bias of the fabric, (8) on a fabric having an up-down direction, a set of markings which identifies the up-down direction of the fabric, (9) on a fabric having a decorative pattern, a set of markings which identifies the position and/or the repeat of the decorative pattern, (10) on a fabric having two selvedges, a set of lengthwise straight of grain markings which identify fabric widths perpendicular to a selvedge, at least one of the markings identifying a position halfway across the width, or a position quarter-way across the width or a position one third-way across the width, and (11) on a fabric having two selvedges, a set of markings which (i) are on at least one of the selvedges, (ii) identify fabric length along one of the selvedges, and (iii) are sequentially numbered.
For example, in some embodiments, the fabric has a first side having a decorative pattern thereon and an opposite second side, and the procedure map comprises a set of markings which (i) is visible only on the second side and (ii) identifies one or both of (a) the position of the decorative pattern, and (b) the repeat of the decorative pattern.
The markings are optionally such that they can be easily removed after they have served their purpose; for example they can be composed of an easily washable dye or a reactive dye. The markings are optionally visible only on one surface of a fabric, for example on the “back” side of the fabric, e.g. on the opposite side of a fabric comprising a decorative pattern intended to be viewed on the front side of the fabric. In some embodiments, the surface carrying the markings becomes the inside surface of a finished product, e.g. so that the markings cannot be seen in the finished product. In some embodiments, any markings on a finished product which remain visible to the naked eye are rendered invisible to the naked eye.
In some embodiments, the markings of the procedure map are visible to the naked eye (and can, therefore, also be detected by a suitable machine). In other embodiments, the markings are not visible to the naked eye, but can be detected by a suitable machine. The markings can for example be visible to the naked eye under ultraviolet light.
In some embodiments, the fabric is produced, e.g. by weaving, and the markings are imparted to the fabric, in a single continuous operation. Alternatively, the markings can be imparted to an existing fabric, e.g. a woven fabric, in a separate operation. In either case, an automated dye and marking system can optionally be used. Preferably, the result of the process is a roll of fabric having the markings throughout the length of the fabric on the roll.
In one embodiment, straight of grain markings are introduced during production of a woven fabric by including warp and/or woof yarns which can be distinguished from the other yarns of the fabric, e.g. by including yarns which are invisible to the naked eye, but detectable by a suitable machine.
Referring now to the drawings, FIGS. 1 and 2 show a bolt of fabric 10 having a selvedge 15 at each edge. FIG. 1 shows equispaced lengthwise straight of grain markings 11 which extend the whole length of fabric; equispaced crosswise straight of grain markings which extend across the whole breadth of the fabric; and bias markings 13 showing the true bias of the fabric. FIG. 2 shows markings 16 showing the lengthwise decorative pattern repeat; markings 17 showing the crosswise decorative pattern repeat; markings 18 showing premeasured widths (center, ¼ and ⅓); and yardage measurements 19 on the selvedges. | A fabric having a procedure map which enables identification, by a machine or by a person, of one or more of the fabric characteristics, e.g. the straight of grain, true bias, up-down direction, decorative pattern characteristic, distance from a selvedge or distance along a selvedge. The procedure map facilitates accurate measuring, marking, and cutting of fabric e.g. for furniture upholstery, garments, draperies, linens and quilts. | 3 |
I. FIELD OF THE INVENTION
[0001] The present invention relates generally to gesture- and expression-based authentication, sensed either in the visible and/or IR spectrum.
II. BACKGROUND OF THE INVENTION
[0002] User input sequences such as passwords are used to unlock computing device behaviors and controls. Examples include unlocking the computing device for operation. Typically, only one input mode is used, e.g., only a text entry or only a biometric input is used to unlock a computer.
[0003] As understood herein, face recognition may also be used as a password-type mechanism, but as also understood herein, the use of face recognition can result in an unwanted auto-login in the presence of others among whom the authorized user may not want automatic authorization to occur. Also, a photo of the user may be used by unauthorized people to gain access in the absence of the user.
SUMMARY OF THE INVENTION
[0004] Accordingly, a computer includes a processor and a computer readable storage medium accessible to the processor and bearing instructions embodying logic comprising permitting a user to select at least first input mode with associated first input parameter. The first input parameter is face recognition in combination with infrared (IR) sensing, face recognition in combination with a user-defined facial expression, image of a physical gesture established by the user, or a combination thereof. A behavior of the computer is executed only when at least one subsequent input of the first input parameter is received as authentication.
[0005] In some examples, the first input parameter is face recognition in combination with infrared (IR) sensing, and the behavior of the computer is executed only responsive to receiving an image matching the face combination and sensing an IR signal at least equal in magnitude to a threshold magnitude. In other examples, the first input parameter is face recognition in combination with a user-defined facial expression, and the behavior of the computer is executed only responsive to receiving an image matching the face combination and also matching the facial expression. In still other examples, the first input parameter is image of a physical gesture established by the user, and the behavior of the computer is executed only responsive to receiving an image matching the image of a physical gesture.
[0006] If desired, the instructions can further include permitting the user to select a second input mode with associated second input parameter, with the first input mode being different from the second input mode. The behavior of the computer is executed only when at least one subsequent input of the first input parameter and second input parameter are received in the first and second input modes in an order specified by the user. A user may be allowed to select the behavior.
[0007] In another aspect, a method includes presenting, on a computer display, a sequence of user interfaces to permit a user to define at least a first input mode with a respective first input value to establish an authentication protocol to enable a computer behavior. The method executes the computer behavior only when the input value is received. The first input value is face recognition in combination with infrared (IR) sensing, face recognition in combination with a user-defined facial expression, a physical gesture established by the user, or a combination thereof.
[0008] In another aspect, a computing device has a processor, a display coupled to the processor, and first and second input devices coupled to the processor that are of different genre from each other. The processor receives a first input mode value from the first input device and a second input mode value from the second input device. The processor then determines whether the first and second values match user-defined values, and only if a match is found, executes a computer behavior. At least one input mode value is established by an image of a gesture, and/or face recognition plus IR sensing satisfying a threshold to ensure a live person is being imaged for authentication, and/or face recognition plus a particular facial expression.
[0009] The details of the present invention, both as to its structure and operation, can best be understood in reference to the accompanying drawings, in which like reference numerals refer to like parts, and in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic perspective view of a computing device which can employ present principles;
[0011] FIG. 2 is a flow chart of example overall logic;
[0012] FIG. 3 shows a sequence of screen shots illustrating example user interfaces that may be presented on the computing device to allow a user to define a multi-modal input sequence; and
[0013] FIG. 4 is an example screen shot of a user interface allowing the user to define which computer behavior is governed by the multi-modal input sequence.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring initially to FIG. 1 , a device 10 that in the embodiment shown includes a portable lightweight housing 12 has a display 14 such as a touch screen display and a key input device 16 such as a keypad. In some embodiments an infrared (IR) sensor 18 may also be provided on the housing 12 .
[0015] The device 10 may be implemented in one example embodiment by a smart phone. In other embodiments, the device 10 may be TV, tablet computer, laptop computer, or home automation computer for operating a door, sensing a person's presence to establish setting for lighting and music, etc. Yet again, the device 10 may be an access door for medical hospital applications or for defense industry security access. Indeed, the device 10 may be established by a banking computer such as but not limited to an ATM, transaction kiosk, mobile phone refill station, etc.
[0016] The key input device 16 and IR sensor 18 typically provide input signals to one or more processors 20 (only one processor shown) in the housing 12 . The processor 20 controls the display 14 to present a demanded image and, when the display 14 is a touch screen display, the processor 20 receives input from the display 14 .
[0017] The processor 20 can access one or more tangible computer readable storage media 22 to read and write data thereto and to execute logic stored thereon. The medium 22 shown in FIG. 1 may be implemented by disk storage, solid state storage, etc.
[0018] FIG. 1 shows various additional sources of input signals to the processor 20 that may be supported on the housing 12 . For example, a microphone 24 may provide voice input to the processor 20 , while a camera 26 may provide still and/or moving image input to the processor 20 .
[0019] When the device 10 is implemented as a smart phone a wireless telephony transceiver 28 may be supported on the housing 12 for enabling voice and/or data calls to be made using the device 10 . The telephony transceiver 28 may be, without limitation, a global system for mobile communication (GSM) transceiver or code division multiple access (CDMA) transceiver or orthogonal frequency division multiplexing (OFDM) transceiver or satellite phone transceiver or variants thereof.
[0020] If desired, a wireless network transceiver 30 may also be provided on the housing 12 to permit network communication using the device 10 . The transceiver 30 may be, without limitation, a Bluetooth transceiver, Wi-Fi transceiver, or other appropriate transceiver.
[0021] FIG. 2 shows example logic that may be implemented by the processor 20 . A set-up screen may be presented on the display 14 at block 36 to enable a user to select to define what specific input modes and values associated therewith are to be used for purposes discussed below. The user's selection to define the modes and values are received at block 38 . At block 40 , the processor 20 causes the display 14 to present a user interface, an example of which is discussed below, on the display 14 to allow the user to define a multi-mode with corresponding multi-value protocol for enabling a user-selected computer behavior. This behavior is unlocked at block 42 subsequently, and only when the user-defined protocol is input as specified by the user, i.e., only when input modal values match the user-defined values, such that only if a match is found, the computer behavior is unlocked.
[0022] FIG. 3 gives an example set of user interface screens that may be presented on the display 14 in the logic of block 40 of FIG. 2 . The screen 44 instructs the user to select a first mode. In the example shown, the first mode may be selected from a list that includes voice recognition, potentially with a corresponding cadence, keypad entry, gesture entry, and image entry, potentially with IR and/or expression augmentation discussed further below.
[0023] Assuming the user selects voice recognition, the screen 46 may be presented, in which the user is instructed to speak into the microphone 24 the desired value or parameter of the voice mode component, e.g., a word or word string. The parameters may include specific words and/or cadence, timing, and/or more advanced voice recognition parameters such as voice prints, voice-to-text recognition, etc.)
[0024] The processor 20 can execute voice recognition software to convert the signal from the microphone to data values that are stored on the medium 22 . The values are associated with “voice mode”, i.e., with a requirement that the values be received subsequently from the microphone 24 .
[0025] Because multiple modes may be defined a screen 48 may next be presented on the display 14 , instructing the user to select a second mode. Note that the mode selected as the first mode (in this example, voice input) need not appear on the screen 48 , but only the remaining available modes. Assuming the user selects “keypad” the screen 50 may appear, instructing the user to input the desired key sequence as corresponding values for the keypad mode. The values are stored on the medium 22 and correlated to the keypad 16 .
[0026] If desired, the user may be given the opportunity to select more than two modes. Or, the user may have selected “gesture” or “face” initially. In any case, a further screen 52 is presented for selection of a third mode. If the user selects “gesture” at 44 , 48 , or 52 , the UI 54 is presented to instruct the user to make a gesture, for example, a hand wave, hand signal, or other gesture/motion. The image of the gesture is captured by the camera 26 and sent to the processor 20 , which stores it on the medium 22 .
[0027] A screen 56 can be presented responsive to a user selecting :face recognition” from 44 , 48 , or 52 , instructing the user to take a picture of the desired image, e.g., the user's face, which is stored in memory and associated with the camera 26 . The image can include still images (pattern, optical character recognition, etc.), video image recognition (which may include movement detection, color pattern analysis, etc.) The user is also given the option of turning IR detection on or off using a toggle selection in the embodiment shown. Moreover, the user may be given the option of electing to have not just recognition of the user's face as an authentication mode, but also recognition of a particular expression on the user's face.
[0028] If IR detection is turned on, this means that subsequent authentication is indicated only by both a face recognition match and a sensed IR level by the IR sensor 18 that meets a threshold which is empirically established to indicate the presence of a live human within a few feet of the camera. This is to avoid the above-noted problem with holding a photograph of the user in front of the camera when the user is otherwise absent.
[0029] Additionally, when “expression” is selected, the expression on the user's face within, e.g., the next few seconds as imaged by the camera must match the expression in a subsequent image of the user intended to be used for authentication. For example, the user can smile and close one eye as an expression-based face recognition password, and subsequent images of the user's face that are intended for authentication will cause successful authentication only if the subsequent images show the user smiling and closing one eye (or repeating whatever expression was originally established). Other examples of expressions include eyes looking left or right or up or down, a frown, closed eyes, a grimace, a tongue sticking out, etc.
[0030] Once the mode sequence and values have been defined by the user, FIG. 4 shows that a screen 58 may be presented to enable the user to define the purpose for which subsequent input of the defined mode sequence and values is to be used. For example, the user may elect to require input of the defined protocol to logon to the computer, or to connect to a network. Other computer behaviors that can be invoked only upon input of the user-defined multi-modal protocol include a transition from a device state with the low power consumption hibernation mode with security device lock engaged to another state with active use of the application software or the network service access functions.
[0031] As an example of input sequences that can be used to unlock user-defined computer behaviors, a simple voice (audio) signal from the microphone 24 may first be required and if the input signal matches the user-defined value from block 40 in FIG. 2 , the second mode is triggered. If the second mode is image detection, the camera 26 is then activated and input from the camera is tested against the user-defined image value stored at block 40 in FIG. 2 . This may be done by activating an embedded camera. The user-defined behavior that is associated with the multi-modal protocol is enabled only when the input mode values match the user-defined values that were established at block 40 .
[0032] While the particular GESTURE- AND EXPRESSION-BASED AUTHENTICATION is herein shown and described in detail, it is to be understood that the subject matter which is encompassed by the present invention is limited only by the claims. | A user can define a gesture-based input mode with respective input value to establish an authentication protocol to unlock a computer or govern other computer behavior. As an alternative or in addition, the user can define a second input mode based on face recognition plus IR sensing satisfying a threshold to ensure a live person is being imaged for authentication, and/or face recognition plus a particular facial expression such as a smile and wink. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not Applicable
FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT
Not Applicable
REFERENCE TO COMPUTER PROGRAM
Not Applicable
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the design of reed valves.
2. Background of the Invention
A reed valve consists of a reed 1 a ( FIG. 1 ), generally designed to be a long slender cantilever made from metal or plastic, flat and rectangular in shape. The fixed end 1 b of the flat face is attached to a stationary surface 1 c , whereas the opposite free end 1 d is free to deflect, primarily about the thinner cross-sectional axis 1 h of the reed. The free end of the reed covers a port 1 e also located also on a stationary surface, hereby referred to as a ported surface 1 f . The deflection is caused by fluid flowing perpendicular to the flat face of the reed's free end. Where fluid flows through the port upward and away from the ported surface, the flow encountering the reed deflects the reed away from the ported surface, providing an opening 1 g for continued free flow of fluid, and is referred to the permitted flow condition. Whereas, for fluid flowing reversely downwards towards the ported surface, and through the port, the reed is deflected towards the ported surface, causing contact with the ported surface, thereby covering the port, and blocking further flow of fluid. The reverse flow direction is referred to as the unpermitted flow direction. Therefore, fluid flow is permitted in one direction, and prevented in the opposite direction.
Reed valves function similarly to check valves, but are much lighter, and much more flexible. The lighter, more flexible reed requires less fluid force to deflect, and therefore provide distinct advantages over check valves. Because of these lower forces, reed valves actuate with lower differential pressures, flow rates, and for fluids with lower mass densities. Reed valves also provide advantages over check valves related to maintaining alignment of the reed free end relative to the port. While the reed is relatively free to bend about its minor axis 1 h , flexure is prevented laterally due to bending rigidity about its major axis 1 i . Additional alignment features such as sliding guides 2 a ( FIG. 2 ) required for check valves are not required, thereby eliminating additional friction or binding forces that can inhibit the motion of the check valve plunger 2 b . Less inhibited motion of the reed valve allows the reed valve to operate more consistently at lower pressures, flow rates, and fluid densities than check valves.
The major disadvantages of reed valves are, because of the lightness and flexibility, the reed must be long and slender. As such, the overall envelope of the reed valve is generally much larger than that of a check valve. For applications inline with piping systems, reeds require relatively large and complicated housings, and may be more susceptible to leakage, and may impractical in application due to the relatively large size. Additionally, reed valves do not contain higher pressures, due to the thin, slender section required for flexibility.
The proposed art is a compact reed 3 a ( FIG. 3 ) that is thin and flexible as the existing art, but is more compact in overall envelope, and therefore able to fit within the cross sectional envelope of adjoining piping. The compactness of the proposed art allows for larger porting and sealing surfaces within smaller housings, and therefore offers more opportunities for practical application. The proposed art achieves these advantages by utilizing maximum length arms 3 b which maximize the flexural length 3 c within the limitation of the port and respective piping diameter envelope. In addition to maximizing flexibility by maximizing length, the arm length extension creates an offset 3 m between the end of the arms and the center of the reed sealing surface 3 g . The offset 3 m permits further flexure of the arms and the reed sealing surface, thereby increasing the overall reed flexibility. The thickness 3 d of the thinner minor flexural axis further maximizes flexibility. The thickness may be the same as the remainder of the reed to simplify manufacturing of the reed by machining, cutting, or etching processes, or may be different to achieve other design goals.
The high flexibility of the arms also reduces stresses resulting from deflection of the reed arms. Such stresses, particularly at junctions 3 e from the arm to the fixed base 3 i and from the arm to the reed sealing surface 3 g , otherwise could be high. In applications where a high number of deflection cycles are anticipated, higher stresses could result in fatigue fracture of the reed arm. The stresses may be further reduced at the said junctions by utilizing compound radius transitions, also considered part of junctions 3 e . A large radius 5 a ( FIG. 5 ) widens the arm 3 b , distributing stresses over a wider surface. A smaller radius 5 b further transitions the arm geometry in the larger area of adjoining structure, controlling any stress concentrations. Both the flexible arms and the compound radii transitions minimize stresses, allowing for longer life in high cycle environments.
The arm thickness 3 d , width 3 f , and location near the reed sealing surface edge 3 h offers less restriction to flow than would other designs where the arms were thicker, wider, or placed farther away from the sealing surface edge 3 h . Smaller overall dimensions of the reed arms provide less drag area and more remaining area in the compact space for fluid to flow. Furthermore, the arms are placed close to the sealing edge to take advantage of direction of the flow streamlines exiting the plane of the sealing surface. Close to the reed sealing surface edge 3 h , the streamlines 4 a ( FIG. 4 ) run parallel to the reed sealing surface 3 g . As such, alignment of the width 3 f of arm 3 b with the flow streamlines 4 a is least restrictive to flow. Aligned with the flow streamline 4 a , the projected area of the arm on the flow is minimized, maintaining a larger remaining passageway for flow. Furthermore, the orientation of the arm width provides structural rigidity and strength of the valve to resist any inadvertent drag forces. Conversely, flow streamlines near port 4 d or close to the housing wall 4 e are oriented perpendicularly to the arm 3 b width. As such, less area would be available for free flow, drag forces on the arms would be higher due to the higher frontal area, and drag related bending about the arm 3 b weaker minor axis would produce higher stresses, and lower fatigue life.
To allow for a thin reed to resist high pressures under reverse flow conditions, a grated seat 3 j ( FIG. 3 ) is used in lieu of a single hole port. The grated seat supports the reed sealing surface span against pressure forces in the unpermitted flow direction. The grating contains a plurality of holes 3 k ( FIG. 3 ), which maximizes flow area in the permitted flow direction, while providing structural support via material remaining between holes 3 k , referred to as grating 3 l , to resist pressure forces in the unpermitted flow direction. Furthermore, the holes 3 k need not be equal in diameter or spacing. The size and spacing may be different in order to adjust the velocity and direction of the streamlines 4 a encountering the arms. For instance, the flow streamlines incident on the arms may be adjusted to be more parallel to the sealing surface 3 g by reducing the hole 3 k diameters on the outer perimeter of the hole pattern, and enlarging the hole 3 k at the center of the pattern. Enlarging the center hole would promote higher fluid velocity in the center of the port 4 d opening, whereas reducing the hole size at the outer perimeter would inhibit flow velocities at the port 4 d periphery. The velocity gradient would therefore bend the streamline 4 a more into alignment with the arm width 3 f.
A reed 3 a assembled with a grated reed seat 3 j defines a reed valve assembly.
The novelty of the proposed art is advantageous for liquid fluids as well as gas fluids. Operation in liquid applications provides for more sensitive actuation of the valve. The grated design allows exposure to higher pressure forces that typically are associated with liquid applications. The proposed art has fewer parts, as the spring, alignment mechanism, and sealing surface may be integrated into one part. As such, the more complicated multiple part check valve construction typically associated with fluidic service is replaced with a simpler, more reliable, and more cost effective integrated part.
3. Objects and Advantages
The objects and advantages of the proposed invention are:
a) A reed valve that is thin and flexible as the prior art, but is able to fit within the envelope of adjoining piping, allowing for smaller housings, b) Through the design of the flexural element junctions, able to minimize stresses related to deflection, thereby improving fatigue life, c) A simple design manufacturable by machining, cutting, or etching processes, d) The ability to consolidate multiple parts found in similarly compact check valves, such as springs, alignment features, and sealing surfaces, into one part, e) Small flexural element cross-sectional dimensions that offer low restriction to flow, and also by orientation of the flexural element cross-sectional minor and major dimensions within the flow streamline, maximizes remaining area available for fluid flow f) Orientation of the said minor and major dimensions to provide strength needed to structurally support the element from any inadvertent fluidic drag forces, g) Support of the sealing surface by a grated seat against the pressure forces in the unpermitted flow direction, and h) The size and location of specific passages in the grated seat to promote or inhibit fluid flow in specific locations in the port area, which affect the direction and velocity of resulting streamlines, particularly in the area of the flexible arms.
Further objects and advantages of the design will become apparent from a consideration of the drawings and ensuing description.
BRIEF SUMMARY OF THE INVENTION
The proposed invention combines the flexibility and lightness of current art reed valves with the compact size of current art check valves by utilizing maximum length arms, which act as the spring and alignment features for the sealing surface. The proposed art integrates these features, including the sealing surface, into one part, as do reed valves, but are difficult to achieve in compact check valve envelopes. The key features of the design, maximum length arms, provide both spring return and alignment of the sealing surface within a compact envelope. The cross-sectional dimensions of the arms are minimized to lower resistance to flow, but equally important, the arms are located near the sealing surface to orient the thin axis of the arm to be parallel to the flow streamline. Aligning the thin axis of the arms with the flow streamlines lowers the frontal drag area encountering the flow, thereby lowering flow resistance and related drag forces on the reed arm, and also maximizes the arm strong axis bending resistance to the inadvertent drag forces. A grated seat is also provided which supports the thin sealing surface of the reed from high pressures in the unpermitted flow direction, and by sizing and spacing the individual passages, further influences the orientation of the streamlines relative to the flexible arms.
DRAWINGS
Figures
FIG. 1 General Depiction of a Reed Valve (Prior Art)
FIG. 2 General Depiction of a Check Valve (Prior Art)
FIG. 3 Compact Reed and Grated Seat (Proposed Art), Exploded Assembly View
FIG. 4 Description of Flow Streamlines about the Compact Reed (Proposed Art), Sectional View
FIG. 5 Compound Radius Transition (Proposed Art), Detail Plan View
DRAWINGS
Reference Item Numerals
1a
Reed (Prior Art)
1b
Reed Fixed End (Prior Art)
1c
Stationary Surface (Prior Art)
1d
Reed Free End (Prior Art)
1e
Port (Prior Art)
1f
Ported Surface (Prior Art)
1g
Opening for Fluid Flow
1h
Reed Minor Axis
1i
Reed Major Axis
2a
Check Valve Sliding Guide
(Prior Art)
2b
Check Valve Plunger
3a
Compact Reed (Proposed Art)
(Prior Art)
3b
Maximum Length Arm
3c
Arm Flexural Length
(Proposed Art)
3d
Arm Minor Thickness
3e
Compound Radius Junction
(Proposed Art)
3f
Arm Width
3g
Reed Sealing Surface
3h
Reed Sealing Surface Edge
3i
Arm Fixed Base
3j
Grated Seat (Proposed Art)
3k
Grated Seat Hole (Proposed Art)
3l
Reed Seat Grating
3m
Offset of Arm Connection to
(Proposed Art)
Reed Sealing Surface
(Proposed Art)
4a
Flow Streamline
4d
Reed Port
4e
Reed Housing Internal Wall
4f
Close Proximity of
Maximum Length Arm to
Sealing Surface Edge
(Proposed Art)
5a
Large Radius of Compound
5b
Small Radius of Compound
Radius Junction (Proposed
Radius Junction (Proposed
Art)
Art)
DETAILED DESCRIPTION OF THE INVENTION
FIG. 3 —Preferred Embodiment
The preferred embodiment of the invention is the maximum length arms 3 b ( FIG. 3 ) of the compact reed 3 a . The arm is one or a symmetric pair, fixed at the base 3 i , spans approximately the entire width of the sealing surface 3 g along a trajectory approximately the same as the sealing surface edge 3 h , and terminates at the reed sealing surface 3 g so as to produce an offset 3 m from the said termination to the center of the sealing surface 3 g . The offset 3 m produces additional flexibility above that attained by the maximum length arms alone, by permitting additional flexure of the said surface 3 g and arm 3 b when urged by a fluid.
The importance of the maximum length arms to the flexibility can be explained by equation 1.
1 k ∝ ( L t ) 3 ( Equation 1 )
where,
1/k=Reed Flexibility L=Length of Arm t=Reed Thickness
The arm flexibility is increased cubically by lengthening the arm, as well as minimizing the thickness of the arm. In many applications, especially where the arm is integral with the reed sealing surface, reed pressure stresses prevent indiscriminate reduction in the thickness. Therefore, lengthening the arm becomes the predominant means to increasing flexibility. The maximum length arms allow for the increase in flexural length within the confines of a relatively small diameter of the adjoining piping.
Although the embodiment states that the reed arms follow a trajectory similar to the sealing surface edge 3 h , the arms may follow a different trajectory, but whose length is contained within the enclosing housing. The novelty of the invention is the ability of the reed arms to be long relative to the piping inside diameter, port diameter, and respective housing cavity to achieve an overall envelope approximately within the confines of the adjoining piping cross-section.
The arms are illustrated as pairs, being symmetric about a common axis. However, the arms may or may not be symmetric. Furthermore, the arm may be singular, not a pair, and may extend around any portion of the sealing surface to maximize length and flexibility. However, extending within one revolution around the cavity is a limitation of the embodiment, so as not to duplicate the prior art of coil springs. The embodiment emphasizes the primary mode of deflection to be by flexure, and not torsion.
The arms may be made from a variety of materials, depending on the application. Metallic materials such as steel, stainless steel, copper based alloys, or nickel based alloys may be used for applications demanding higher pressure and/or temperature. Non-metallic materials such as composites, polyethylene, polypropylene, or rubber may also be used in applications where pressure and/or temperature will not debilitate the material. The arms may be integral with the reed seat, and manufactured by cutting, machining, or chemical etching. The arms may also be separate from the reed seat, and joined mechanically, or by welding or bonding.
Additional Embodiments— FIGS. 3 , 4 , and 5
The compound radius transition 3 e ( FIG. 3 ) located at transitions from the arm 3 b to the fixed base 3 i and from the arm 3 b to the reed sealing surface 3 g is an additional embodiment. The compound radius transition 3 e contains a larger radius arc 5 a ( FIG. 5 ), and a smaller radius arc 5 b . The larger radius is approximately 2 times larger than the smaller radius, whose arcs are tangent to one another, and tangent to said adjacent transitions. The larger radius is located nearest the arm 3 b whereas the smaller radius is located nearest to the adjoining base 3 i or sealing surface 3 g.
Although compound radii generally consist of two radial arcs, tangent to each other, proportional by about 2:1, the compound radius transition may consist of more than two arcs of different radii, may or may not be tangent to one another or adjoining transitions, and may be proportional by other ratios than 2:1. Such features of the compound radii may be adjusted to produce the lowest possible stresses in areas of geometric transition, and stress concentration.
The close proximity 4 f ( FIG. 4 ) of the arm 3 b to the sealing surface edge 3 h is an additional embodiment. The close proximity 4 f aligns the width 3 f of the arm 3 b parallel to the flow streamlines 4 a . Near the sealing surface 3 g , the said streamlines are parallel to the sealing surface 3 g , and therefore are also parallel to the said aligned arm width, resulting in less obstruction to flow. While reorientation of the arm minor axis relative to the flow streamlines is possible in order to facilitate flow when locating the arms in other regions, the embodiment emphasizes that orientations of streamlines are less predictable farther away from boundary conditions. Furthermore, orientation of the arms out of plane with the remainder of the valve face is more costly to manufacture.
The grated seat 3 j ( FIG. 3 ) is an additional embodiment. The grated seat 3 j contains a plurality of holes 3 k contained within the sealing surface 3 g region which allow for minimal resistance to air flow in the permitted flow direction. Surrounding the holes is the remaining seat structure, either plastic or metallic, referred to as grating 3 l , which supports the reed sealing surface 3 g span from high pressures in the unpermitted flow direction. The reed sealing surface 3 g would otherwise encounter much higher stresses if the mid-span support was not present, as described in equation 2.
σ ∝ p × ( a t ) 2 ( Equation 2 )
where,
σ=Reed Sealing Surface Bending Stress due to Pressure p=Pressure a=Radius (½ Unsupported Span of Reed Sealing Surface) t=Reed Sealing Surface Thickness
For instance, grating whose hole span is one half the distance of the overall sealing surface would reduce the stress to one quarter of the stress without grating support.
The grating 3 l is further embodied to minimize the thickness of the maximum length arms 3 b in cases where the said arms are integral with the reed sealing surface. Minimizing the thickness maximizes arm flexibility, a preferred embodiment, and reduces arm flexural stresses.
The hole 3 k size and location are an additional embodiment. Each hole 3 k size and location in the sealing surface 3 g region influence the overall flow gradient across the port region, and therefore influence the direction of the flow streamlines 4 a ( FIG. 4 ). The hole 3 k diameter may or may not be circular, similar to each other in size, or whose location is equally spaced. The size, number, and spacing may be adjusted to accomplish any combination of structural support to the reed sealing surface 3 g , change in flow gradient, and subsequently, orientation of flow streamline 4 a for either flow performance or structural considerations.
Operation—Introduction to Prior Art
To understand the operation of the embodied invention, a discussion of the operation of the prior art may assist in the understanding of the more complex operation of the invention claimed. Fluid flowing through a port 1 e ( FIG. 1 ) in an upward direction impinges on the reed free end 1 d sealing surface. The reed 1 a is thin about the minor axis 1 h , long relative to the thickness, and therefore considered slender and flexible. Based on the slenderness, corresponding flexibility, and the fluid's impingement forces due to its pressure, density, and velocity, the sealing surface 1 d may deflect upward by some magnitude 1 g . The port is opened to flow, and fluid flow is permitted in the upward direction. Conversely, fluid flowing in the reverse direction will impinge downward upon the opposite face of the reed sealing surface, urging the reed upon the ported surface 1 f , thereby sealing the port and preventing fluid flow.
The reed and port may be in oriented differently, so as to directionally control flow in the desired direction.
Laterally, alignment of the reed free end 1 d relative to the port 1 e is maintained without supplemental alignment features such as guides. The major axis 1 i of the reed offers rigidity. Furthermore, the fluid impingement forces on the reed are not as significant due to the low projected frontal area in the lateral direction. As such, no additional alignment features are required, and related friction and binding are eliminated as problematic failure modes.
Operation—Preferred Embodiment ( FIGS. 3 and 4 )
The proposed art compact reed functions similarly to the prior art, with a major advantage of smaller overall reed size for a similar corresponding port 4 d ( FIG. 4 ) size, thereby accommodating smaller housing cavities. Said slenderness and flexibility are attained by maximum length arms 3 b ( FIG. 3 ). The arms utilize to the maximum extent the available space and perimeter around the sealing surface 3 g , and the port covered by the said sealing surface, to achieve greatest possible length and flexibility, as illustrated in equation 1. An offset 3 m between the arm connection to the said sealing surface and the center of the said sealing surface further increases overall reed flexibility by permitting inclination of the said sealing surface, and also permitting flexure of the said sealing surface itself, when urged. Laterally, the arms provide rigidity as does the prior art for maintaining alignment of the sealing surface 3 g with the said port. The reed sealing surface 3 g functions identically in permitting and restricting flow as does the prior art.
Operation—Additional Embodiments ( FIGS. 3 , 4 , and 5 )
The compound radius transition 3 e ( FIG. 3 ) mitigates high stresses that otherwise could be generated in prior art junctions. Where the flexural element, the arm 3 b , transitions in size to a fixed base 3 i or reed sealing surface 3 g , high stresses generally are encountered at the transition. To mitigate these stresses, single radii, thicker sections, or reinforcement may be added to reduce the stress levels. However, compound radii are simple and more effective in lowering concentrated stresses by gradually transitioning the flexural width 3 f . A larger radius 5 a ( FIG. 5 ) is used to gradually widen the section, and disperse the stresses, whereas, a smaller radius 5 b near the root of the transition may absorb the less intensive stresses. The ratio of the two said radii is generally 2:1, but may be different, and may include more than two radii.
Close proximity 4 f ( FIG. 4 ) of the arm 3 b to the sealing surface edge 3 h aligns the width 3 f of the arm 3 b in the streamline 4 a . Prior art generally limits reed deflection in the area of the sealing surface by way of a stationary surface, and does not generally encounter high flow rates in other unsupported flexural areas of the reed due to the large size, and remoteness from the port. The compact reed will incur higher flow rates around the arm 3 b where the arm is susceptible to unsupported flexure. Such flow in the arm regions may produce undesired drag, flow resistance, and arm stresses. To minimize drag related effects, the arm is located near the sealing surface edge 3 h to take advantage of streamlines 4 a aligned with the sealing surface 3 g flat boundary. Near the said edge, the flow streamline 4 a will be aligned with the surface 3 g , and therefore aligned with the adjacent arm 3 b width 3 f . Such alignment will reduce arm frontal area incident to the flow, and subsequent drag forces, and furthermore reduces bending stresses by orientation along the stronger axis of the arm section.
The grated reed seat 3 j ( FIG. 3 ) provides approximately the same flow area as a single hole port of the same overall envelope by employing a plurality of smaller holes 3 k contained within the region of the sealing surface 3 g . The holes are placed such that seat material remains between the holes, referred to as a grating 3 l . The grating supports the relatively thin reed, reducing the unsupported span, thereby reducing stresses due to pressure in the unpermitted flow condition, as demonstrated in equation 2. The holes 3 k need not be equal in size or spacing in order to adjust the nature of the flow impinging on the reed, and the direction and velocity of streamlines 4 a ( FIG. 4 ) encountering the arms. For instance, the flow streamlines 4 a incident on the arms 3 b may be adjusted to be more parallel to the sealing surface 3 g by reducing the hole 3 k ( FIG. 3 ) sizes on the outer perimeter of the hole pattern, and enlarging the hole 3 k at the center of the pattern. Enlarging the center hole would promote higher fluid velocity in the center, whereas reducing the hole size at the outer perimeter would inhibit flow velocities at the sealing surface 3 g periphery. The velocity gradient would therefore bend the streamline 4 a more before impinging upon the sealing surface 3 g , thereby adjusting the alignment of the streamline 4 a relative to the arm width 3 f.
Conclusion, Ramifications, and Scope
The proposed invention permits the use of reed valves in a wider range of applications. Such a design creates distinct and unique advantages:
a) A smaller, more compact, lighter reed valve assembly that may fit in smaller spaces, or in-line with smaller piping systems. b) A more robust reed which sustains higher fluid pressures, velocities, and densities. c) Although smaller and more robust, reed flexibility and lightness, and performance benefiting from said flexibility and lightness, which are maintained to that of prior art reed valves through the use of flexible arms which maximize their length within the confines of the smaller attainable housing. d) Furthermore, ability to maintain critical part alignment without additional alignment features in comparably small prior art check valves. e) Consolidation of multiple parts, such as sealing surfaces and return springs, into one part readily manufacturable by chemical etching, machining, or cutting. f) As such, broadening the range of applications for reed valves from prior art reed and check valves.
Although the description above contains much specificity, these should not be construed as limiting in scope of the invention, but merely providing illustrations of some of the presently preferred and additional embodiments of this invention. For example, the benefits of the proposed invention are not limited to housed assemblies attached to in-line piping systems, but may be more integral with fluidic circuits. The compact reed and grated reed seat may be installed in manifolds, internal to existing piping, or within the connection of two piping joints, threaded, welded, or brazed, without the use of a specially designed housing. The valve may be applied as a check valve, intake or exhaust valve for reciprocating pumps and gas compressors, or any other application requiring directional flow control. The fluids passing through the valve may be liquid or gas. The valve may be applied to medical applications as well as mechanical applications. The materials employed in the reed and reed seat may be metallic, plastic, wood, or composite. The sealing surface may not be in contact with the port when fluid is not impinging on or pressurizing the sealing surface. Fluid impingement or pressure may urge the sealing surface in contact with a ported surface, thereby preventing further flow in the fluid direction.
The flexible arms are illustrated as pairs, being symmetric about a common axis. However, the arms may or may not be symmetric. Furthermore, the arm may be singular, not plural, and may extend around any portion of the internal cavity to maximize length and flexibility. However, extending within one revolution around the cavity is a limitation of the embodiment, so as not to duplicate the prior art of coil springs. The offset between the end of the arms and the center of the sealing surface may or may not further incline the reed sealing surface so as to produce additional flexibility.
The reed valve assembly is defined as the compact reed assembled with a grated seat. However, the novelty applies also to a compact reed assembled with a prior art single hole port. The compact reed is advantageous without the added benefit of a grated reed seat.
To further distinguish the invention from prior art, the scope of the invention does not pertain to swing check valves, or directional control valves which utilize rotating hinges as a primary mechanism for movement of the sealing surface. The said hinges may or may not include springs which assist in returning the sealing surface to a predisposed position. Although the said sealing surface may displace in a similar trajectory to that of the proposed art, the proposed art is distinguished from the said hinge in that the proposed art displacement is by flexure of a single part, the flexible arm, and not by torsion of a single part such as a coil spring, and not via rotation of two separate parts connected by a pin, axle, or other rotary joint.
Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given. | Compact reeds maximize flexural length by efficiently utilizing available space surrounding the port. Maximum length arms are disposed at the perimeter of the housing inlet port. Stresses at the ends of the arms are mitigated by utilizing compound radius transitions. The transitions are constructed by two or more arcs of different radii, which produce lower stresses at such junctures than if single radius transitions were used. The arms are disposed close to the reed sealing surface edge to orient the flow streamlines to be aligned with the arm width, thereby minimizing frontal drag area. The reduced frontal area reduces drag forces and related stresses on the arms, and reduces the overall flow related pressure drop across the reed.
Replacing a single hole port, a port comprised of multiple passages of varying size control the velocity exiting the passages. The velocity gradient across the port provides further capability to orient the said streamlines to reduce said drag. In the reverse direction, where the reed obstructs flow, the ends of the passage walls provide structural support to the reed sealing surface, enabling the said surface to be thinner than otherwise possible. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Applications 60/905,379 filed Mar. 7, 2007 and 60/905,413 filed Mar. 7, 2007.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
TECHNICAL FIELD OF INVENTION
[0003] The invention relates to compositions employing organosilane compounds and their use as microbiocidal agents.
BACKGROUND OF THE INVENTION
[0004] Water stable organosilane compounds, products, and compositions for treating various substrates, articles treated with the compounds, products and compositions, and methods of treatment using the compounds, products and compositions are disclosed in U.S. Pat. Nos. 5,959,014, 6,221,944 and 6,632,805 to Liebeskind and Allred.
[0005] Improved compositions and methods employing these compounds are disclosed herein which provide advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1A depicts the use of a volume of a formulation of the invention for spray application to a substrate.
[0007] FIG. 1B depicts the use of an equal volume of a formulations not utilizing the disclosed invention in spray application to a substrate.
[0008] FIG. 2A depicts a side view of a single drop of the formulation of the invention depicted in FIG. 1A immediately after dropping onto a substrate.
[0009] FIG. 2B depicts a side view of a single drop of a formulation depicted in FIG. 1B immediately after dropping onto a substrate.
[0010] FIG. 3 is a graph showing the results of a fabric test comparing use of the formulation of the invention with 10% nonionic agent on fabric from a clinical gown inoculated with a known amount of Staphylococcus aureus bacteria incubated for 24 hours prior to testing for bacterial count at the intervals shown. In FIGS. 3-5 , the numbers on the vertical axis represent an exponential value of the number ten. As such, 1.00E+00 is equivalent to 10 0 , or 1. 1.00E+01 equals 10 1 , or 10, and so on up to 1.00E+09, or 10 9 . On this axis is also “CFU”, meaning “Colony Forming Units”. In FIGS. 3 and 5 , the horizontal axis represents the number of days over which the experiment was monitored.
[0011] FIG. 4 is a graph, showing the results of a second fabric test comparing use of the formulation of the with the 10% nonionic agent treated and untreated material from a clinical gown inoculated with a known amount of Staphylococcus aureus bacteria incubated for 48 hours prior to testing for bacterial count at the intervals shown. In FIG. 4 , the horizontal axis represents the number of hours over which the experiment was monitored.
[0012] FIG. 5 is a graph showing the results of a third fabric test comparing use of the formulation of the invention with 10% nonionic agent treated and untreated material from a clinical gown inoculated with a known amount of Staphylococcus aureus bacteria incubated for 7 days at room temperature prior to testing for bacterial count at the intervals shown.
DETAILED DESCRIPTION
[0013] Water stable organosilane compounds are described in U.S. Pat. Nos. 5,959,014, 6,221,944 and 6,632,805 which are herein incorporated by reference as if fully set forth in their entireties herein.
[0014] In one embodiment, it has been found that the compounds can be applied to various substrates via a spraying technique which reduces the size of the drops of the formulation to small micron size droplets such as 1-8 microns. This benefits the application process by minimizing labor, providing consistency and balance in the application process. The aerosolization spray technique can be done with deminimus labor force. In order to provide the droplets in the size preferred, an ultrasonic device for atomizing liquids is preferably employed, such as is disclosed in U.S. Pat. No. 5,922,247 which is herein incorporated by reference as if fully set forth herein. Other spraying or atomizing apparatuses can be used to achieve the droplet size preferred.
[0015] In another embodiment, it has been found that regardless of application technique, advantageous formulations employing these compounds can be made by adding a nonionic wetting agent to the previously described compounds and compositions. These formulations can be applied via the spraying technique described above in a particularly preferred embodiment, or via a number of other techniques. The formulation provides an advantage by allowing for more coverage of the substrate to be treated.
[0016] The non-ionic wetting agent is employed to provide the characteristics of a facilitator to reduce surface tension and allow the composition to more rapidly penetrate the substrate or surface to be treated. By reducing the interfacial tension between the two media (the antimicrobial agent and the nonionic) it will permit the combined formula to penetrate the surface more quickly while providing greater coverage on the surface. This phenomena is illustrated in FIG. 2A and FIG. 2B . FIG. 2A illustrates a droplet of a formulation comprising a non-ionic wetting agent while FIG. 2B illustrates a droplet without the wetting agent.
[0017] Suitable non-ionic wetting agents include ethoxylated alcohols; ethoxylated nonyl phenol(s); and ethoxylated alkyl phenol(s). When choosing a nonionic surfactant it is most preferred that the ethoxylation is between 9-12 moles to give the best wetting and detergency. Lower or higher ethoxylation reduces the surface tension properties and thus is not preferred although could provide some improved characteristics.
[0018] Preferably, the nonionic wetting agent is selected from the group consisting of: Ethoxylated Nonyl Phenol 9-12 moles, Ethoxylate, Ethoxylated Alcohol 9-12 moles and Ethoxylate, and Ethoxylated Alkyl Phenols 9-12 moles ethoxylate. Most preferably, the nonionic wetting agent is ethoxylated nonyl phenol 9-12 moles.
[0019] The compositions disclosed herein provide an advantage over previously described compositions in that they will better adhere to surfaces, including inert materials such as polypropylene and polystyrene. In addition, improved flow into crevices in surfaces is made possible. Another advantage is that the compositions disclosed herein allow for the formation of smaller droplets when using an aerosolization application method. The preferred application technique which allows for the smaller droplet size increases the affinity to certain surfaces and textiles, including materials composed of inert fibers. The surface tension is reduced and thus allows the formula to covalently bond more quickly. The compositions are non-toxic and so can be applied to surfaces, textiles and substrates in such exemplary industries as the healthcare and food and beverage industries without fear of harming humans either in contact with treated surfaces or who eat or handle food products.
[0020] FIG. 1A and FIG. 1B show another advantage of using the formulation disclosed herein in combination with the preferred spraying technique. For the same volume, more coverage of a substrate can be achieved. FIG. 1A illustrates a substrate treated with the improved formulation containing the non-ionic wetting agent. The substrate is fully covered with the given quantity of liquid agent. FIG. 1B illustrates a substrate treated with a formulation which does not utilize the formulation of the invention. As can be seen, the same given quantity of liquid agent does not provide full coverage of the substrate. Therefore, more agent will have to be used to achieve full coverage. The nozzle in FIGS. 1A and 1B is representative of an aerosolization technique. Some improved coverage can be obtained with the formulation used in 1 B over other techniques, but most preferred is using aerosolization (1-8 micron droplets, most preferably 0.5 to 5 micron droplets) in conjunction with the improved formulation of the invention.
[0021] The improved Organosilane-Non-Ionic Water Stabilized compositions can be made by first preparing an aqueous solution of water stable organosilane compounds (Solution A) pursuant to methodology disclosed in U.S. Pat. Nos. 5,959,014, 6,221,944 and 6,632,805 to Liebeskind and Allred.
[0022] A quantity of Solution A is then mixed with the selected non-ionic wetting agent and water necessary to make up the volume required. It is preferred that the invention can range from 0.5% of the active ingredient (3-trihydroxysilylpropyldimethyloctadectyl ammonium chloride) to 5.0% of the active ingredient in Solution A while proportionally maintaining the same percentage of the nonionic wetting agent(s) as would exist in the most preferred embodiment which is 90% Solution A with about 10% nonionic wetting agent tergitol NP-10 (Ethoxylated Nonyl Phenol 10 moles EO) and 0.5% D-Limonene (or without D-Limonene, wherein the 0.5% of such materials is replaced by an equal percentage of water) or other wetting agents disclosed as suitable herein.
[0023] Solution A, previously described by Liebeskind and Allred, supra, is improved by the addition of the disclosed non-ionic wetting agents in the proportions disclosed herein. The formula to be applied to selected surfaces can be better adapted to the application with employment of the present invention. The formula of the present invention results in creation of a smaller droplet size better able to penetrate hard and porous surfaces and textile materials and do to so more quickly. This provides better coverage, faster drying and greater efficacy.
[0024] Organosilane-Non-Ionic Water-stabilized composition is non-flammable and when stored in original, unopened containers has a minimum shelf life of 12-18 months from shipment.
Example 1
Henry Ford Hospital, Infectious Disease, Detroit, Mich. Summary of Fabric Test Conducted by Henry Ford Hospital System Using Solution A and 10% of Nonionic Agent
[0025] The role of contaminated surfaces within the hospital environment is an area of infection control management that is difficult to control in both the laboratory and patient settings. Henry Ford wanted to evaluate the ability of an antimicrobial surfactant that permanently coats surfaces and fabric with covalently bound octadecyldimethylammonium ions (Solution A defined above) to reduce bacterial burden on contaminated surfaces. They also tested the ability of the product to inhibit growth of bacteria on fabric and surfaces in a patient room. In the fabric test they used the Solution A product and an extract of the formulation, the nonionic surfactant.
[0026] Methods: The fabric test was conducted according to the garment industry AATCC 100 protocol. Swatches of fabric were cut from a patient gown. Treated and untreated material was inoculated with S. aureus . Bacterial surveys were conducted over a 14 day period.
[0027] Overall Results: In the fabric test, Solution A with a 10% addition of the nonionic prevented the growth of S. aureus immediately upon contact and prevented growth for 14 days.
[0028] In the fabric test detailed below, Solution A with the 10% nonionic agent was successful in completely preventing the growth of S. aureus . In evaluating the product for its antimicrobial activity, they have demonstrated Solution A with the 10% nonionic agent has the potential to become an important component in infection control practices for textiles.
[0029] The fabric test was conducted according to the protocol set forth in AATCC 100. 2″ circular swatches of fabric were cut from a patient gown consisting of a 50% cotton blend obtained from their Infectious Disease Clinic. All swatches were hand washed in luke warm water with Solution A with the 10% nonionic agent and allowed to completely air dry. Test swatches were treated with Solution A with the 10% nonionic agent by thoroughly soaking the fabric in the product. The material was then allowed to air dry completely before inoculation. Four stacked swatches of treated and untreated fabric were infected with 4 mL of Staphylococcus aureus at 0.5 McFarland. An additional control of untreated and uninfected material was established. Three different test conditions were conducted.
[0030] First Test Condition: The first condition collected bacterial samples from the fabric at time points 0, 24 h, 48 h and 72 h after initial inoculation. All swatches were washed between collections with Solution A and the nonionic agent and allowed to air dry. The fabric swatches were incubated for 24 h at 35° C. prior to the sampling. The samples were then aliquoted and incubated for 24 h at 35° C.
[0031] Second Test Condition: The second condition bacterial samples at 0, 24 h, 72 h and 96 h. Swatches were incubated at 35° C. for 24 h prior to sampling and washed between samplings as before. The samplings were then aliquoted and incubated for 48 h at 35° C.
[0032] Third Test Condition: The third condition collected bacterial samples at time points 0, 1 d, 7 d and 14 d without washing between samplings. Fabric was allowed to sit at room temperature and exposed to air for the time between samplings. The fabric was not incubated prior to sampling.
[0033] Sampling was conducted by placing each stack of four swatches in 100 mL of sterile saline and vigorously shaking for 1 minute. An aliquot of the saline was then removed and dilutions were prepared equivalent to 10 0 , 10 1 and 10 2 . 100 uL from each dilution was plated as a lawn on to TSA blood plates and incubated at 35° C. without CO 2 for 18-24 h or 48 h depending on the condition. Resulting colonies were counted as appropriate.
[0034] In order to determine the impact of Solution A with the nonionic agent on treated fabric, a patient gown was retrieved from a clinical office and cut in to swatches for testing. The first experiment evaluated the product using Staphylococcus aureus ATCC strain 29213 as the inoculum. The fabric was sampled every 24 h post initial inoculation. Prior to sampling, the swatches were incubated at 35° C. for 24 h. The material was then washed and dried between sampling. Organisms were sampled from the fabric by vigorously shaking the material in sterile saline. Aliquots of the samples were then incubated for 24 h and growth of organism was assessed.
[0035] Referring to FIG. 3 , in general S. aureus was applied to Solution A with the 10% nonionic agent treated and untreated material. Control fabric was untreated and not inoculated. Fabric was sampled every 24 h and aliquots were incubated at 35 C for 24 h.
[0036] As shown in FIG. 3 , Solution A with the nonionic agent was able to reduce the bacterial burden on the fabric immediately after treatment. No growth was observed in any of the test swatches or controls after 48 h. This is presumed to be due to the efficiency of the Solution A with the nonionic agent used in the washing process. The spike observed in the control swatch was a contaminant and was not S. aureus.
[0037] Now referring to FIG. 4 , S. aureus was applied to Solution A with the 10% nonionic agent treated and untreated material. Control fabric was untreated and not inoculated. Fabric was sampled every 24 h and aliquots were incubated at 35 C for 48 h.
[0038] To determine if longer incubations were required to detect organism growth after the detergent washings, they sampled the fabric every 24 h as before, however they increased the incubation time of the aliquots to 48 h at 35° C. As before, the swatches were washed with detergent and dried between samplings. Swatches were also incubated at 35° C. between samplings. As shown in FIG. 4 , a reduction in bacterial burden following the detergent washings was observed. Still, Solution A with the nonionic agent was able to immediately reduce the bacterial burden after the initial inoculation.
[0039] Under normal usage condition, patient gowns in their infectious disease (ID) Clinic would be more likely to be stored for several days to weeks before being used and since the last washing. In an effort to simulate a more real world application, fabric swatches were inoculated with S. aureus and then allowed to sit at room temperature exposed to air for 7 days. Swatches were not incubated prior to sampling. They also wanted to determine the effect of Solution A without the added activity of the nonionic.
[0040] Now referring to FIG. 5 . S. aureus was applied to Solution A with the 10% nonionic agent treated and untreated material. Control fabric was untreated and not inoculated. Fabric was sampled every 7 days and aliquots were incubated at 35 C for 48 h.
[0041] Therefore, the fabric was not washed between sampling periods. The results are displayed in FIG. 5 . In this experiment, the untreated material was observed to have a much slower decay in the number of organisms recovered as compared with the previous conditions. This provides evidence that the nonionic was also beneficial in reducing bacterial burden over time. Taken together these data demonstrate that Solution A is efficient at preventing bacterial growth on contaminated fabric. Furthermore, a combination of Solution A with the nonionic agent provides satisfactory protection against contamination as an infection control measure.
Example 2
[0042] Another test was conducted at the Henry Ford Hospital System wherein Solution A containing 5% of the active ingredient was applied to a polypropylene material by spray method and fan dried, and the Organosilane-Non-Ionic Water Stabilized composition as described above was applied and dried in the same manner. Three samples of polypropylene material were provided for each test. Each material was cut into four equal parts. Two sections from each material were identified as replicates A and two were identified as replicates B. Replicates A were placed into each of three sterile culture containers. B replicates were also placed into each of three sterile culture containers for a total of six separate cultures. Each culture container held two material sections, one to be used for the 2 hour time point and one to be used for the 24 hour time point. The polypropylene material was either treated with 5% concentrated Solution A (Liebeskind and Allred), 4.5% Organosilane-Non-Ionic Water Stabilized composition, or left untreated.
[0043] A methicillin resistant Staphylococcus aureus patient isolate was grown overnight in a Muehler-Hinton liquid broth culture. Titer was determined by optical density and liquid culture was diluted to a concentration of 1×10 7 organisms per mL. Material in each culture container was inoculated with 5×10 7 organisms. All liquid was absorbed by the material, though total absorption took longer for dark blue and pink colored polypropylene materials used for the invention and control respectively in order to differentiate the experimental conditions more easily.
[0044] Materials were incubated at 35° C. without CO 2 . At 2 hours, one material section from each of the six containers was selected and placed into sterile jars into which 100 mL of sterile saline was added. The jars were vigorously shaken for approximately 2 minutes. Aliquots of the saline solution were taken and dilutions were made for 100, 101 and 102. 100 microliters from each dilution was plated as a lawn on to TSA plates containing 5% sheep blood. Plates were incubated at 35° C. without CO 2 for 24 hours and colony forming units were enumerated. Plates were placed back into incubation for a further 24 hours for a total of 48 hours and colony forming units were enumerated again.
[0045] At 2, 24 and 48 hours post inoculation, the remaining materials sections were removed from each of the six containers and sampled as previously described. Results observed are tabulated in Table 1.
[0000]
TABLE 1
2 h
24 h
dilu-
dilu-
tion
24 h
48 h
ave
tion
24 h
48 h
ave
Mask
untreated
rep A
1
TNC
TNC
1
TNC
TNC
10
TNC
TNC
10
TNC
TNC
100
600
TNC
100
1320
TNC
rep B
1
TNC
TNC
1
TNC
TNC
10
TNC
TNC
10
TNC
TNC
100
1500
TNC
1050
100
1836
TNC
1578
Solution A
rep A
1
0
0
1
0
0
10
0
0
10
0
0
100
0
0
100
0
0
rep B
1
1972
TNC
1
12
12
10
271
TNC
10
4
4
2
100
19
22
10
100
0
0
Organosilane-
Non-Ionic
Water
Stabilized
composition
rep A
1
0
0
1
0
0
10
0
0
10
0
0
100
0
0
100
0
0
rep B
1
0
0
1
0
0
10
0
0
10
0
0
100
0
0
0
100
0
0
0
TNC = too numerous to count
[0046] At the 2 hour evaluation, the 5% concentrated product (Solution A) resulted in a reduction in bacterial load of 99.05%. The material treated with the 4.5% Organosilane-Non-Ionic Water Stabilized composition resulted in a 100% reduction.
[0047] At the 24 hour evaluation, the 5% concentrated product (Solution A) reduced bacterial load by 99.99%. The material treated with the 4.5% Organosilane-Non-Ionic Water Stabilized composition resulted in a 100% reduction.
[0048] Reductions were calculated using the number of colonies obtained from blood plates after 24 hours of incubation.
[0049] This demonstrated several supporting advantages of the new inventions, those being better efficacy; excellent residual protection over 24 and 48 hours, better formula coverage on the material, and at the production and application stages smaller droplets, greater fabric adherence, quicker drying and greater surface penetration. Colonies were still detected in the test under all conditions, indicating the presence of live organisms which can replicate except with the fabric treated with the organosilane non-ionic water stabilized composition. The 100% effectiveness of the organosilane non-ionic water stabilized composition represents an improvement.
[0050] In various embodiments, surfaces and substrates treatable with the compositions, products and compositions of the invention solution include, but are not limited to, textiles, carpet, carpet backing, upholstery, clothing, sponges, plastics, metals, surgical dressings, masonry, silica, sand, alumina, aluminum chlorohydrate, titanium dioxide, calcium carbonate, wood, glass beads, containers, tiles, floors, curtains, marine products, tents, backpacks, roofing, siding, fencing, trim, insulation, wall-board, trash receptacles, outdoor gear, compressible and incompressible fluid filtration materials, water purification systems, and soil. Furthermore, articles treatable with the compounds, products and compositions of the invention include, but are not limited to, materials used for the manufacture thereof, aquarium filters, buffer pads, fiberfill for upholstery, fiberglass duckboard, underwear and outerwear apparel, polypropylene fabrics, filters and membranes, polyurethane and polyethylene foam, sand bags, tarpaulins, sails, ropes, shoes, socks, towels, disposal wipes, hosiery and intimate apparel, cosmetics, lotions, creams, ointments, disinfectant sanitizers, absorbents, wound dressings; micro-fibers; wood preservatives, plastics, adhesives, paints, pulp, paper, cooling water, and laundry additives and non-food or food contacting surfaces in general.
[0051] The composition can be sprayed, rolled, wiped, fogged, or applied by mopping to the article to be treated or can be exhausted or padded onto textile materials. It can also be processed through dipping, soaking, or roller pressure and heat setting processing. Choice of application and/or processing method depends upon the nature of the surface to be treated.
[0052] As previously stated, the composition can be advantageously used in an aerosolization spray techniques for certain surfaces or rooms with the spray comprising preferably small micron size droplets such as 1 to 8 microns, most preferably 0.5-5 microns. This benefits the application process by minimizing labor, providing consistency and balance in the application process. The aerosolization spray technique can be done with deminimus labor force.
[0053] Another advantageous application method is applying by ‘wet-wipe’ by first soaking the wipe, letting it remain moist in a container and then applying provides effective application and provides the surface with the desired prophylactic protection because by lowering the interfacial tension between the two media of the antimicrobial and the wetting agent, the resulting composition will play a key role in the removal of dirt from surfaces and textiles.
Example 3
Preparation of Organosilane-Non-Ionic Water-Stabilized Composition
[0054] A 5% W/V (weight/volume) aqueous solution of 3-(trimethoxysilyl)propyldimethyloctadecyl ammonium chloride was converted to 5% 3-(trihydroxysilyl)propyldimethyloctadecyl ammonium chloride, 0.8% 3-chloropropyltrimethoxysilane, and 1.9% pentaerythritol. (hereinafter “Solution A”) pursuant to a method disclosed in U.S. Pat. No. 5,959,014. In brief,
[0055] A 22 L reaction flask was charged with 6250 g. (21.0 Mol.) of dimethyloctadecylamine, 5844 g. (29.4 Mol.) of 3-chloropropyltrimethoxysilane, and 76 g. (0.84 Mol.) of trioxane. The mixture was heated to 140.degree. C. for 12 hours while stirring and was then cooled to 80.degree. C. 2 L of methanol was then added and the mixture was cooled to approximately 40.degree. C.
[0056] This mixture was then transferred to 171 L of water, into which 4000 g. of pentaerythritol had been previously dissolved. After thorough mixing the pH of the solution was checked. (If the pH is above 7.0 (basic) a small amount of HCl is added until the pH is below 7.0).
[0057] The mixture was then diluted to 209 L with additional water. The resulting solution contained approximately 5% 3-(trihydroxysilyl)propyldimethyloctadecyl ammonium chloride, 0.8% 3-chloropropyltrimethoxysilane, and 1.9% pentaerythritol. (hereinafter “Solution A”)
[0058] To a quantity of Solution A (to equate to 90% of the final mixture), was added 10% of the nonionic Tergitol NP-10 (Ethoxylated Nonyl Phenol 10 moles EO) an amount to form the final mixture. After mixing, 0.5% of D-Limonene may be added. The final composition (an “Organosilane-Non-Ionic Water-stabilized Composition”) exhibited improved adherence to a variety of surfaces.
Example 4
Processes for Textile Applications
By Exhaustion
[0059] Fabric should be dyed as usual, post scoured and neutralized. Alkalinity may prohibit Organosilane-Non-Ionic Water-stabilized compositions from attaching to fabric. The pH of the fabric should be less than 6.0 to aid exhaustion.
[0060] Set temperature at 110°-120° F.
[0061] Make up solution of Organosilane-Non-Ionic Water-stabilized composition in head tank or side tank of jet or dye bath equipment commonly found in textile facilities (or: Take solution of Organosilane-Non-Ionic Water-stabilized composition in the amount of 2%-4% of the weight of the goods to be laundered. (100 lbs. of textiles would use 3 lbs. of liquid concentrate or less than ½ gallon).
[0062] Weigh Organosilane-Non-Ionic Water-stabilized composition carefully and take the solution and pour it into a separate five gallon pale and mix with warm water (80°-90° F.) for ten minutes (10) to assure proper dispersion. Acetic Acid or Citric may be used to adjust pH if necessary.
[0063] Inject solution of water and Organosilane-Non-Ionic Water-stabilized composition into jet. Hold temperature at 110°-120° F. for fifteen to twenty minutes to provide adequate time for exhaustion.
[0064] At end of cycle time, drop water. No rinsing is required.
[0065] Organosilane-Non-Ionic Water-stabilized composition can be exhausted on in the softener bath. The compatibility of all softeners with Organosilane-Non-Ionic Water-stabilized composition prior to employing this method.
[0066] Application of Organosilane-Non-Ionic Water-stabilized composition can be checked by two means: Bromophenol Blue indicator-indicates the presence of Organosilane-Non-Ionic Water-stabilized composition by a blue cast. If no Organosilane-Non-Ionic Water-stabilized composition is present, no color will form. pHydron quaternary Test Strips QT-10 can be used to indicate the presence of a quaternary compound. These can be used to determine the effectiveness of the bath treatment. The strips can be used to test the bath by dipping the strip therein and one can read the amount of quaternary compound, if any, that has been left in the bath. As an added benefit, testing with the strips would determine if any anionic surfactant would be necessary to add to wastewater prior to release to city sewer. These test strips can be purchased from Fisher Scientific.
[0067] Fabric can then be dried according to conventional methods. It should be noted that the product will exhaust at low temperatures at the right pH. The procedures recommend that testing be done to insure proper application of the product which will cover the differences between liquor ratios in a paddle, jet, rotary or pad application
[0068] To prevent the discoloration or yellowish of fabrics, for example in the textile industry, it is necessary to control the pH of the bath. Alkalinity may prohibit Organosilane-Non-Ionic Water-stabilized composition from attaching to fabric. The pH of fabric should be less than 5.5 to aid exhaustion. Different Acids can be used for this process. The most common used are acetic acid and citric acid.
[0069] The concentration will be determined by the original solution used. Organosilane-Non-Ionic Water-stabilized composition will work and keep white fabrics from discoloring when the pH is from 4.5 to 5.5. It will also, pad or exhaust better when the pH is below 6.0. pH can be determined with a standard pH-meter or test strips.
By Padding
[0070] Fabric should be previously scoured and/or dyed and neutralized. Alkalinity may prohibit Organosilane-Non-Ionic Water-stabilized composition from attaching to fabric. The pH of the fabric should be less than 6.0 to aid pick up.
[0071] Determine an accurate wet pick up. It is preferable that fabric be padded wet or dry. However, if wet on wet finishing is necessary, it is imperative than an accurate exchange rate be calculated to effect enough Organosilane-Non-Ionic Water-stabilized composition to fabric.
[0072] Make up solution of Organosilane-Non-Ionic Water-stabilized composition in head tank or side tank near pad (Organosilane-Non-Ionic Water-stabilized composition solution and the amount of Organosilane-Non-Ionic Water-stabilized composition will be 1%-4% on the weight of the goods). Calculate amount needed adjusting for wet pick up of fabric being padded. If vacuuming is used, make adjustment for this also.
[0073] Weigh Organosilane-Non-Ionic Water-stabilized composition carefully and accurately into warm water (80°-90° F.) Blend for 10 minutes to assure Organosilane-Non-Ionic Water-stabilized composition is adequately dispersed in water.
[0074] Drop solution to pad and run fabric through pad.
[0075] Check a wet pick up during run to assure Organosilane-Non-Ionic Water-stabilized composition is being affected to fabric.
[0076] Organosilane-Non-Ionic Water-stabilized composition can be padded on in the softener bath. Check compatibility of all softeners with Organosilane-Non-Ionic Water-stabilized composition prior to tying this.
[0077] Fabric can be dried according to conventional methods.
[0078] Application of Organosilane-Non-Ionic Water-stabilized composition can be checked by two means: Bromophenol Blue indicator-indicates the presence of Organosilane-Non-Ionic Water-stabilized compound by a blue cast. If no Organosilane-Non-Ionic Water-stabilized compound is present, no color will form. pHydron quaternary Test Strips QT-10-indicate the presence of a quaternary compound. These can be used to determine the effectiveness of the bath treatment. The strips can be used to test the bath by dipping the strip therein and one can read the amount of quaternary compound, if any, that has been left in the bath. As an added benefit, testing with the strips would determine if any anionic surfactant would be necessary to add to wastewater prior to release to city sewer. These test strips can be purchased from Fisher Scientific.
[0079] To prevent the discoloration or yellowish of fabrics, for example in the textile industry, it is necessary to control the pH of the bath. Alkalinity may prohibit Organosilane-Non-Ionic Water-stabilized composition from attaching to fabric. The pH of fabric should be less than 5.5 to aid exhaustion. Different Acids can be used for this process. The most common used are acetic acid and citric acid.
[0080] The concentration will be determined by the original solution used. Organosilane-Non-Ionic Water-stabilized composition will work and keep white fabrics from discoloring when the pH is from 4.5 to 5.5. It will also, pad or exhaust better when the pH is below 6.0. pH can be determined with a standard pH-meter or test strips.
By Spraying
[0081] On certain textiles, filters, membrane, nano and micro-fiber materials and non-woven extruded fabrics all pre-made, the formulation comprising material (Organosilane-Non-Ionic Water-stabilized composition) can be sprayed on in dilutions levels of 0.05%-4.5% of the active ingredient with conventional trigger spraying equipment, by aerosolization fogging [mist] spray, or by singular or multiple overhead nozzle spray releasers. Textiles can be hung after cleaning, and then spray on all sides, permitting the textile to either air dry or be processed through heat chamber or commercial dryer at less than 210° F. In certain instances of non-woven materials, the formula can be applied by spray, automatic sprayer or aerosolization spray release method, with preferable micron droplets of less than 6 in size, and air dried with a fan or processed through a heat chamber.
Healthcare Applications
Example 5
Medically Related Substrates
[0082] Organosilane-Non-Ionic Water-stabilized compounds described above can be effectively employed in the healthcare industry. Most preferably, the formulations taught herein employing the non-ionic wetting agent are employed. Examples of suitable locations and medical substrates where said compounds would be useful are healthcare facilities: hospitals, nursing homes, physician, dental and veterinary offices and operatories, waiting rooms, laboratories, and laboratory equipment, ambulatory clinics; “clean-rooms” and ambulances, patient transportation vehicles, computer keyboards, telephones, out-patient facilities; warehouse rooms in such facilities; including floors, walls, ceilings, door knobs, water and air-filtration systems; all air and arid duct systems, all bathrooms; showers; shower stalls and glass, and synthetic shower door coverings; shower faucets and drain covers; all tiles and adhesive fillers; laminates and finishes including alkyd, urethane, enamel, epoxy, siloxaline, amino resins, textile coatings, extrusion coatings, architectural coatings and overlays, anti-corrosion coatings, fire-resistant coatings, aliphatic coatings, vinyl-ester and polyester coatings, gel coatings, amino resins, resins used as additive mixes for cement, epoxy laminating resins, and blends and copolymers thereof; oncology departments; epidemiology departments; operating and recovery rooms; storage areas; elevators and stair wells, hand rails and buttons; soap dispensers and tabs; towel dispensers and tabs and pulls; toilet seats and covers; stalls, sinks and faucets; mirrors and windows, drapes and curtains; bed curtains and privacy curtains of all textile materials, woven, knitted and non-woven constructions; all beddings and sheets and pillow case of all textile materials and fiber and/or micro-fiber constructions, whether woven, non-woven or combinations of both, as well as all knitted materials used separately or in combination with woven and non-woven materials; body bags or bio-barrier body coverings; bed pads and absorbents; bed rails, and backs; table chairs and other furniture used within these facilities whether made of wood, wood by-products, or metals including but not limited to steel of all varieties; all furniture of extruded polymers of synthetic origins including but not limited to plastics; all floor coverings including synthetic tiles; ceramic tiles; wood, cement, concrete; carpeting of all fiber constructions All desk, computer key boards, mouse; phones; remotes, ear and head sets. In addition, medical equipment designed to contact a patient and take readings, including digital transmission surfaces.
[0083] Organosilane-Non-Ionic Water-stabilized compounds disclosed in Liebeskind and Allred as described above, and most preferably the formulations taught herein which employ the non-ionic wetting agent can be used to treat filters, including but not limited to air filters for furnaces, air-conditioners, air purification devices, automobiles, re-circulating air handling systems, air filters/materials); water filters; all materials consisting in the composition of such filter materials like carbon based filters; polypropylene and cellulose fibers, nano and micro-fibers, and all membrane materials used for filtration included but not limited to such materials and fibers.
[0084] These compounds and formulations can be employed in the treatment of blood filtration material consisting of but not limited to polypropylene, polystyrene; polyethylene, membrane and nano micro-fibers, resin materials used and treated with the formula to be incorporated into such filters; kidney filtration and blood filtration.
[0085] Further applications are the treatment of treat textiles used in the healthcare industry made of woven, non-woven, knitted and knitted and woven and nonwoven, nano and micro-fiber compositions, of fibers including but not limited to rayon, polyester, silk, nitril, polypropylene, polyolefin; polystyrene; polyethylene, cotton, linen, cotton and nylon blends, cotton and polyester blends, raime and nano and micro-fibers. Examples of such textiles are uniforms; linens; beddings; operating gowns; gloves used in the medical field; foot gear, such as disposable hospital slippers; towels; privacy curtains; body bags [as bio-barriers]; absorbents, woven and non-woven; socks; head gear; masks; face and eye protectors; disposable single-use blood cuffs; privacy curtains; foot coverings; sterile equipment blankets of woven; non-woven; knitted and combinations of knitted and woven and non-woven constructions including but not limited to cotton; cotton blends; polypropylene; polyester and polyester and cotton blends; nylon and nylon and cotton blends; rayon and rayon and cotton blends; silk; ramie; nano and micro fiber materials of synthetic and natural origins fibers whether woven or non woven, knitted or combination of knitted and woven or nonwoven, wool and wool blended fabrics and fibers. It is appropriate for the aforesaid material whether woven, knitted, non-woven, brushed, fleeced, or sheared. It also may be used to treat gauze and band-aid dressing as well as wound-dressing materials
[0086] The above-described compounds and formulations can be used to treat dry and wet wipes of woven; non-woven, knitted or combinations thereof, pre-moistened towelettes and tissue wipes, institutional sponges and mops, water pails, and squeegee rollers, mop handles, and vacuum cleaner bags, disposable plastic garbage bags and bed bags of all sizes and on all synthetic compositions.
[0087] The above-described compounds and formulations can be used to treat the interior and exterior of ambulances, carts, gurneys, stretchers, blankets, warming devices, stabilizing accessories, intravenous (i.v.) pole materials whether synthetic or metallic, IV lead wires; EKG lead wires and all bases, and tubing thereof. It can also be used to treat bed pans, trays, wheelchairs, machined mechanical components for assembly into final products, Endoscope sterilizers and disinfectors and associated equipment, Central supply shelving and counter tops, stethoscopes, metallic and synthetic derivatives, blood pressure cuff and single use disposable blood pressure cuffs, band-aids, gauze, wound dressing bandages, and catheters; stints; all assay equipment and materials used in the manufacture of such; skin grafts and synthetic skin grafts and protective covers, endoscopes, and other surgical apparatus, EKG wires and skin tabs, and for sterilizing garbage disposable bags, medical gloves of all synthetic material compositions (such as nitril, polypropylene and polystyrene) and finger tip coverings made of a variety of materials including but not limited to latex or nitril. Furthermore it has applications to periodontal uses such including but not limited paste, liquids, creams or ointments.
[0088] The above-described compounds and formulations also have application in emergency vehicles, homes, offices, automobiles, all transportation vehicles; hospitals and contagious illness rooms, hotels, schools, day care centers, and correctional facilities.
Agribusiness Applications
[0089] In addition to the health care industry, the above-described compounds and formulations have application in agribusiness for bacterial control in the raising of and processing of meat-producing animals, including poultry, swine, cattle, fish etc. They can also be used on plants and plant materials and derivatives. Example 6 concerns the poultry industry applications, but many of the same principals apply to the raising and processing of other meat producing animals. Example 7 provides an example of the use in plant agriculture.
Example 6
Poultry Industry Applications
[0090] The above-described compounds and formulations compositions can be used in the poultry industry. Spraying, fogging, mist, brushing, dipping, soaking, ultrasonic aerosolization, etc, can be employed to apply this solution to areas used to raise animals, meat processing areas, and to the animals themselves. For cleaning and disinfecting commercial applications, the above-described compounds and formulations can be used on livestock houses including cages and equipment, farm and transportation vehicles for animals, foot and tire dips, food processing plants (walls, ceilings, floors & fixtures), refrigerators and coolers, hatcheries (hatchers, setters, evaporative coolers, humidifying systems, cooling towers, ceiling fans, etc.) ability to protect pedigree eggs during collection, storage and incubation.
[0091] Brooder houses, laying houses, and equipment may be treated as follows. After houses and equipment are thoroughly cleaned, washed down and allowed to dry—and before a new flock is housed—the entire inside surface of the room (building) and all the equipment are sprayed with the proper concentration of the above-described compounds and formulations compositions and let dry before rehousing.
[0092] For example, the above-described compounds and formulations can be applied via spraying, fogging, mopping or rollers. Aerosol spray at different droplet sizes ranging from one-8 micron can be employed.
[0093] Application to and stainless steel equipment or processing machines by re-treating with an aminodiacetic acid for highly buffed stainless steel may be employed. Liquid aminodiacetic acid is first applied to the surface or stainless steel permitted to dry and then the above-described compounds and formulations compositions is applied, adhering to the acid instead of the actual metal.
[0094] Hatcheries (hatchers, setters, evaporative coolers, humidifying systems, ceiling fans, etc.) can be treated with the above-described compounds and formulations Chick hatcheries are thoroughly cleaned, washed downed, and disinfected after each hatch. The above-described compounds and formulations may be used to treat these areas and has the advantage of being long-lasting in that it does not need to be applied after every cleaning and wash down as it has residual activity in killing threatening bacteria or viruses before it is scheduled for the next application. An application schedule can be determined by periodic microbial testing using standard methods.
[0095] Egg Holding, Cooling and Storage Rooms can be treated with the above-described compounds and formulations. These facilities are air cooled and usually equipped with humidifiers connected to automatic controls. The above-described compounds and can be mixed with the humidifier spray and will add a controlling factor to kill salmonella or other harmful bacteria that might be on the surface of the eggs, cases, holding racks and room's interior surfaces.
[0096] Egg Breaking and Processing Rooms and Equipment can be treated with the above-described compounds and formulations compositions. Work rooms and equipment are thoroughly cleaned, washed downed and disinfected at the end of each day. Non-Ionic Microbiostatic Agent can be applied by a cleaning crew after one of the cleanings. The cleaning crew does not need to reapply the organosilane-non-Ionic-water-stabilized compositions after each cleaning since it continues to exhibit antibacterial activity.
[0097] Broiler Processing and Further Processing Operations can be treated as described above.
[0098] Other poultry application examples include application to feed packaging material and food storage bins to mitigate mold and fungi, poultry houses including cages and equipment, application to synthetic fingers (the synthetic like cork screws that beat off the feathers), walls, ceilings, crates, and filters, farm and transportation vehicles for animals (it will not damage brake linings of the vehicles and it is non-corrosive); foot and tire dips, processing Plants (walls, ceilings, floors & fixtures), refrigerators and coolers, conveyors belts of synthetic and natural based fibers in woven and non-woven constructions, and textiles worn or employed by poultry workers (e.g., uniforms, towels, masks, hats, shoes).
[0099] It can be applied to packaging as it will not leach off the surface, yet will kill the organisms which are encapsulated in the packaging, but not limited to trays, napkins inserts and clear package covering, those providing a longer shelf life. It can be applied to the egg shell, which would create a lattice prophylactic against environmental contaminants. This could also have utility in the pharmaceutical industry in the use of eggs for developing vaccines. It can be used on textiles used as bio-barrier to cover and protect vegetable, fruit and plant growth.
Example 7
Plant Applications
[0100] The Organosilane-Non-Ionic-Water-stabilized compositions disclosed in Liebeskind and Allred and the formulations thereof disclosed herein can be used on seedlings, on feed- and fertilizer storage bins and packaging materials to mitigate microbial growth therein. It can be sprayed on stems and leaves as well as fruits and vegetables.
[0101] The above-described compounds and formulations can be used on textiles, used as bio-barriers against microbial contamination, such as for fruit, vegetables, and plants, whether grown just above soil or on trees or harvested in green houses.
[0102] Other applications include Congregational and Sports Hygiene for correctional institutions; cruise lines convention centers; subways and terminals; airports and terminals theaters, buses; trains and planes, sport and fitness facilities, including but not limited to locker rooms, training rooms, pools, mats such as Yoga wrestling and wall mats, exercise balls basket balls, soccer balls, volleyballs: benches synthetic fields, team uniforms and team equipment. The above-described compounds and formulations compositions can be used on all interior and exterior applications of this type of congregational structure. The cruise and ship lines can use it as an anti-fouling coating. It can be applied for example to handrails, all textiles, carpets, seats furniture, outdoor furniture, umbrellas; trays, furnishing, and linens such as sheets and napkins. The same applications above can be used for hospitality inclusive of restaurants and hotels,
[0103] The above-described compounds and formulations can also be used in the Food & Beverage industry. Possible applications include conveyor belts; interior and exterior surfaces, including walls, floors, ceilings; filters air-ducts systems; roofing and siding materials; refrigerators; cooling and heating systems; all holding tanks; hooks, carcasses; all materials used in packaging such as paper; cellophane; composite trays; tray napkins, all textiles, masks, gloves, uniforms, towels; wipes, hats foot gear, metallic processing tables, and industrial processing equipment; bins; trays; boxes corrugated or wood; hoses; beverage tanks; tubing; bottling and storage, disposable garbage bags, trucks and other transportation vehicles, and disposable wiping cloths that can be used for multiple purposes such as dusting or washing furniture, cars, walls, windows, floors, appliances, dishes, counter tops.
[0104] There are numerous applications in the military as well. Some examples are application to wound dressings, uniforms, socks, footgear; head gear; masks; underwear; gloves, outerwear; absorbents; sleeping bags; tents; mobile hospital textiles; trucks; helicopters; planes ambulances; and hospital settings as described above. | Methods of applications of organosilanes optionally having a nonhydrolyzable organic group, but having one or more hydrolyzable groups, with a polyol containing at least three hydroxy groups, where any two of the hydroxy groups are separated by at least three intervening atoms by aerosolization of droplets between 0.5-8 microns are disclosed and an improved formulation comprising adding a nonionic wetting agent are disclosed. An improved aerosolization application technique and the improved formulation provide for smaller droplet size and better coverage of substrates to which the organosilanes are applied. The improved formulation has increased affinity, reduces surface tension and therefore can covalently bond more quickly. A method of treating a substrate, and the treated substrate so formed, by contacting the substrate with the improved formulation for a period of time sufficient for treatment of the substrate are disclosed. | 0 |
BACKGROUND OF THE INVENTION
The present invention relates to the linkage construction for a hydraulic excavator. Typically the shovel linkage for such excavators includes a boom pivotedly connected to the frame of the excavator, and a stick pivotedly connected to the boom and having its distal end adapted for fitting with a bucket or other digging implement. The construction of the prior art boom and stick comprises spaced parallel side plate members joined by top and bottom plate members to form a generally rectangular box-like construction. The distal end of the boom typically has offset brackets extending from the sides thereof which are provided with pivots which are connected with mating pivots on the stick by means of pins, whereby the side walls of the stick are embraced between the sidewalls of the boom. As a result forces transmitted between the boom and stick through such pivot joints result in torsional loads on the boom and stick side walls.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a shovel linkage for a hydraulic excavator wherein the links are connected in line to avoid bending moments induced by the offset brackets of the prior art.
It is also an object of the present invention to provide a shovel linkage for a hydraulic excavator which eliminates torsional loads in the members thereof.
These and other objects and advantages are achieved in the present invention wherein the shovel linkage boom and stick comprise spaced parallel rail members joined by cross tubes therebetween and having cooperating pivots provided in the mating ends thereof whereby the respective rails of the boom and stick will be coplanar, avoiding torsional loads transmitted therebetween.
This absence of torsional loads in the boom and stick rails permits reduction in a number of cross members joining the rails while providing a shovel linkage of greater strength than that provided by the prior art.
The pivots provided in the ends of the boom and stick allow the use of shorter pivot pins, and the associated reduction of bending moments therein.
Bucket stops provided on the bucket implement on the end of the linkage are arranged to cooperate with stops provided in the center of the boom (stick) rails for better strength and further elimination of torsional loads.
DESCRIPTION OF DRAWINGS
In the drawings:
FIG. 1 is an elevational view of shovel linkage embodying the present invention,
FIG. 2 is a plan view of the boom link of the shovel linkage shown in FIG. 1,
FIG. 3 is a side elevational view of the boom link of the shovel linkage of the present invention,
FIG. 4 is a plan view of the stick link of the present invention,
FIG. 5 is a side elevational view of the stick link of the present invention,
FIG. 6 is a sectional view of the boom link of the present invention taken along the line and in the direction indicated by the arrows 6--6 in FIG. 2,
FIG. 7 is a sectional view of a boom rail of the present invention taken along the line and in the direction indicated by the arrows 7--7 in FIG. 2,
FIG. 8 is an enlarged view of the junction of the boom and stick rails of the present invention.
FIG. 9 is a sectional view of the stick link cross tube shown in FIG. 4 taken along the line in the direction indicated by the arrows 9--9,
FIG. 10 is a sectional view of the rod pivot joint of the present invention taken along the line in the direction indicated by the arrows 10--10 in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a shovel linkage for a hydraulic excavator, which comprises an undercarriage 12 and a frame 14 rotatable mounted thereon and supporting an engine compartment 16 and an operator's cab 18, is shown generally at 20. The shovel linkage includes a boom 22 pivotedly mounted on the excavator frame by means of pivots 24, and a stick 26 pivotedly connected to the boom in a manner to be hereinafter described. Pivotedly attached to the distal end of the stick is a bucket 28 which is controllable by means of a hydraulic jack 30 connected to links 32 and 34 which in turn are pivotedly connected to the stick and bucket respectively.
Hydraulic jacks 36 pivotedly connected to the excavator frame and to the outer end of the boom controls motion of the boom, and hydraulic jacks 38 pivotedly connected to the boom and to a stick controls movement of the stick with respect to the boom.
A master cylinder 39 if pivotedly connected to the excavator frame and to the outer portion of the boom to control bucket attitude upon raising of the boom.
Referring to FIGS. 2 and 3, boom 22 comprises a pair of spaced, parallel rails 40 and 41, being of a generally box-like cross section and comprising spaced, parallel side walls 42 joined by parallel top and bottom walls 43 and 44, as shown in FIG. 7. Pivots 24 provided in one end of the boom rails comprise cylindrical sleeves 45 disposed between the side walls of the rails and retained therein by conventional means.
Rails 40 and 41 are interconnected by means of cross tubes 48 and 50 comprising cylindrical members which are secured therebetween by flanges 52 welded to the tubes immediately outward of the two outside walls of each of the rails.
Attached to each of the cross tubes are tabs 54 having pivots 56 provided therein for attachment of hydraulic cylinders 38 thereto.
The outer ends of the boom rails are also provided with pivots 58 similar to pivots 24 comprising cylindrical sleeves 62 secured therein.
The lower forward portion of sidewalls 42 rails 40 and 41 are provided with depending tabs 64 and 66 having pivots 68 and 70 provided therein for connection of boom jacks 36 and bucket jacks 30 thereto respectively, intermediate the side walls of each rail. Accordingly, the boom and bucket jacks are on the longitudinal center lines of the boom and stick rails. Thus the loads imparted by these cylinders are transmitted down the center line of the boom.
Referring to FIGS. 4 and 5, stick 26 also comprises a pair of spaced parallel rails 72 and 73 comprising box sections having sidewalls 74 joined by top and bottom walls 75 and 76. The rails are joined by cross tubes 77 and 78 comprising cylindrical members which project through appropriate openings in the side walls of the rails and are retained therein by flanges 80 secured to the cylindrical members immediately adjacent to the outside edges of the rail sidewalls. Provided on cross tube 77 are collars 82 which include depending ears 84 having pivots 86 provided therein for connection of the rod ends of the hydraulic jacks 38 thereto.
As seen in FIGS. 4 and 8, one end of stick rails 72 and 73 are adapted for pivotal connection with the outer ends of the boom rails, and have bifurcated ends 88 provided by extended portions 90 of the rail sidewalls which project beyond the top and bottom walls joining the rail sidewalls and have pivot journals 92 provided therein whereby the extended portions of the rail sidewalls are adapted to embrace the outer ends of the boom rails wherein the pivot journals 92 will be in coaxial alignment with the pivot 58 provided in the boom rails for pivotal connection therewith by means of pins 94. As shown in FIG. 8, this construction results in rails 72 and 73 of stick 26 being disposed in direct alignment with the rails 40 and 41 of boom 22. Thus forces transmitted between the boom and stick through the pivot joints impart no torsional loads to the boom or stick rails. In addition, pins 94 may be kept relatively short, being little longer than the width of the boom and stick rails, and are symetrically loaded in a manner which will minimize bending moments in the pins.
The other, distal end of stick 26 is bifurcated by a similar extension of the rail sidewalls beyond the top and bottom walls thereof, and said extended end portion, 96 is also provided with pivots 98 for pivotal connection with a bracket 100 provided on bucket 28. Links 32 and 34 are pivotedly connected with the end of hydraulic cylinder 30 and the stick and bucket respectively for selective rotation of the bucket with respect to the stick. As shown in FIG. 4, parallel links 32 are pivotedly mounted on the stick by means of cylindrical pivot pins 102 extending through each of the stick rails 72 and 73, and are pivotedly connected with a pivot 104 provided in the cylinder end of hydraulic cylinder 30 by means of a pin 106 outboard of parallel links 34 and spaced therefrom and from 104 by spacers 108. Links 34 are in turn pivotedly connected to a bracket 110 provided on the rear of bucket 28, by means of pivot pins 112 and spacers 114. Bracket 110 has a flatened edge 116 which is disposed to engage the bottom of the stick rails upon a retraction of cylinder 30, and thus serves as a stop means for bucket 28. As seen in FIG. 4, bracket 110 and edge 116 on each side of the bucket are in line with the stick rails and will engage the rails upon full retraction of hydraulic cylinder 30 at the center thereof, avoiding unsymetrical loading of the stick rails.
The top of the stick will also have a stop 118 which is similar to that described above. This stop stops rotation of the bucket upon extension of the bucket cylinders. | A shovel linkage for a hydraulic excavator or the like has spaced parallel boom link rails which are coplanar with associated spaced parallel stick link rails and pivotedly connected thereto by means of pivot joints provided on the ends thereof.
Bucket stops are provided on a bucket attached to the stick and are arranged to contact the centers of the stick rails for greater strength. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for texturing an advancing yarn, and which includes a nozzle wherein a pressurized heating fluid, such as hot air, is brought into contact with the advancing yarn, and a perforated stuffer box is disposed adjacent the outlet end of the nozzle for forming the yarn exiting from the nozzle into a compressed plug.
Texturing nozzles of the described type are known from DE 26 32 082, EP 256 448, and U.S. Pat. No. 5,088,168. In these texturing nozzles, the nozzle includes an annular duct which surrounds the yarn passageway, and a conical duct which leads from the annular duct to the yarn passageway. The heated air is delivered into the annular duct so that it proceeds via the conical duct into the yarn passageway. However, the heated air tends to form turbulences in the annular duct and the conical duct which is adjacent thereto. Such turbulences lead to a twisting of the yarn. It is then not possible to crimp the yarn to an adequate extent in the subsequent stuffer box. On the other hand, however, a slight twist formation is desired, so that the yarn advances smoothly. To produce clear conditions, a preferred direction of twist is predetermined by the layout of the annular duct. This again results in that in certain applications, the twist insertion is too strong, and does not permit an adequate crimping. In a multi-position texturing machine, it is also desired that the twist formation of all texturing nozzles be identical. This necessitates a very fine adjustment of all texturing nozzles, which can be carried out only by highly qualified personnel with good knowledge and experience.
It is accordingly an object of this invention to construct a texturing nozzle such that it allows a totally twistfree texturing, but avoids differences in texturing from production station to production station during its operation, by providing that each texturing nozzle is controllable and adjustable.
SUMMARY OF THE INVENTION
The above and other objects and advantages of the present invention are achieved by the provision of a yarn texturing apparatus which comprises a nozzle including a passageway through which the yarn is to advance at high speed from an inlet end to an outlet end, and duct means for conducting a pressurized heating fluid into the passageway during operation of the apparatus. The duct means includes an annular duct surrounding the yarn passageway in said nozzle, a supply duct communicating with the annular duct, and the conical duct extending from the annular duct to the yarn passageway. A perforated stuffer box is disposed adjacent the outlet end of the yarn passageway for receiving and forming a compressed plug from the advancing yarn exiting from the passageway. Also, in accordance with the present invention, means are provided in the supply duct for adjustably controlling the predominant direction of flow of the heating fluid into the annular duct.
One advantage of the invention is that while basically all nozzles can be designed for optimal and twistfree processing, it is nonetheless desirable to be able to eliminate differences in the twist insertion from station to station by the adjustment of each nozzle during operation.
In one preferred embodiment, the direction controlling means comprises a generally flat baffle plate which is mounted for rotation about a pivotal axis which is parallel to the direction of the yarn passageway. This construction offers the advantage of influencing also the velocity of the hot air along with the adjustment of the direction of its inflow.
The pivotal axis of the flat baffle plate may be located adjacent the downstream end of the plate. This offers the advantage that, along with the increasing deflection of the inflowing hot air, an increasing portion of the arriving hot air current is caught and deflected.
This advantage is achieved in that the baffle plate or deflector points upstream with its movable end. This allows the deflector to block the free cross section of the supply duct only such that the "stream lines" of the hot air impacting upon the deflector are deflected with a directional component in direction toward the intended twist insertion. The formation of dead zones between the impact surface of the deflector and the supply duct is avoided with certainty.
The axis of rotation of the flat baffle plate is preferably arranged in the supply duct immediately adjacent the annular duct. This construction contributes to a substantially lossfree entry of the hot air into the annular duct directly after the twist insertion. It is preferred to arrange the axis of rotation at the end of the deflector, so that the angular position of the deflector establishes the direction of inflow at its end related to the axial direction of the arriving flow.
The direction controlling means may also be constructed as a rotatable pin, whose axis of rotation is arranged such that it extends parallel to the central axis of the annular duct. Through the pin a radial bore extends, which lies parallel to the axis of the supply duct for the hot air. The axis of the supply duct itself extends perpendicularly to the axis of the rotatable pin, i.e., the air flows through the radial bore of the pin and enters then into the annular duct.
In this arrangement, the diameter of the radial bore of the pin on the inlet side will correspond for flow reasons (i.e. the avoidance of losses) substantially to the diameter of the supply duct of the hot air stream. It may however be also made greater than the supply duct for the hot air stream, so as to ensure in the rotated arrangement a lossfree entry from the supply duct into the radial bore of the pin. Likewise, it is conceivable that the radial bore has on its outlet side either the same diameter as on the inlet side or a smaller diameter. Such a conical radial bore may be utilized for structurally influencing the flow in the annular duct.
In any rotated position of the pin, the outlet side of the radial bore abuts or lies close to the annular duct, so that likewise in any rotated position of the pin it is possible to align the flow through the radial bore into the annular duct either to the left, or to the right, or to the center when the angle of rotation is zero.
A further, alternative embodiment of the direction controlling means consists of a rotatable cylindrical insert, which is arranged parallel to the axis of the supply duct. The insert in this embodiment is provided with an axial bore extending therethrough, which starts on the inlet side of the hot air in concentric relationship to the supply duct, and emerges on the outlet side into the annular duct with a defined offset in eccentric relationship to the supply duct.
The diameter of the axial bore may again correspond on the inlet side substantially to the diameter of the supply duct for the hot gas stream so as to prevent losses, or it may be greater than same. Likewise, it is again conceivable that on the outlet side the axial bore has the same diameter as, or a smaller diameter than the supply duct for the hot gas flow.
The outlet side of the axial bore preferably abuts or lies close to the annular duct and the outlet may possibly even project into the annular duct. By rotating the insert about its axis, i.e., the axis of the supply duct for the hot air flow, the flow through the axial bore into the annular duct is directed either to the left, or to the right, or to the center when the angle of rotation is zero.
The eccentricity by which the axial bore is offset between the inlet side and the outlet side, depends on the production process, and is preferably small in comparison with the other deflection of the hot air flow in the annular duct.
The insert is adjusted via suitable adjustment means from the outside of the texturing nozzle. Preferably, the insert is adjusted via a worm drive, in which the insert is used as a worm gear, and a worm actuatable from the outside rotates the worm gear and thus the insert.
A further, alternative embodiment of the direction controlling means comprises a translationally movable member, which will normally be shaped in a flow-favorable manner, for example, as an elongate cylinder. The axis of the cylinder will be arranged parallel to the axis of the annular duct, it being possible to displace this movable member perpendicularly to the axis of the annular duct and simultaneously perpendicularly to the axis of the supply duct. A suitable positioning of this movable member relative to the hot air flow allows to urge upon same a desired twist. More particularly, the lateral positioning of the movable member relative to the hot air flow, i.e., absent a flow around both sides of the movable member by the hot air stream, allows to achieve likewise a twist-imparting deflection of the hot air flow.
The above described movable member will be arranged close to the annular duct, and causes by its displacement along its possible movement the hot air flow to enter into the annular duct either to the right, or to the left, or in the center.
A further, alternative embodiment for imparting a twist may consist not only of deflectors or deflecting devices arranged at a fixed point to impart to the hot air flow the desired twist, shortly before its entry into the annular duct, but also that this twist impartation may be already generated during its flow through the supply duct. To this end, it is possible to achieve by a suitable configuration of the supply devices, such as, for example, by spatially arranged winding guide elements, a pulse transmission to the hot air flow, and thus a twist impartation to the yarn by a corresponding introduction of the air stream into the annular nozzle. Thus, the hot air stream flows already with a certain angle of deflection into the texturing nozzle, and is therein caused to enter into the annular duct at the desired angle of deflection. The guide elements may be adjustably mounted to permit adjustable control of the predominant direction of flow, or they may be fixed in the supply duct.
BRIEF DESCRIPTION OF THE DRAWINGS
Some of the objects and advantages of the present invention having been stated, others will appear as the description proceeds, when considered in conjunction with the accompanying drawings, in which:
FIG. 1 is a partly schematic sectional view of a first embodiment of a texturing apparatus of the present invention, with a pivotal, preferably a flat baffle plate as a deflector;
FIG. 2 is a top view of a deflector of FIG. 1 in one operative position;
FIG. 3 is a top view of the deflector of FIG. 2 in a partially blocking position;
FIG. 4 is a top view of a deflector with a downstream positioned axis of rotation;
FIG. 5 is a top view of the deflector of FIG. 4 in a partially blocking position;
FIG. 6 shows an alternative embodiment of a texturing apparatus of the present invention, with a rotatable pin having a radial channel extending therethrough;
FIG. 7 is a top view of the deflector in accordance with FIG. 6;
FIG. 8 is a top view of the deflector in accordance with FIG. 6 for an alternative direction of twist;
FIG. 9 shows a further embodiment of a texturing apparatus of the present invention, with an insert having an axial channel extending therethrough, which is adjusted by means of a set screw with a worm;
FIG. 10 is a top view of the deflector in accordance with FIG. 9;
FIG. 11 is a top view of the deflector in accordance with FIG. 9 for an alternative direction of twist; and
FIG. 12 is a top view of yet a further texturing apparatus of the present invention, with a cylindrical deflector.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Unless otherwise specified, the following description will always apply to all Figures.
A texturing apparatus 1 consists of a feed nozzle 2 and a stuffer box 3. The feed nozzle 2 consists of two, substantially identical nozzle halves 4 and 5, which can be tightly pressed against each other along a separating joint 16. Formed in both nozzle halves 4 and 5 is an annular duct 8. This annular duct 8 is preferably concentric with a yarn passageway 6, which is formed by communicating grooves respectively provided in the one and the other nozzle half 4, 5. Also, the annular duct 8 defines a plane which is disposed perpendicular to the direction of the yarn passageway 6.
The annular duct 8 receives via a supply duct 7 a heated fluid, i.e., hot air or hot vapor. The supply duct 7 communicates with the annular duct 8 in a transverse direction which is generally perpendicular to the direction of the yarn passageway 6, and which defines a plane of symmetry 19 which includes the yarn passageway 6.
Extending downwardly from the annular duct, and coaxially with respect to the yarn passageway 6, is a conical duct 9. This conical duct tapers in the direction 17 of the advancing yarn and terminates at is lower end via an annular gap 18 in the yarn passageway. The hot air jet entering at this point into the yarn passageway entrains the yarn 10 and advances it into the subjacent stuffer box 3. There, the yarn is accumulated and compressed to a yarn plug 11, and thereby crimped by the action of pressure and heat. The hot air escapes laterally through perforations 12 in the walls of stuffer box 3. Upon leaving the stuffer box 3, the plug 11 is disentangled to form a crimped yarn 10.
As can be seen in FIG. 2, the hot air may have the tendency of assuming in annular duct 8 a preferred direction of flow to the left or right. In this assumed direction of flow, the hot air flows then through conical duct 9 into annular gap 18, and imparts here to the yarn the specific twist, which leads in part to a true twist, and in part to a false twist of the yarn. On the one hand, this twist is useful for a smooth advance of the yarn supplied to the feed nozzle. On the other hand, this twist prevents the yarn from opening in the stuffer box as the hot air expands, and from being fully exposed to and crimped by the action of heat and pressure. This will turn out to be noticeably disturbing in particular, when in a multiposition texturing machine the specific direction of flow differs from position to position, thereby developing a different twist tendency in the yarn.
To alleviate this, a deflector 13 is provided in supply duct 7. This deflector, as shown in Figure 1, has the shape of a flat baffle plate, which is rotatable about the axis of post 14. This axis of rotation lies on the one hand in the plane of the deflector plate, and on the other hand parallel to the passageway 6 and the yarn advance direction 17. The deflector plate is arranged on a rotatable post 14, which can be adjusted from the outside and secured in position by a nut 15. As a result, it is possible to adjust the inclination of the deflector plate relative to the plane of symmetry 19 of supply duct 7, which simultaneously extends through the axis of the advancing yarn 10. The plane of symmetry 19 thus equals the plane of drawing in FIG. 1. This allows, within a certain range of adjustment, to direct the hot air stream, which is supplied through duct 7, into a certain direction, so that the hot air assumes a certain direction of flow in the annular duct. Likewise, it is possible to influence the intensity of this flow. If the deflector 13 is still further adjusted, it will partially close the supply duct on the one side of the plane of symmetry 19, as is shown in FIG. 3, thereby influencing likewise the direction of flow in the annular duct.
FIGS. 4 and 5 illustrate the deflector 13 as being rotatable about a post 14, which is located in the downstream end region of the deflector. As a result, the freely movable end of the deflector is directed oppositely to the arriving flow.
At its foremost tip, this free end possesses a defined leading edge for the arriving hot air. Consequently, at this point, the arriving hot air stream is divided as a function of the respective angle of incidence. A very fine adjustment of the general direction of inflow is thus made possible.
With its free end the deflector can be rotated by the incident flow, and in so doing moves through a sector angle, the apex of which is located downstream with respect to the leading edge of the deflector, and coincides with the axis of the rotating shaft.
In a randomly rotated position, the incident flow is presented with an impact surface, which deflects the incident "stream lines" in direction toward the axis of the rotating post, and thus in direction toward the generally intended direction of inflow.
As can be noted, an increasing angle of incidence of the deflector thus allows to block an increasing portion of the free cross section of flow in the supply duct, so that an increasing number of "stream lines" is thereby affected and deflected in the general direction of inflow.
Consequently, the arrangement of the axis of rotation at the downstream located end of the deflector allows to increase, as the deflection becomes greater, the hot air stream which is throughput, to the extent it assumes the intended direction of inflow.
It becomes therefore possible to influence at the same time the mechanical parameters, such as mass throughput and angle of deflection, which are relevant to the twist impartation.
In combination with the arrangement of the axis of rotation at the end of the deflector, this fact is of considerable advantage, since the cross section of the duct, which remains always open, is not influenced by the rotating motion. The cross section remaining always open, will then be predetermined only by the position of the axis of rotation in the channel.
Moreover, when the axis of rotation is arranged, as illustrated, in the end region of the supply duct, it will be accomplished that the deflected stream flows with the imparted twist into the annular duct directly after the deflection. This allows to largely avoid a loss-carrying impact of the hot air molecules upon the walls of the supply duct and/or annular duct, since the flow arrives in the annular duct substantially with a direction of inflow, which is predetermined by the duct geometry. There exists, at least at the moment of entry into the annular duct, a substantial flow component in the circumferential direction.
It is preferred that the axis of rotation be arranged either in the end region of the supply duct or in the region of transition between supply duct and annular duct. In both instances, a trailing edge forms on the deflector, the tangent of which predetermines the flow-off direction, in which the hot air enters into the annular duct. The below-described, alternative embodiments of the deflecting devices, which are arranged in the texturing nozzle, are based on the foregoing description of FIGS. 1 or 2-5. In these embodiments, only the deflector as well as its actuating elements are exchanged. Therefore, for a complete description, reference may be made to the foregoing text.
Shown in FIG. 6 is a deflector, which consists of a rotatable pin 21. Its axis of rotation is arranged such that is extends parallel to the axis of annular duct 8. The rotatable pin 21 possesses a radial bore 22 extending therethrough, the axis of which is again aligned parallel to the axis of supply duct 7 for the hot air. As a result, the hot air entering into supply duct 7 is guided through radial bore 22 into annular duct 8.
By rotating the pin 21 about its axis of rotation with the aid of rotating shaft 20, it becomes possible to rotate the radial bore relative to the axis of the supply duct (note FIGS. 7 and 8). This rotation allows the hot air flow to be given a predetermined direction, in which it is intended to enter into annular duct 8. Alternative directions of flow are on the one hand to the left, on the other hand to the right, and to the center of annular duct 8, when an angle of rotation is set to zero, namely when the axis of the radial bore is aligned parallel to the axis of supply duct 7.
Normally, the diameter of radial bore 22 is selected as a function of the diameter of supply duct 7. Conceivable are the following alternatives:
(a) A cylindrical radial bore having equal inlet and outlet diameters;
(b) The inlet diameter of the radial bore is greater than the outlet diameter, i.e., a conically narrowing radial bore is present; and
(c) The inlet diameter of the radial channel is smaller than the outlet diameter, i.e., a "reverse" conical radial bore is present, which influences the hot air flow as a diffusor.
With respect to the inlet diameter of radial bore 22 it is always necessary to make sure that the flow from supply duct 7 into radial bore 22 is free of losses in any possible rotated position. Therefore, as a rule, it will be necessary to select the supply duct 7 smaller than the inlet diameter of the radial bore. Shown in FIGS. 7 and 8 are the two alternative positions of pin 21 for the flow to the right or to the left. A conical radial bore 22 is illustrated, the inlet diameter of which is greater than its outlet diameter.
Shown in FIG. 9 is a further, alternative embodiment of the deflector. It is in this instance a rotatable, cylindrical insert 24, which is arranged parallel to the axis of supply duct 7. An axial bore 25 extends through this deflector, which starts on its inlet side for the hot air in concentric relationship with supply duct 7, and emerges on its outlet side into annular duct e with a defined offset in eccentric relationship to the axis of supply duct 7. This rotation of the axial bore allows to achieve, when deflecting insert 24 is adjusted to different angles of rotation, a deflection of the hot air flow to the left in the direction of flow, to the right in the direction of flow, or centrically upward or downward in the direction of flow. The foregoing thoughts with respect to the selection of diameter for the radial bore 22 of FIG. 6 apply analogously also to axial bore 25 of FIG. 9. Also conceivable in this instance are cylindrical or conical embodiments of the axial bore.
The eccentricity of axial bore 25 between the inlet diameter and outlet diameter of insert 24 is normally selected as a function of the production process and is preferably small, when compared with the other deflection of the hot air flow in annular duct 8.
The rotation of deflector insert 24 about its axis may be performed via suitable adjustment devices, preferably from the outside of the texturing nozzle. A preferred embodiment for this purpose may be a worm drive, in which deflector insert 24 is used as a worm, and is provided on its exterior with a worm gear tooth system. An externally actuatable worm 23 allows to rotate the worm gear and thus the insert about the axis of the deflector insert. Shown in FIGS. 10 and 11 are two positions of the deflector insert, with FIG. 10 illustrating a deflection of the flow to the left in the direction of flow, and FIG. 11 a deflection of the flow to the right in the direction of flow. In the Figures, the drive worm 23 is indicated only as a sectional plane. The axial bore 15 is shown as a cylindrical channel, with the outlet side of the bore projecting slightly into annular duct 8.
In the embodiment shown in FIG. 12, the hot air flows around an elongate, in the example cylindrical deflector 26, which is arranged on a sliding pin 27, the latter being actuatable from the outside. As a result, the deflector 26 can be displaced perpendicularly to the axis of supply duct 7. In this embodiment, use is made of the lifting surface or airfoil effect, and as a result of the configuration of deflector 26, a vacuum is produced in the location of deflector 26 in supply duct 7, when air flows around deflector 26, behind (when viewed in direction of flow) the deflector 26, whereby the hot air undergoes a deflection in the respectively desired direction. Thus, when pin 27 is displaced, and thus deflector 26, the desired twist is imparted to the hot air, as it enters into annular duct 8.
It should be emphasized that a body utilizing this effect need not be absolutely symmetrical in rotation. In the place of the circular cylinder shown in FIG. 12, it is also possible to use other body shapes, as long as the desired flow pattern is obtained, when they are surrounded by a flow, and the hot air flow becomes thereby controllable.
In the drawings and specification, there have been disclosed typical preferred embodiments of the invention and, although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being set forth in the following claims. | A yarn texturing apparatus which comprises a nozzle having a passageway through which the yarn is advanced, and a duct system for introducing heated air into the passageway. A perforated stuffer box is disposed adjacent the outlet end of the passageway. The duct system for the heated air includes an annular duct surrounding the passageway, and a supply duct communicating with the annular duct. Also, an adjustable deflector is mounted in the supply duct immediately adjacent the annular duct for imparting a circumferential component to the heated air as it enters the annular duct, and which in turn imparts a slight twist to the advancing yarn so as to facilitate its smooth advance. | 3 |
TECHNICAL FIELD
The present invention relates to vehicles having lift arms such as skid-steer loaders, and more particularly to a quick attach device for releasably connecting a variety of working implements with a carrier mounted to the lift arms of such vehicles.
BACKGROUND OF THE INVENTION
Working vehicles such as skid-steer loaders or other small utility loaders have lift arms that can be used with various work implements such as buckets, blades, and lift forks. Various mechanisms have been proposed to provide quick interchange of the work implements so the same loader can be used for different work functions.
Working vehicles frequently have tool carriers supported at the end of their lift arms. These carriers are adapted to be attached to a variety of implements. To simplify and expedite the mounting and removal of various implements, the carriers are equipped with quick-attach devices. The carrier and/or quick-attach devices typically include positioning structures to orient and locate one part of the carrier relative to the implement as well as a latching structure to secure the implement to the carrier.
Some quick-attach mechanisms rely on pins which must be inserted into aligned holes in the implement. This type of mechanism can require careful and time consuming alignment of the pins and holes. Additionally, dirt or other obstructions may make insertion and removal of the pins somewhat difficult. It would be desirable to visually inform the operator of the existence of a misalignment or non-engagement of the pin with the implement. Additionally, it would be desirable to provide some mechanical advantage to assist in engaging the pin with the implement, such as during a misalignment condition.
Accordingly, it would be desirable to provide a coupling assembly which avoids deficiencies in the prior art and is easy to use and provides for efficient releasable coupling of an implement to a working vehicle.
SUMMARY OF THE INVENTION
Accordingly, it would be desirable to provide a coupling assembly which avoids deficiencies in the prior art and is easy to use and provides for efficient releasable coupling of an implement to a working vehicle.
Toward these ends, there is broadly provided a coupling assembly including a tool carrier attached to the work vehicle and supporting a pin guide. A pin is supported upon the carrier by the pin guide and interacts with one or more cam surfaces supported by the carrier. During rotation of the pins, the cam surfaces transfer an axial force to the pin to assist in the extraction or insertion of the pins into the implement. In one embodiment, the pin has a graspable handle which may be rotated and axially moved by an operator. As a result, the pin and cam surfaces cooperate to convert a rotational motion of the pin handle into a linear motion assisting in the extension of the pin into its engaged position within an implement aperture or in the retraction of the pin into its disengaged position so that implement may be removed.
The cam surface which engages the pin may be provided upon a small insert or upon the guide block or both. In one embodiment, two cam surfaces are provided so that axially forces may be transferred to the pin to assist in both the extraction and insert of the pin relative to the implement.
In a preferred embodiment of this invention, the improved coupling assembly includes a carrier supporting a pair of similar pin assemblies, each as described above.
One object of the present invention is the provision of a visual indication that the pin is not fully engaged with the implement. An operator may visually reference the pin assembly to determine that the pin is properly engaged with the implement.
Yet another object of the present invention is the provision of a locking mechanism which prevents a pin from disengagement under axial-only force. As described herein, to disengage the pin from the implement an axial and rotation force must be applied.
These and other objects, features, and advantages of the invention will be evident from the following description of the preferred embodiment of this invention, with reference to the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a working vehicle having an implement carrier according to the present invention and positioned relative to an implement.
FIG. 2 is a perspective view of an implement and carrier according to the present invention, wherein the pin assembly is illustrated in an engaged orientation.
FIG. 3 is a detailed exploded view of a pin assembly and carrier according to the present invention.
FIG. 4 is an elevational view of a pin assembly and carrier of FIG. 1 , illustrating the engaged orientation of the elements.
FIG. 5 is an elevational view of a pin assembly and carrier of FIG. 1 , illustrating an intermediate orientation of the elements.
FIG. 6 is an elevational view of a pin assembly and carrier of FIG. 1 , illustrating the disengaged orientation of the elements.
FIG. 7 is a cross-sectional view of the pin assembly and carrier taken along lines 7 — 7 of FIG. 4 .
FIG. 8 is a cross-sectional view of the pin assembly and carrier taken along lines 8 — 8 of FIG. 5 .
FIG. 9 is a cross-sectional view of the pin assembly and carrier taken along lines 9 — 9 of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention can be embodied in many different forms, there is shown in the drawings and described in detail, a preferred embodiment of the invention. The present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiment illustrated.
For ease of description, the coupling assembly embodying this invention will be described in a normal upright operating position and such terms as upper, lower, upwardly, downwardly, will be used with reference to this position. It will be understood, however, that the coupler assembly embodying this invention can be used in an orientation other than the position described.
Referring to the Figures, a tractor or utility loader 10 having a lift arm assembly 12 and dump cylinder 14 , and commonly referred to as a skid steer loader, is shown in association with a work implement 16 , a bucket. The illustrated tractor 10 is a DINGO brand compact utility loader manufactured by The Toro Company. As described in more detail herein, a carrier 18 engages implement 16 . Alternative tractors 10 or utility loaders may utilize a coupling assembly according to the present invention.
The present invention, a coupling assembly, can be used with other mechanized equipment having a lift arm assembly and can be used to couple a variety of implement such as a bucket, blade, or fork assembly, etc. to a carrier of a machine. The term “carrier” is meant to broadly cover an intermediate structure between a loader 10 and an implement 16 . Typical carriers 18 are movably connected to lift arms 12 of loader 10 so that implement 16 may be raised or lowered by lift cylinders 13 attached between lift arms 12 and a frame of loader 10 . A variety of carriers 18 could be utilized to practice the present invention. Alternative carriers 18 may not have a “plate-like” structure 32 for engaging implement 16 , but instead may have a plurality of contact points between carrier 18 and implement 16 .
Implement 16 is provided with an attachment structure 20 which includes a downwardly facing recess 22 and an upwardly facing member 24 having a pair of apertures 26 for engaging tractor 10 . Attachment structure 20 is designed to cooperate with carrier 18 as further described herein to facilitate alignment and connection between the elements. Various implements, such as a bucket, auger, loading forks and the like having associated attachment structure 20 can be connected to carrier 18 .
Referring to FIGS. 1 and 2 , carrier 18 is attached to lift arm assembly 12 with 3 pins 30 , (2 pins are shown in FIG. 1 ). Carrier 18 includes a plate surface 32 for engaging a generally flat surface 34 of implement 16 . Pins 30 pass through appropriately sized apertures 35 , 36 upon carrier 18 . Dump cylinder 14 is connected at an upper aperture 36 , allowing carrier 18 to pivot in operation relative to lower pins 30 . Carrier 18 further includes a plurality of guide block structures 38 A, 38 B for slidably receiving a pair of pins 40 of the coupling structure of the present invention. Guide block structures 38 A, 38 B include a pair of upper guides 38 A and a pair of lower guides 38 B.
Carrier 18 is selectively connected to attachment structure 20 of implement 16 through the coupling assembly of the present invention. As described herein, the coupling assembly of the present invention provides a selective connection between attachment structure 20 of implement 16 and carrier 18 of loader 10 .
In overview, a preferred embodiment of the coupling assembly of the present invention includes a pair of pins 40 , upper and lower inserts 42 , 44 , a spring 46 , and upper and lower guide blocks 38 A, 38 B.
Referring particularly to FIG. 3 , pin 40 has a handle 50 adapted to be grasped by an operator during a coupling method as described herein. Pin 40 is slidably received within bores 52 of both upper guide 38 A and lower guide 38 B of mounting frame 18 so that pin 40 may both rotate and translate relative to its longitudinal axis. Lower guide 38 B includes a grease fitting 54 permitting lubrication of the coupling assembly.
Lower guide 38 B further includes a cam surface 56 . A shoulder 58 is positioned at a top portion of cam surface 56 . As described hereinafter, cam surface 56 may be engaged by lower insert 44 causing pin 40 to rotate during a coupling operation. In this embodiment, cam surface 56 is an inclined surface which is generally planar. Alternative cam surfaces 56 may include curves or more complex surfaces. As used herein the term “cam surface” means a surface which is at least partially oblique relative to an axis passing through bore 52 centers.
Upper insert 42 , spring 46 , and lower insert 44 are positioned relative pin 40 between upper guide 38 A and lower guide 38 B. Inserts 42 , 44 and spring 46 are sized to slidably receive pin 40 . Lower insert 44 is connected to pin 40 by a small pin 60 passing through an aperture 62 in insert 44 and an aperture 64 in pin 40 . As a result, lower insert 44 and pin 40 rotate and move together. Upper insert 42 includes a second cam surface 70 . As described herein, second cam surface 70 may be engaged by lower insert 44 causing pin 40 to extend into its engaged position. Upper insert 42 includes a birfucated end 72 which engages a protrusion 74 of carrier 18 . Bifurcated end 72 prevents upper insert 42 from rotating relative to pin 40 . Spring 46 is compressed during assembly so that spring 46 biases apart inserts 42 , 44 .
Operation of the coupling assembly may be described with reference to the figures. In overview, attachment and detachment of the implement 16 is made by manually grasping pin handle 50 to engage and retract pin 40 relative to apertures 26 of implement 16 .
As depicted in FIG. 1 , loader 10 may engage implement 16 by retracting pins 40 , tilting carrier 18 relative to implement 16 , moving the loader 10 forward, and inserting the upper lip of carrier 18 into the downwardly facing recess 22 of implement 16 . FIGS. 1 , 6 and 9 illustrate pins 40 in their retracted position. With the upper lip of carrier 18 retained within downwardly facing recess 22 , carrier 18 may be rotated by action of cylinder 14 so that the plate surface 32 engages flat surface 35 of implement 16 . At this point, pin 40 handles 50 may be rotated to engage pins 40 into apertures 26 of implement 16 . FIGS. 2 , 4 and 7 illustrate pins 40 in their extended position (implement engaged position).
To remove the implement 16 , pin 40 handles 50 are rotated and lifted to retract pins 40 from apertures 26 of implement 16 . The implement 16 may then be lowered to the ground and carrier 18 rotated so that the upper lip of carrier 18 is removed downwardly facing recess 22 . Additional features of the coupling assembly of the present invention are revealed by closer examination of FIGS. 2 through 7 .
FIGS. 2-7 illustrate three orientations of pin 40 relative to mounting plate 18 . FIGS. 2 , 3 , 4 and 7 illustrate the coupling assembly in its engaged position, wherein pins 40 are extended from the bottom of carrier 18 and may be engaged with apertures 26 of implement 16 to connect implement 16 to loader 10 . FIGS. 5 and 8 illustrate the coupling assembly in an intermediate position with handle 50 partially rotated from an engaged position. Pin 40 in intermediate orientation is not engaged with implement 16 . When handle 50 is in the intermediate position of FIGS. 5 and 8 , handle 50 provides a visual indication to the operator that pin 40 is not engaged with implement 16 . FIGS. 6 and 9 illustrate the coupling assembly in its detached position, wherein pins 40 are retracted within carrier 18 allowing the implement 16 to be detached from loader 10 .
To couple implement 16 to carrier 18 , pins 40 are each placed into respective retracted positions as illustrated in FIGS. 6 and 9 and carrier 18 is inserted into attachment structure 20 of implement 16 , typically by moving loader 10 into engagement with implement 16 . In the retracted position, a flat 78 of lower insert 44 fully engages shoulder 58 of lower guide 38 B as spring 46 biases upper insert 342 and lower insert 44 apart. Next an operator grasps pin handle 50 and rotates pin 40 toward its engaged orientation. As pin 40 and lower insert 44 are rotated into the intermediate position of FIGS. 5 and 8 , a portion of flat 78 engages shoulder 58 .
As pins 40 are further rotated past an intermediate position toward an engaged (extended) position, flat 58 may engage cam surface 56 as spring 46 biases inserts 42 , 44 apart. Alternatively, if pin assembly is dirty or a lower aperture is partially blocked or misaligned with aperture 26 of implement 16 an upper portion 80 of lower insert 44 may engage second cam surface 70 so that as pin 40 is rotated, a downward force is transferred through second cam surface 70 to insert 44 forcing pin 40 to align with implement aperture 26 and extend thereinto.
In this manner, a positive alignment and engagement between pin 40 and implement aperture 26 is provided when pin 40 is rotated from its disengaged position into its engaged position. In the absence of second cam surface 70 , pin handle 50 could be rotated into its engaged position without pin 40 extending into position within implement aperture 26 . The pin 40 , lower insert 44 , and second cam surface 70 cooperate to convert a rotational motion of handle 50 into a linear motion assisting in the extension of pin 40 into its engaged position within implement aperture 26 .
If pin 40 is blocked or misaligned relative to apertures 26 , the operator will be prevented from further rotating pin handle 50 toward the engaged orientation of FIGS. 2 , 3 , 4 and 7 as upper surface 80 of lower insert 44 engages and is blocked by cam surface 70 of upper insert 42 . In this regard, a visual indication may be presented to the operator that a misalignment and non-engagement situation exists. In some situations, upon subsequent alignment of pin 40 with aperture 26 (such as upon rocking the implement, etc.), spring 46 may bias insert 44 causing pin 40 to rotate into its engaged orientation. An operator may visually monitor the pin 40 transition from an intermediate non-engaged position to the engaged position, and may facilitate the transition by manipulating the implement 16 (manually or through operation of dump cylinder 14 and/or lift cylinder 13 ) so that pin 40 aligns with aperture 26 .
Regarding the engaged position, as illustrated in FIGS. 2 , 3 , 4 and 7 , an inclined surface 82 of lower insert 44 fully engages cam surface 56 . Pin 40 is prevented from substantially displacing in an axial direction, e.g., upwardly, as an upper surface 80 of the lower insert 44 engages and is blocked by a lower surface 84 of the upper insert 42 upon slight axial movement. This provides a positive lock mechanism which prevents pin 40 from axially displacing when in its engaged position. As a result, forces transferred in an upward axial direction at the pin 40 bottom or upward axial forces alone at the handle 50 will not disengaged pin 40 from its engaged position. As described hereinafter, handle 50 must be both axially lifted and rotated to retract pin 40 into carrier 18 .
To disengage implement 16 from carrier 18 , pin handle 50 is grasped and rotated. Pin 40 may be upwardly lifted by the operator as pin handle 50 is rotated. Alternatively, in the absence of an upward force by the operator, lower insert 44 positively engages cam surface 56 as the pin handle 50 is rotated to cause an upward force retracting pin 40 . In this manner, as pin handle 50 is rotated, cam surface 56 may provide an upward force to assist in the retraction of pin 40 from implement aperture 26 . The pin 40 , lower insert 44 , and cam surface 56 cooperate to convert a rotational motion of the handle 50 into a linear motion assisting in the retraction of pin 40 into its disengaged position.
Those skilled in the relevant arts will appreciate that a variety of connections may be utilized to connect carrier 18 to lift arm assembly 12 . Additionally, a variety of differently configured attachment structures 20 and carrier 18 may be utilized in conjunction with the coupling assembly of the present invention. For example, a different attachment structure may include a pair of flange structures, each for separately engaging one of a pair of upper lips of a carrier.
Other alternatives to the illustrated embodiment may include forming the second cam surface 70 not on a separate upper insert 42 , but instead as a portion of carrier 18 , e.g. a machined second cam surface being integral with carrier 18 . Lower insert 44 may be formed as an integrated part of pin 40 . The lower insert 44 features of an upper surface 80 to engage the second cam surface 70 and a lower surface 82 to engage the first cam surface 56 may be formed into a single pin, rather than a two-piece pin and insert 42 , 44 of the illustrated embodiment. For example, a pin 40 may have one or more weldment or other protrusion which engage cam surfaces 56 , 70 causing the pin to extend or retract as the pin is rotated. Yet other pins (not shown) for engaging cam surfaces 56 , 70 and converting a rotation motion into a linear motion would be practicable.
In another embodiment, handle 50 may be eliminated and a hydraulic or other actuator may be used to provide a rotation motion to a pin 40 . The term actuator as used herein means any type of power actuator that provides for extension or retraction under control of an operator. Appropriate linkages between an actuator and a pin 40 would be within the scope of those of ordinary skill in the art. In this regard a positive lock and release mechanism may be provided as the linear motion of the actuator causes pin 40 to rotate and extend or retract in response to engagement with cam surfaces 56 , 70 .
Various other modifications can be made in the present invention without departing from the scope and spirit of the invention. | An improved coupling assembly and method of use are disclosed herein to include a tool carrier attached to a utility loader or other work vehicle and supporting a pin guide. A pin is supported upon the carrier by the pin guide and interacts with one or more cam surfaces supported by the carrier. During axial rotation of the pin, the cam surface transfers a force to the pin to assist in the extraction and/or retraction of the pin into the implement. In one embodiment, the pin has a user graspable handle which may be rotated and axially moved by an operator. A visual indication that the pin is not fully engaged with the implement is also provided. Additionally, a locking mechanism is provided which prevents a pin from disengagement with the implement. | 4 |
CROSS REFERENCE TO RELATED DOCUMENT
[0001] The present application claims the benefit of Japanese Patent Application No. 2006-99193 filed on Mar. 31, 2006, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field of the Invention
[0003] The present invention relates generally to a gas sensor which may be employed in measuring the concentration of a selected component of exhaust gasses emitted from automotive engines, and more particularly to an anti-corrosion structure of such a gas sensor.
[0004] 2. Background Art
[0005] Japanese Patent First Publication No. 10-10082 discloses a gas sensor to be installed in an exhaust pipe of an internal combustion engine for automotive vehicles to measure the concentration of a given gas component of exhaust emissions. FIG. 8 shows such a type of a gas sensor 9 .
[0006] The gas sensor 9 consists essentially of a sensor element (not shown) to measure the concentration of a gas (will also be referred to below as a measurement gas), a housing (not shown) in which the sensor element is retained, and an air cover assembly 94 joined to a base end of the housing.
[0007] The air cover assembly 94 is, as illustrated in FIGS. 8 and 9 , made up of an inner cover 941 and an outer cover 942 . The inner cover 941 is joined to the base end of the housing. The outer cover 942 surrounds a base end portion (i.e., an upper end portion, as viewed in the drawings) of the inner cover 941 .
[0008] The inner cover 941 and the outer cover 942 have portions 943 crimped circumferentially thereof.
[0009] However, when air is introduced into the gas sensor 9 from air inlets 945 formed in a base end portion of the outer cover 942 , water 7 may enter a clearance between the inner cover 941 and the outer cover 942 along a path, as indicated by a thick line Wand stay, as clearly illustrated in FIG. 9 , especially in a clearance 96 near the crimped portions 943 , which will lead to the corrosion of an interface 8 between the inner cover 941 and the outer cover 942 . Specifically, when the water 7 stays in the clearance 96 , it results in a variation in concentration of oxygen between the clearance 96 and the interface 8 to facilitate or promote the transfer of metal ions from the inner and outer covers 941 and 942 , thereby causing the interface 8 to be eroded.
SUMMARY OF THE INVENTION
[0010] It is therefore a principal object of the invention to avoid the disadvantages of the prior art.
[0011] It is another object of the invention to provide an improved structure of a gas sensor designed to minimize gap corrosion between an inner cover and an outer cover of an air cover assembly.
[0012] According to one aspect of the invention, there is provided a gas sensor which may be employed in measuring the concentration of a component of exhaust gasses emitted from automotive engines. The gas sensor comprises: (a) a sensor element sensitive to a gas to produce a signal as a function of concentration of the gas, the sensor element having a length with a top end and a base end opposite the top end; (b) a housing in which the sensor element is retained, the housing having a top end and a base end opposite the top end; (c) an air cover assembly having a top end and a base end opposite the top end, the air cover assembly being made up of an inner cover and an outer cover, the inner cover being secured to the base end of the housing, the outer cover surrounding the inner cover and being joined to the inner cover through at least one crimped portion; (d) an air inlet formed in a portion of the air cover assembly which is closer to the base end of the air cover assembly than the crimped portion, the air inlet being designed to admit air into the air cover assembly; and (e) an air chamber defined by the crimped portion between the inner and outer covers of the air cover assembly from the crimped portion circumferentially of the air cover assembly. The air chamber is exposed outside the air cover assembly at a side opposite the air inlet across the crimped portion to define a water drain path establishing fluid communication between the air inlet and outside the air cover assembly.
[0013] The crimped portion is formed to occupy only a portion of the circumference of the air cover assembly, thereby defining the air chamber in which the water drain path extends from the air inlet to outside the air cover assembly. When the water enters at the air inlet, it will flow between the inner and outer covers along the water drain path and drain out of the air cover assembly, thereby minimizing gap corrosion between the inner and outer covers of the air cover assembly.
[0014] According to another aspect of the invention, there is provided a gas sensor which comprises: (a) a sensor element sensitive to a gas to produce a signal as a function of concentration of the gas, the sensor element having a length with a top end and a base end opposite the top end; (b) a housing in which the sensor element is retained, the housing having a top end and a base end opposite the top end; (c) an air cover assembly having a top end and a base end opposite the top end, the air cover assembly being made up of an inner cover and an outer cover, the inner cover being secured to the base end of the housing, the outer cover surrounding the inner cover and being joined to the inner cover through a crimped portion which extends over the whole of a periphery of the air cover assembly; (d) an air inlet formed in a portion of the air cover assembly which is closer to the base end of the air cover assembly than the crimped portion, the air inlet being designed to admit air into the air cover assembly; and (e) a water drain hole formed in the air cover assembly to establish fluid communication of outside the air cover assembly with a clearance extending from the crimped portion to the air inlet between the inner and outer covers of the air cover assembly.
[0015] When the water enters at the air inlet, it will flow between the inner and outer covers and drain out of the air cover assembly from the water drain hole, thereby minimizing gap corrosion between the inner and outer covers of the air cover assembly.
[0016] In the preferred mode of the invention, the drain hole is formed in the outer cover of the air cover assembly to extend from an edge of the crimped portion toward the air inlet, thereby avoiding staying of the water around the crimped portion between the inner and outer covers to facilitate ease of draining of the water.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be understood more fully from the detailed description given hereinbelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiments but are for the purpose of explanation and understanding only.
[0018] In the drawings:
[0019] FIG. 1 is a longitudinal sectional view which shows an internal structure of a gas sensor according to the first embodiment of the invention;
[0020] FIG. 2 is a partially enlarged sectional view, as circled by a broken line B in FIG. 1 , which shows an inner and an outer cover of an air cover assembly of the gas sensor, as illustrated in FIG. 1 ;
[0021] FIG. 3 is a transverse sectional view, as taken along the line A-A in FIG. 1 ;
[0022] FIG. 4 is a longitudinal sectional view which shows an internal structure of a gas sensor according to the second embodiment of the invention;
[0023] FIG. 5 is a partially enlarged sectional view, as circled by a broken line C in FIG. 4 , which shows an inner and an outer cover of an air cover assembly of the gas sensor, as illustrated in FIG. 4 ;
[0024] FIG. 6 is a partially side view which shows an air cover assembly of the gas sensor of FIG. 4 ;
[0025] FIG. 7 is a graph which shows results of corrosion tests;
[0026] FIG. 8 is a partially longitudinal sectional view which shows an internal structure of a conventional gas sensor; and
[0027] FIG. 9 is a partially enlarged sectional view, as circled by a broken line D in FIG. 8 , which shows an inner and an outer cover of an air cover assembly of the gas sensor, as illustrated in FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring to the drawings, wherein like reference numbers refer to like parts in several views, particularly to FIGS. 1 , 2 , and 3 , there is shown a gas sensor 1 according to the first embodiment of the invention which may be used in measuring the concentration of a given component of exhaust emissions of automotive engines. For instance, the gas sensor 1 may be designed as an O 2 sensor, an A/F sensor, or a NOx sensor.
[0029] The gas sensor 1 consists essentially of a sensor element 2 sensitive to a gas to be measured (which will also be referred to as a measurement gas below) to produce an electrical signal as a function of the concentration of the measurement gas, a housing 3 in which the sensor element 2 is retained, and an air cover assembly 4 joined to a base end (i.e., an upper end, as viewed in FIG. 1 ) of the housing 3 .
[0030] The air cover assembly 4 is made up of an inner cover 41 and an outer cover 42 . The inner cover 41 is secured at an end thereof to the base end of the housing 3 . The outer cover 42 is placed to surround a base end portion (i.e., an upper end portion, as viewed in FIG. 1 ) of the inner cover 41 .
[0031] The air cover assembly 4 has formed therein air inlets 5 through which air is admitted inside the gas sensor 1 .
[0032] The air cover assembly 4 has, as clearly shown in FIGS. 1 and 3 , joints 43 by which the inner and outer covers 41 and 42 are connected together. The joints 43 are, as can be seen in FIG. 1 , located closer to the top (i.e., a lower end, as viewed in the drawing) of the gas sensor 1 than the air inlets 5 and formed by elastically deforming or crimping, for example, four circumferentially spaced portions of each of the inner and outer covers 41 and 42 inwardly. The joints 43 will also be referred to as crimped portions below. The crimped portions 43 define, as clearly illustrated in FIG. 3 , air chambers 44 between adjacent two thereof which open outside the air cover assembly 4 at the top end of the outer cover 42 .
[0033] The sensor element 2 is, as clearly shown in FIG. 1 , of a cup-shape with a bottom.
[0034] The housing 3 has formed in an outer periphery thereof a thread 31 for installation of the gas sensor 1 in, for example, an exhaust pipe (not shown) of the automotive engine. When the gas sensor 1 is installed in the exhaust pipe, the top end portion (i.e. the lower end portion, as viewed in FIG. 1 ) of the gas sensor 1 extends downward within the exhaust pipe, while the base end portion (i.e., the upper end portion) of the gas sensor 1 extends upward outside the exhaust pipe.
[0035] The outer cover 42 has formed in the base end portion thereof air intake openings 425 through which the air is to be admitted thereinto.
[0036] The inner cover 41 is made up of a large-diameter portion 411 extending to the top end thereof and a small-diameter portion 412 extending to the base end thereof. The inner cover 41 has formed in the small-diameter portion 412 air intake holes 415 which face the air intake openings 425 radially of the air cover assembly 4 .
[0037] The air cover assembly 4 also has a ventilation filter 50 made of, for example, a water-repellent filter 50 nipped between the inner cover 41 and the outer cover 42 . The ventilation filter 50 constitutes the air inlets 5 along with the air intake openings 425 and the air intake holes 415 .
[0038] The air cover assembly 4 , as described above, has the four crimped portions 43 which are located at equi-intervals in the circumferential direction thereof to define the four air chambers 44 , as clearly illustrated in FIG. 3 , which are identical in size or volume with each other.
[0039] A rubber bush 13 is, as illustrated in FIG. 1 , fit in the base end of the air cover assembly 4 . The rubber bush 13 retains therein leads 12 which are connected electrically with the sensor element 2 and is held by crimping the outer cover 42 inwardly to establish a liquid-tight seal in the base end of the gas sensor 1 .
[0040] The gas sensor 1 is designed to have a drain path for water entering at the air inlets 5 , as described below.
[0041] When the vehicle is splashed with water during traveling or washing, it may enter, as indicated by an arrow W, between the inner cover 41 and the outer cover 42 from the air inlets 5 . The water then flows, as illustrated in FIG. 2 , toward the top end or downward of the gas sensor 1 , enters the air chambers 44 , and drains outside the air cover assembly 4 . When hitting one of the crimped portions 43 , the water, as indicated by arrows Win FIG. 3 , flows into an adjacent one(s) of the air chambers 44 and then drains outside the air cover assembly 4 . This avoids the staying of the water between the inner cover 41 and the outer cover 42 , thus preventing the gap corrosion therebetween.
[0042] The number of the crimped portions 43 is not limited to four. The air cover assembly 4 may alternatively have at least one crimped portion 43 to join the inner cover 41 and the outer cover 42 together.
[0043] FIGS. 4 to 6 show the gas sensor 1 according to the second embodiment of the invention which is different from the first embodiment in that the air cover assembly 4 has one crimped portion 45 which extends over the overall circumference of the air cover assembly 4 to join the inner and outer covers 41 and 42 . The crimped portion 45 is, like the first embodiment, located closer to the top end of the gas sensor 1 than the air inlets 5 .
[0044] The outer cover 42 has at least one drain hole 421 which is, as clearly illustrated in FIG. 6 , formed to extend vertically across an upper edge of the crimped portion 45 closer to the base end of the air cover assembly 4 . The water having flowed to the crimped portion 45 between the inner and outer covers 41 and 42 escapes, as indicated by an arrow Win FIG. 5 , outside the air cover assembly 4 from the drain hole 421 .
[0045] The crimped portion 45 of the air cover assembly 4 , as referred to herein, is made up of portions of the inner and outer covers 41 and 42 which are, as illustrated in FIG. 5 , pressed inwardly into direct abutment with each other in a range R.
[0046] Other arrangements are identical with those in the first embodiment, and explanation thereof in detail will be omitted here.
[0047] The inventor of this application performed corrosion tests on comparison of the gas sensor 1 with a conventional type of gas sensor.
[0048] The inventor prepared two types of test samples: one is the gas sensor 1 of the invention, and the other is a conventional type. Specifically, the inventor prepared, as can be seen form a graph of FIG. 7 , four No. 1 test samples identical in structure with the one illustrated in FIG. 8 and sixteen No. 2 test samples identical in structure with the gas sensor 1 , and broken down the No. 2 test samples into four groups.
[0049] Each of the corrosion tests was performed by installing one of the test samples in a pipe by screwing a thread (like the one, as denoted at 31 in FIG. 1 ) thereinto, heating the pipe for eighteen minutes until the thread reaches 300° C., and then spraying salt water containing 5% by weight of salt over the whole of a portion of the test sample exposed outside the pipe. This cycle was repeated 300 times for the No. 1 test samples and the first group of the No. 2 tests samples, 600 times for the second group of the No. 2 test samples, 900 times for the third group of the No. 2 test samples, and 1200 times for the fourth group of the No. 2 test samples.
[0050] The air cover assembly of each of the test samples is made of stainless steel (SUS304).
[0051] After the above corrosion tests, the inventor disassembled the air cover assembly of each of the test samples, removed extraneous matter from opposed surfaces of the inner and outer covers of the air cover assembly, and observed the surfaces visually using a microscope to check them for cracks. When the crack was found in either of the surfaces of the inner and outer covers, it was decided that the surfaces of the inner and outer covers were corroded. This is because usually, when corrosion occurs between the inner and outer covers, it will cause the opposed surfaces of the inner and outer covers to darken, but however, it is difficult to determine whether such darkening has arisen from the corrosion or stains on the surfaces. Therefore, when the crack arising from the corrosion was visually perceived, the corrosion was determined as having occurred between the inner and outer covers.
[0052] Results of the corrosion tests are plotted in the graph of FIG. 7 . The graph shows that when subjected to 300 cycles (100 hours) of the corrosion test, all the No. 1 test samples are cracked, and when subjected to 900 cycles (300 hours) of the corrosion test, the No. 2 test samples are all not yet cracked, however, when subjected to 1200 cycles (400 hours) of the corrosion test, two of the fourth group of the No. 2 test samples are cracked. It is, therefore, found that the structure of the gas sensor 1 is useful for avoiding the corrosion between the inner and outer covers 41 and 42 of the air cover assembly 4 which usually leads to cracks.
[0053] While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding thereof, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention as set forth in the appended claims. | An anti-corrosion structure of a gas sensor is provided. The gas sensor includes a hollow cylindrical air cover assembly made up of an inner and an outer cover. The air cover assembly has formed therein air inlets through which air is admitted into the gas sensor. The inner and outer covers are joined together through at least one crimped portion which defines a water drain path extending from the air inlets to outside the air cover assembly, thereby draining the water entering at the air inlets out of the gas sensor. This avoids staying of the water between the inner and outer covers to minimize gap corrosion therebetween. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to vapor-deposited metal layers which are protected from damage by the application of an organic layer to its surface. The invention further relates to the process of applying the protective organic layer to the surface of the vapor-deposited metal layer and to the photosensitive articles made with the protected metal layer.
In particular, the present invention relates to the application of an organic layer onto the surface of a vapor deposited metal layer. The metal layer is generally formed on a supporting base by any of the various vapor-depositing techniques. Prior to subjecting the deposited metal layer to any physical treatments or stress likely to damage the continuity of the coating (e.g., rolling, folding, bending, and the like) an organic layer is vapor deposited onto the surface of the metal.
2. Description of the Prior Art
Vapor-deposited layers of metals, particularly those on flexible webs, tend to be soft and easily rubbed off. These defects are particularly unacceptable where such layers are to be used as part of an imaging system consisting of a vapor-deposited metal layer and an overcoated photoresist or photopolymer layer. Marks, scuffs, kinks, or abrasions in the metal layer produce voids or areas in the film which contain no useful image, thus interrupting the faithfulness of the image. These photographic defective areas have been called by various names such as pinholes, cinch marks, scuffs, etc., depending on where and how the abrasion was produced. In order to avoid such defects, a protective resin layer is generally coated on the metal layer. This is often done in a separate coating operation on a different coating machine. The difficulty with this practice, however, is that the unprotected vapor-coated metal film must be wound after the vapor-coating operation to transport the material to the more conventional resin coater. Defects such as cinch marks, abrasions, and kinks are often produced during this winding operation.
In order to avoid the problems described above, several attempts have been made to vapor-deposite the metallic and organic layers in the same vaccum chamber, thus eliminating the need to wind the film in a roll between coating operations. One such process is described in U.S. Pat. No. 4,268,541. Here the vapor-deposition chamber is divided into 2 sections, by means of a partition, thereby separating the metal deposition area from the organic deposition section. Thus the organic protective layer is deposited over the metal layer without the need to rewind the roll in between the two coating operations.
The organic compounds used in U.S. Pat. No. 4,268,541 include polymers (for example, those derived from methacrylic acid and acrylic acid), low molecular weight organic compounds containing a carboxyl group (e.g., compounds such as abietic acid, isophthalic acid, behenic acid, terephthalic acid, phthalic acid, etc., and a few random compounds (e.g., Rhodamine B, rosin, a phthalocyanine, a monosaccharide, and an oligosaccharide).
The technique and materials described in U.S. Pat. No. 4,268,541 have been found to be suitable for only limited uses. The layer thickness of 30-600 nm specified is not suitable for many imaging film constructions, and for many processing techniques. In particular, the friction properties of the coating cause layers of the coated material which are stacked or rolled to slide and move out of register. In rolled form, telescoping of the roll is quite serious. This can cause serious delays and expense in further use of the film.
Organic protection layers located between the metal layer and a photoresist layer can drastically affect the oxidizing or etching step and the quality of the resulting image. For, example, excessive thickness of such layers may provide a preferential pathway for the developer or etch solution thereby resulting in image degradation or fine detail loss. This is especially true of material whose final designation is copy or contact reprographic work. Films such as these, called lith or contact films, depend on fine dot arrays to reproduce image tone. Fine dots (3-5%) may be undercut and etched away thereby degrading the quality of the reproduction.
The relatively thick layer of some acid-containing protective materials such as disclosed in U.S. Pat. No. 4,268,541 can also interfere with the etching of the metal by neutralizing the alkaline metal etching solution. Such neutralization inhibits the formation of an etched metal image and thus interferes with the formation of an image of acceptable quality.
Another attempt at overcoming the abrasion problems is described in Japanese patent publication number 56/9736. In this case, the metal and the organic compound are deliberately coated as a single layer; i.e., the metal and organic vapors are substantially mixed in the vapor stream before they are deposited on the support. This is not completely satisfactory because the heated metal vapor can carbonize or decompose the organic material resulting in an unacceptable product. Also, the thickness of the layer is required to be at least 20 to 1000 mm. The scope of organic materials is also quite specific and generally emphasizes organic acid materials.
SUMMARY OF THE INVENTION
The application of layers of organic material with a vapor pressure at 20° C. no greater than 1-n-octanol said material having (1) carbonyl groups whch are not part of carboxyl groups, (2) phenoxy groups, (3) ester groups, (4) urea groups, or (5) alcohol groups onto vapor-deposited metal surfaces has been found to provide excellent damage resistance to the metal layer. The presence of these organic materials on the vapor-deposited metal layer in photoresist imaging constructions provides for uniform development characteristics in the image. These materials reduce or eliminate the low friction properties attendant with the use of acids as protective layers, and because of reduced acidity these materials do not neutralize alkaline developing solutions as much as acid protective layers.
DETAILED DESCRIPTION OF THE INVENTION
The basic article of the present invention comprises a substrate, a vapor-deposited metal layer on at least one surface of said substrate, and a protective organic layer on said metal layer comprising a material having phenoxy groups, alcohol groups, urea groups, ester groups, or carbonyl groups which are not part of carboxyl groups. In a preferred embodiment, a photoresist layer is coated over said protective layer.
The substrate may be any surface or material onto which metal may be vapor-deposited. The substrate may be rough or smooth, transparent or opaque, and continuous or porous. It may be of natural or synthetic polymeric resin (thermoplastic or thermoset), ceramic, glass, metal, paper, fabric, and the like. For most commercial purposes the substrate is preferably a polymeric resin such as polyester (e.g., polyethyleneterephthalate), cellulose ester, polycarbonate, polyvinyl resin (e.g., polyvinylchloride, polyvinylidene chloride, polyvinylbutyral, polyvinylformal), polyamide, polyimide, polyacrylate (e.g., copolymers and homopolymers of acrylic acid, methacrylic acid, n-butyl acrylate, acrylic anhydride and the like), polyolefin, and the like. The polymer may be transparent, translucent or opaque. It may contain fillers such as carbon black, titania, zinc oxide, dyes, pigments, and of course, those materials generally used in the formation of films such as coating aids, lubricants, antioxidants, ultraviolet radiation absorbers, surfactants, catalysts and the like.
The vapor-deposited metal layer may be any vapor-deposited metal or metalloid layer. According to the practice of the present invention, the term metal layer is defined as a layer comprising metal, metal alloys, metal salts, and metal compounds. The corresponding meaning applies to the term metalloid layer. The term metal in metal layer is defined in the present invention to include semi-metals (i.e., metalloids) and semiconductor materials. Metals include materials such as aluminum, antimony, beryllium, bismuth, cadmium, chromium, cobalt, copper, gallium, germanium, gold, indium, iron, lead, magnesium, manganese, molybdenum, nickel, palladium, rhodium, selenium, silicon, silver, strontium, tellurium, tin, titanium, tungsten, vanadium, and zinc. Preferably the metal is selected from aluminum, chromium, nickel, tin, titanium and zinc. More preferably the metal is aluminum. Metal alloys such as aluminum-iron, aluminum-silver, bismuth-tin, and iron-cobalt alloys are included in the term metal layer and are particularly useful. Metal salts such as metal halides, metal carbonates, metal nitrates and the like are useful. Metal compounds such as metal oxides and metal sulfides are of particular utility in imaging systems. Metal layers comprising mixtures of these materials such as mixtures of metal-metal oxides, metal-metal salts, and metal salts-metal oxides are also of particular interest.
The thickness of the vapor-deposited metal layer depends upon the particular needs of the final product. In imaging constructions, for example, the thickness should be at least about 3 nm. Generally, the layer would be no thicker than 750 nm which would require a long etching period. A more practical commercial range would be between 10 and 500 nm. A preferred range would be between 20 and 400 nm and a more preferred range would be between 25 and 300 nm or 30 and 200 nm.
It is preferred that the majority of the cross-section of the metal layer consist essentially of metal, metal alloys, metal salts and metal compounds. Traces of up to 10% or more of other materials may be tolerated generally in the layer, and in fact in certain processes of manufacture the boundary region of the metal layer and the protective layer may have a graded or gradual change from 100% metal to 100% organic material. But metal layers with the majority (at least 50%) of its cross-section consisting essentially of metals, metal alloys, metal salts, metal compounds and combinations thereof are preferred. The metal layer should have fewer than 100, preferably fewer than 50, and more preferably fewer than 30 defects per 177 mm 2 .
Vapor-deposition of the metal layer may be accomplished by any means. Thermal evaporation of the metal, ion plating, radio frequency sputtering, A.C. sputtering, D.C. sputtering and other known processes for deposition may be used in the practice of the present invention. The pressure may vary greatly during coating, but is usually in the range of 10 -6 to 10 -4 torr.
The organic protective layer comprises a material with a vapor pressure at 20° C. no greater than that of 1-n-octanol selected from the group consisting of (1) organic materials having carbonyl groups which are not part of carboxyl groups, (2) phenoxy groups, or (3) alcohols. The term "organic material" is used because the protective coating does not have to be a single compound or a monomeric compound. In addition to those types of materials, dimers, trimers, oligomers, polymers, copolymers, terpolymers and the like may be used.
The organic materials containing carbonyl groups which are not part of a carboxyl group, for example, include (1) amides, such as phthalamide, salicylamide, urea formaldehyde resins, and methylene-bis-acrylamide, and (2) anilides, such as phthalanilide and salicylanilide. It has been found that these organic materials may be used in layers as thin as 1 nm and provide good abrasion or mar protection. They may be used in thicknesses of up to 600 nm, but without dramatic improvement of results, and in fact often with some diminution of properties. A preferred range would be between 3 and 200 nm, more preferably between 5 and 100 nm, and most preferably at least 5 and lower than 30 or 20 nm.
The organic material containing ester groups includes such materials as polyester oligomers, low molecular weight polyester polymers (e.g., polyethyleneterephthalate, polyethyleneisophthalate, etc. having molecular weights between 5,000 and 50,000), diallyl phthalate (and its polymers), diallyl isophthalate (and its polymers), monomethyl phthalate, carboxylic acid alkyl esters, and the like.
The organic material containing phenoxy groups include such materials as Bisphenol A, and low molecular weight phenol formaldehyde resins (e.g., Resinox®). The alcohol containing materials would include 1-n-octanol, dodecanol, benzyl alcohol and the like.
The organic material should be vapor-depositable as this is the general method preferred for application of the protective layer. The organic material may, for example, be deposited in the apparatus and procedures disclosed in U.S. Pat. No. 4,268,541. The partition or baffle described in that apparatus (e.g., Example 1) has not been found to be essential. The two vapor streams (i.e., metal and organic material streams) may be physically spaced apart or directed so that the coating zones for the two materials do not completely overlap. No serious problem has been found even when 50% of each of the coating zones overlap (so that at least 50% of the thickness of the metal layer consists essentially of metal, metal salts, metal compounds, and combinations thereof), although this is not a preferred construction. It is preferred that less than 25% of the total weight of the metal component be in such an overlapping or mixing zone and more preferably less than 10% or even 0% be in such zones. The recitation of a metal layer in the practice of the present invention requires, however, that at least a region of the coating, usually adjacent to the substrate, consists essentially of a metal layer without a dispersed phase of organic material therein.
The photoresist layer may be either a negative-acting or positive acting photoresist as known in the act. Positive acting photoresist systems ordinarily comprise polymeric binders containing positive acting diazonium salts or resins such as those disclosed, for example, in U.S. Pat. Nos. 3,046,120, 3,469,902 and 3,210,239. The positive acting photosensitizers are commercially available and are well reported in the literature. Negative acting photosensitive resist systems ordinarily comprise a polymerizable composition which polymerizes in an imagewise fashion when irradiated, such as by exposure to light. These compositions are well reported in the literature and are widely commercially available. These compositions ordinarily comprise ethylenically or polyethylenically unsaturated photopolymerizable materials, although photosensitive epoxy systems are also known in the art. Preferably ethylenically unsaturated photopolymerizable systems are used, such as acrylate, methacrylate, acrylamide and allyl systems. Acrylic and methacrylic polymerizable systems are most preferred according to the practice of the present invention. U.S. Pat. Nos. 3,639,185, 4,247,616, 4,008,084, 4,138,262, 4,139,391, 4,158,079, 3,469,982, U.K. Pat. No. 1,468,746, disclose photosensitive compositions generally useful in the practice of the present invention. U.S. Pat. No. 4,314,022 discloses etchant solutions particularly useful in the practice of the present invention.
The following examples further illustrate practice of the present invention.
EXAMPLE 1
Using the apparatus described in U.S. Pat. No. 4,268,541 without a baffle, a 10 -4 m polyester web was coated by vacuum deposition with 70 nm of aluminum. During the same operation in the same vacuum chamber a layer of a commercially available terpolymeric acrylate material (derived from 62% methylmethacrylate, 36% n-butylacrylate and 2% acrylic acid by weight) was applied. This sample represents an article made according to the teachings of U.S. Pat. No. 4,268,541. A control length of non organic-coated aluminum film was also produced. Ellipsometric measurements of the resultant organic/metal package indicated that the thickness of the acrylate layer was 30.5 nm.
The resultant aluminum plus organic coated material was examined by way of transmitted light and exhibited very few pinholes or defects. The otherwise soft aluminum layer of this package could not be rubbed off using thumb pressure. The non organic coated aluminum film could be rubbed off using thumb pressure.
Both the organic vapor coated sample and the unprotected sample were immersed in a bath of 1.2% sodium hydroxide and 3% of the tetra sodium salt of nitrilotriacetic acid at 32° C. The unprotected Al layer was uniformly, cleanily oxidized away in 15 seconds. The organic-protected layer was not cleanly removed. In fact, the aluminum lifted off in sections during the immersion time and then the aluminum generally oxidized in solution.
EXAMPLE 2
Using the apparatus described in the Example 1, a 2000 meter continuous web was vapor coated with a 70 nm layer of aluminum and immediately thereafter in the same chamber, a 10 nm layer of terephthalic acid was applied. At the 1400 meter level, the terephthalic coated roll telescoped on itself and telescoped further when removed from the chamber. After removal from the chamber, the vapor-coated aluminum/terephthalic acid roll was judged to be unacceptable for production purposes.
EXAMPLE 3
Using the technique described in Example 1, three more rolls of 2000 meters were coated and a different organic material applied to the aluminum of each of these rolls. Roll A contained an organic layer (on top of the aluminum layer) consisting of Resinox, a phenol formaldehyde condensate resin made by the Monsanto Corp.
Roll B was identical to Roll A except than an organic layer of Vitel 200, a low molecular weight polyester resin (approximately 10,000 molecular weight) made by and commercially available from Goodyear was applied to the aluminum layer. Roll C consisted of a control roll of vapor-coated aluminum film identical to rolls A and B with no organic protective coating.
None of these three rolls telescoped.
EXAMPLE 4
Using the apparatus of Example 1, the following materials were applied to vapor-coated aluminum webs in various thicknesses from 15 to 250 nm.
(1) Dimethyl terephthalate
(2) Phthalic anhydride
(3) Mono methyl phthalate
(4) Dapon 35-a diallyl phthalate prepolymer made by FMC Corp.
(5) Bisphenol A
(6) Epon 828-an epoxy resin made by the Shell Corp.
(7) Michlers Ketone
(8) Benzophenone
(9) Benzyl alcohol
(10) Salacylamide
These materials were unrolled after coating and inspected with a 10X hand lens by transmitted light. The defects in an area of 177 mm 2 were counted and compared to those of a non-organic coated aluminum film prepared as a control. The control film exhibited defect levels over 100. The materials tested had defect levels of 30 or less. The control material that had no protective layer could be rubbed off using thumb pressure--the organic protective material could not. None of the above materials felt slippery and none produced any telescoping during or after rolling.
EXAMPLE 5
Using the apparatus of Example 1, two coatings were made on top of a 70 nm aluminum layer, one using a protective coating of Resinox as the organic layer; another using terephthalic acid as the organic layer. Both these organic layers were applied to produce an organic layer of about 5 nm thickness as determined by a Gaertner Ellipsometer.
These two webs were further coated with a resist layer of the type described in our copending application Ser. No. 350,737, filed this same day in the name of B. Cederberg et al. A control web consisting of only the 70 nm aluminum layer was prepared as well.
After coating and drying these films were exposed to a 10 step Stauffer grey scale using a 2 kw Berkey Ascor printing source (light to film distance 1 mtr) for 15 seconds. The exposed films were developed in the processing solution described in Example 1 of U.S. Pat. No. 4,314,022 for 30 sec, at 38° C. followed by a warm water wash. On inspection it was evident that the Resinox and control film had grey scale values of step 5, the terephthalic acid roll however had a grey scale value of 7 indicating a faster, more uncontrolled development.
EXAMPLE 6
Using the technique of Example 1, a Vitel 200 polyester coating was applied in a thickness of 10 nm to various metal layers including
(1) Tin
(2) Copper
(3) Aluminum/Mg (Al 94.8%; Mg 5.0%; Mn 0.1%; Cr 0.1%)
(4) Aluminum plus Iron (ratio Al 2 Fe 5 )
(5) Nickel
A control non-organic coated layer was included for each metal while thumb action rubbing was able to remove the unprotected metal. The protected metal layers (organic coated) would not rub off. | The use of organic materials containing carbonyl groups (which are not part of carboxyl group), phenoxy groups, ester groups, or alcohol groups over vapor deposited metal layers improves their mar resistance. These organic materials can improve the properties of the metal layer when used in photoresist imaging films. | 8 |
RELATED APPLICATIONS
[0001] This application claims benefit under 35 U.S.C. 119(e) from U.S. Provisional Application Ser. No. 61/038,227, filed on Mar. 20, 2008, entitled “Cellular Lattice Structures with Multiplicity of Cell Sizes and Related Method of Use,” the entire disclosure of which is hereby incorporated by reference in its entirety.
US GOVERNMENT RIGHTS
[0002] This invention was made with United States Government support under Grant No. N00014-07-1-0114, awarded by the Defense Advanced Research Projects Agency/Office of Naval Research. The United States Government has certain rights in the invention.
FIELD OF INVENTION
[0003] The present invention relates generally to cellular materials used in structural applications and specifically to materials comprising hierarchical cellular lattices and related methods of using and manufacturing the same.
BACKGROUND OF THE INVENTION
[0004] Sandwich panels are structural materials that may comprise a core enclosed between two sheets of material. Some of the existing lattice structure geometries used in sandwich panel cores include tetrahedral, pyramidal, and octet truss, kagome, and honeycomb. Typically, lattice structures utilizing trusses to form the core material of a sandwich panel are constructed from a lattice with a single unit cell size, that is, the trusses comprising the lattice are all of equal size. The size of the cells can of course be varied from one lattice to another, but typically in a given lattice, the cells are all of one size.
SUMMARY OF THE INVENTION
[0005] An embodiment of a sandwich panel core or the like that may be comprised of a lattice structure utilizing a network of hierarchical trusses, synergistically arranged, to provide support and other functionalities disclosed herein. Since this design results in a generally hollow core, the resulting structure maintains a low weight while providing high specific stiffness and strength. Sandwich panels are used in a variety of applications including sea, land, and air transportation, ballistics, blast and impact impulse mitigation, thermal transfer, multifunctional structures, armors, ballistics, load bearing, construction materials, and containers, to name a few. Any of the front, bottom or side panels involved may be an adjacent structure, component or system or may be integral with an adjacent structure, component or system. It should be appreciated that the panels (face sheets) may be applied to the sides, rather than only top and bottom. Adjacent structures may be, for example, floors, walls, substrates, platforms, frames, housings, casings, or infrastructure. Adjacent structures may be associated with, for example: land, air, water vehicles and crafts; weapons; armor; or electronic devices and housings.
[0006] An aspect of an embodiment (or partial embodiment) comprises a structure. The structure may comprise a first lattice structure, the first lattice structure comprising: a first primary array, wherein the first primary array comprises an array of first order cells; and at least one of the first order cells comprising second order cells; an ancillary array, wherein the ancillary array comprises an array of second order cells; and at least one of the second order cells comprising third order cells; and wherein the ancillary array is nested with the first primary array, whereby the second order cells of the ancillary array are essentially coaligned with: the second order cells of the first primary array, the first order cells of the first primary array, or both the second order cells of the first primary array and the first order cells of the first primary array. An aspect of an embodiment (or partial embodiment) further comprises a second lattice structure, the second lattice structure comprising: a second primary array, wherein the second primary array comprises an array of first order cells; and wherein the second primary array is mated with the first primary array to form a third lattice structure, whereby at least one of the first order cells of the first primary array are oppositely oriented to and essentially coaligned with at least one of the first order cells of the second primary array.
[0007] An aspect of an embodiment (or partial embodiment) comprises a structure. The structure may comprise a first lattice structure, the first lattice structure comprising: a first primary array, wherein the first primary array comprises an array of first order cells; and an ancillary array, wherein the ancillary array comprises an array of second order cells; and wherein the ancillary array is nested with the first primary array, whereby the second order cells of the ancillary array are essentially coaligned with the first order cells of the first primary array. An aspect of an embodiment (or partial embodiment) further comprises a second lattice structure, the second lattice structure comprising a second primary array, wherein the second primary array comprises an array of first order cells; and wherein the second primary array is mated with the first primary array to form a third lattice structure, whereby at least one of the first order cells of the first primary array are oppositely oriented to and essentially coaligned with at least one of the first order cells of the second primary array.
[0008] An aspect of an embodiment (or partial embodiment) comprises a method of making a structure, the method comprising forming a first lattice structure through the steps comprising: providing a first primary array, wherein the first primary array comprises an array of first order cells; and at least one of the first order cells comprising second order cells; providing an ancillary array, wherein the ancillary array comprises an array of second order cells; and at least one of the second order cells comprising third order cells; and nesting the ancillary array with the first primary array, whereby the second order cells of the ancillary array are essentially coaligned with: the second order cells of the first primary array, the first order cells of the first primary array, or both the second order cells of the first primary array and the first order cells of the first primary array. An aspect of an embodiment (or partial embodiment) further comprises providing a second lattice structure, the method comprising: providing a second primary array, wherein the second primary array comprises an array of first order cells; and mating the second primary array with the first primary array to form a third lattice structure, whereby at least one of the first order cells of the first primary array are oppositely oriented to and essentially coaligned with at least one of the first order cells of the second primary array.
[0009] An aspect of an embodiment (or partial embodiment) comprises a method of making a structure, the method comprising forming a first lattice structure through the steps comprising: providing a first primary array, wherein the first primary array comprises an array of first order cells; and providing an ancillary array, wherein the ancillary array comprises an array of second order cells; and nesting the ancillary array with the first primary array, whereby the second order cells of the ancillary array are essentially coaligned with the first order cells of the first primary array. An aspect of an embodiment (or partial embodiment) further comprises a providing a second lattice structure, the method comprising: providing a second primary array, wherein the second primary array comprises an array of first order cells; and mating the second primary array with the first primary array to form a third lattice structure, whereby at least one of the first order cells of the first primary array are oppositely oriented to and essentially coaligned with at least one of the first order cells of the second primary array.
[0010] It should be appreciated that any number of arrays may be stacked, nested and mated on top of another. It should be appreciated that any number of the top, bottom, and side panels (facesheets) may be implemented by being attached or in communication with any of the arrays (and layers, stacking, mating and nesting of arrays). Further, it should be appreciated that any number of the top, bottom, and side panels (facesheets) may be implemented by being disposed between any of the arrays (and layers, stacking, mating and nesting of the arrays).
[0011] These and other objects, along with advantages and features of the invention disclosed herein, will be made more apparent from the description, drawings and claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The foregoing and other objects, features and advantages of the present invention, as well as the invention itself, will be more fully understood from the following description of preferred embodiments, when read together with the accompanying drawings, in which:
[0013] FIG. 1 schematically depicts a perspective view of unit cells of a lattice structure that may be used in constructing materials.
[0014] FIG. 2 schematically depicts a perspective view of a primary array of unit cells and an ancillary array of unit cells.
[0015] FIG. 3 schematically depicts an overhead plan view of a lattice structure wherein an ancillary array has been nested with a primary array.
[0016] FIG. 4 schematically depicts a perspective view of a lattice structure and an oppositely oriented lattice structure ( FIG. 4A ) and wherein these two lattice structures can be mated to form mated lattice structure ( FIG. 4B ).
[0017] FIG. 5 schematically depicts a side view of a balanced or mated lattice structure.
[0018] FIG. 6 schematically depicts a side view of a balanced or mated lattice structure having face sheets (or panels) applied or disposed thereto.
[0019] FIG. 7 schematically illustrates a perspective view of face sheets (or panels) being applied or disposed to a balanced or mated lattice structure.
[0020] FIG. 8 schematically depicts an injection molding process for fabricating a unit cell of a cellular lattice by use of an injection molding apparatus and a mold.
[0021] FIG. 9 schematically depicts a perspective view of a mold used to form an array of unit cells by an injection molding process.
[0022] FIG. 10 schematically depicts a cell array being used as a template for the deposition of other materials; wherein the cell array is heated in a furnace without air, resulting in a carbonized unit cell array comprised of graphite; and wherein a deposition process results in a coated unit cell array.
[0023] FIG. 11 schematically depicts a process for forming various developmental stages of a unit cell array.
[0024] FIG. 12 schematically depicts a method of manufacture of an embodiment of tetrahedral unit cells of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present disclosure sets forth a hierarchical lattice structure that comprises unit cells of various sizes connected together to form a lightweight lattice structure with improved specific stiffness and strength.
[0026] FIG. 1 schematically depicts unit cells of a lattice structure that may be used in constructing materials having exceptional stiffness and strength for a given mass or volume of material. FIG. 1A , for example, schematically depicts a perspective view of unit cell 100 that is a first order cell 101 comprised of three ligaments 102 . The hierarchical order of a structure is typically defined as the number of levels of scale that are present within a structure. A lattice framework made of trusses of equal size is considered to be of the first-order, a lattice framework having trusses of two different sizes would be considered to be of the second-order, and so on. Thus, in the present disclosure, the order of a cell corresponds to its size in relation to other cells, where size is measured by the length of a cell's ligaments. A first order cell has the longest ligament length of any cell used in a particular lattice structure, a second order cell has the second longest ligament length, and so on. For the purposes of this specification, larger cells will be referred to as being of a higher order than smaller cells. Thus a first order cell is of a higher order than a second order cell. Cells are considered to be of the same order if they are substantially similar in size. Although ligament length is variable, an exemplary embodiment may include a unit cell 100 wherein the length of each ligament is within the range of about fifty micrometers to tens of meters. Ligaments 102 may be of any desirable cross section, including but not limited to circular or rectangular.
[0027] It should be appreciated that the cross sectional shapes of the ligaments may also be varied in order to change the overall structural properties of the lattice structure, as well as for other desired or required purposes. Possible cross sectional shapes for the ligaments include, but are not limited thereto the following: circular, triangular, rectangular, square, oval and hexagonal (or any combination or variation as desired or required).
[0028] It should be appreciated that the ligaments may be hollow, semi-solid, or solid, or any combination thereof.
[0029] In FIG. 1A , unit cell 100 is depicted by way of example and not limitation as having a tetrahedral geometric structure. In other embodiments, the geometric structure of unit cell 100 may be, but is not limited to, pyramidal, octet truss, or three-dimensional Kagome. It should be appreciated that other embodiments may include any unit cell that may be nested and mated according to the teachings of the present disclosure. Unit cells may also be comprised of multiple cell sizes. For example, as shown in FIG. 1B , unit cell 110 is comprised of a first order cell 101 formed by ligaments 102 , and three second order cells 103 each formed by two of ligaments 104 and a portion of a ligament 102 . As another example, as shown in FIG. 1C , unit cell 120 is comprised of a second order cell 103 formed by ligaments 122 , and three third order cells 105 each formed by two of ligaments 124 and a portion of a ligament 122 . Unit cells can be comprised of more than two orders of cells. For example, unit cell 110 could also be comprised of one or more third order cells that each utilize a portion of a ligament 102 of the first order cells or a portion of a ligament 104 of the second order cells, along with two additional ligaments, where the two additional ligaments are smaller than ligaments 104 of the second order cells. In other embodiments, the unit cell 110 may be comprised of less than three second order cells, including zero second order cells. Similarly, unit cell 120 could be comprised of less than three third order cells. Other unit cells may be comprised of cells of an order lower than two, for example a unit cell may be comprised of a third order cell and three or less fourth order cells.
[0030] Unit cells of other embodiments of the present disclosure may comprise more or less than three second order cells. For example, if unit cell 100 included a fourth ligament such that the shape of the unit cell was pyramidal, such a unit cell could also be comprised of four second order pyramidal cells, where each second order cell would utilize a portion of a ligament of the first order cell as one of its ligaments.
[0031] Although FIG. 1 shows the second order cells formed by ligaments 104 and portions of ligaments 102 as tetrahedral in shape, in other embodiments these second order cells may be, but are not limited to, pyramidal, octet truss, or three-dimensional Kagome in shape, or any combination thereof. Similarly, any cells of an order lower than two, such as the third order tetrahedral cells 105 formed by ligaments 124 and portions of ligaments 122 , may also be of shapes other than tetrahedral. Furthermore, the lower order cells need not be geometrically similar to higher order cells such as first order cell 100 . As an example, the angles between the ligaments comprising the second order cells may differ from the angles between the ligaments comprising the first order cells. The ligaments of lower order cells may, but are not required to, connect with the ligaments of an adjacent lower order cell. As an example of ligaments of adjacent cells connected together, in FIG. 1B , a ligament 104 of a second order cell 103 is connected at node 106 to a ligament of an adjacent second order cell.
[0032] The materials for manufacturing these unit cells encompass any material subject to deformation, punch and die, casting, injection molding, or other forming methods: these include, but are not limited to, metals, metal alloys, inorganic polymers, organic polymers, ceramics, glasses, and all composite derivatives, or any combination thereof. In some embodiments, the material used to construct cells of one order may be different than the material used to construct cells of another order. In some embodiments, different cells of the same order may be comprised of different materials. Similarly, as will be discussed later, panels implemented with the core may be of the same or different materials as the core.
[0033] FIG. 2 schematically depicts a primary array 130 of unit cells 110 replicated in two dimensions. As shown in FIG. 2A , the primary array may be formed by joining ligaments of adjacent cells together at nodes. In some embodiments, multiple cells of the primary array 130 may be constructed concurrently, such that the ligaments of adjacent cells are joined during the fabrication process. In other embodiments, cells of the primary array may be attached through their ligaments by other suitable means, including but not limited to brazing, transient liquid phase bonding, welding, diffusion bonding, or adhesive bonding after construction (or any other available adhesion process). In some embodiments, if the cells are constructed of a polymer they are attached together by an adhesive. In some embodiments, if the cells are constructed of a metal, they are attached through welding or brazing. Similarly, multiple primary arrays 130 can be attached to each other by suitable means after construction by attaching ligaments of their respective cells. In other embodiments, the cells of the primary array need not be joined together, so long as they are in close proximity with each other. FIG. 2A also depicts an ancillary array 140 of unit cells 120 replicated in two dimensions. As shown, these unit cells 120 are not required to be connected through their respective ligaments, though in some embodiments these adjacent ligaments may indeed be connected. Ancillary array 140 may be nested with primary array 130 to form lattice structure 200 .
[0034] Nesting may be accomplished when a portion of a ligament of a higher order cell of a primary array abuts a ligament of a lower order cell of an ancillary array along at least a substantial portion of the length of the ligament of the lower order cell. Nesting may also occur when a ligament of a cell from an ancillary array abuts along at least a substantial portion of the length of a ligament of a similarly ordered cell of a primary array. When either or both of these nesting scenarios occur, the respective cells are said to be nested and “co-aligned” with each other. When at least one cell from a primary array is nested with at least one cell from an ancillary array, the arrays are said to be nested with each other. In an embodiment, when two arrays are nested, at least one ligament of each of the highest ordered cells in the ancillary array will abut to a portion of a ligament of one of the highest ordered cells in the primary array. As an example, in referring to FIG. 2B , after nesting, one ligament of each of the second order cells 103 of unit cell 120 abuts with a portion of a ligament of a first order cell 101 of unit cell 110 . In some embodiments and as shown in FIG. 2B , nesting may also occur because other ligaments of the second order cells 103 of unit cell 120 abut with the ligaments of the second order cells 103 of unit cell 110 . In other embodiments, there may be further nesting between lower order cells. For example, an array of third order cells could be nested with the ancillary array 140 , and an array of fourth order cells could be nested with the array of third order cells, and so on. Nesting can also occur between cells that have a difference of order greater than one. For example, an array of third order cells could nest with an array of first order cells. This nesting of lower order cells with higher order cells as described herein results in a lattice with a hierarchical structure.
[0035] FIG. 3 schematically depicts an overhead plan view of a lattice structure 200 wherein an ancillary array 140 has been nested with a primary array 130 . Ligaments 102 form the first order cells, ligaments 104 along with portions of ligaments 102 form the second order cells, and ligaments 124 along with portions of ligaments 104 form the third order cells. Because in the lattice structure comprising nested arrays in FIG. 3 , ligaments 122 abut substantially with ligaments 104 , only ligaments 104 are explicitly shown. In FIG. 3 , each cell is of a tetrahedral shape.
[0036] FIG. 4 schematically depicts a perspective view of a lattice structure 200 and an oppositely oriented lattice structure 210 ( FIG. 4A ). These two lattice structures can be mated to form mated lattice structure 220 ( FIG. 4B ). Mating is accomplished when at least one ligament of at least one of the highest order cells of an array or lattice structure abuts with at least a substantial portion of at least one ligament of at least one of the highest order cells of an oppositely oriented lattice structure or array. In some embodiments of a mated lattice structure or array, substantially all of the ligaments of the highest order cells of a lattice structure or array abut with at least a substantial portion of one of the ligaments of the highest order cells of an oppositely oriented lattice structure. This is shown by way of example in FIG. 4B where the ligaments of the highest order cells of lattice structure 200 abut with the ligaments of the highest order cells of oppositely oriented lattice structure 210 . When the ligaments abut along at least a substantial portion of their respective lengths, the corresponding cells are said to be “co-aligned” with each other. In FIG. 4 , it is readily observable that, excepting the cells at the boundary, each ligament of the highest order cells of oppositely oriented lattice structure 210 abuts along at least a substantial portion of its length with a ligament of the highest order cells of lattice structure 200 , such that the cells of these respective lattice structures are co-aligned with each other. Mated lattice structures may also be referred to as balanced lattice structures.
[0037] In FIG. 4 , the lattice structure 200 and the oppositely oriented lattice structure 210 are each shown by way of example and not limitation as comprised of a primary array 130 and an ancillary array 140 , with each array having two orders of cells. In reality, all that is necessary for mating are two lattice structures each comprised of a primary array of first order cells. In other embodiments, one or both of the mated lattice structures may also be comprised of multiple orders of cells.
[0038] FIG. 5 and FIG. 6 schematically depict a side view of balanced or mated lattice structure 220 . FIG. 6 also schematically illustrates face sheets 230 (or panels) being applied to a balanced or mated lattice structure 220 . FIG. 7 schematically illustrates a perspective view of face sheets being applied to a balanced lattice structure 220 . In some embodiments, after mating, a solid face sheet 230 may be attached either directly or indirectly, to the top, the bottom, or both the top and bottom of the balanced lattice structure 220 . In other embodiments, a solid face sheet 230 may be attached either directly or indirectly, to the top, the bottom, or both the top and bottom of a lattice structure 200 or a primary array 130 . The face sheets 230 may be attached by any suitable means, including but not limited to brazing, transient liquid phase bonding, welding, diffusion bonding, or adhesive bonding. Alternatively, an open cell face sheet may be used in place of solid face sheet 230 in any of these configurations
[0039] By way of example and not limitation, the lattice structures provided herein are illustrated as comprising unit cells replicated in two dimensions. In other embodiments, although not shown, the unit cells making up a lattice structure may also be formed in three dimensions, thus creating a three dimensional cube-shaped array or lattice structure. In other embodiments, the unit cells making up a lattice structure could be replicated solely in one dimension.
[0040] It should be appreciated that any one of the primary arrays, nested arrays, or mated arrays or lattice structures, or combinations thereof may be implemented as the core of a sandwich panel or other structure that the core or panel may be in communication with. The panels and/or cores may be implemented with or as part of floors, columns, beams, walls, jet or rocket nozzles, land, air or water vehicles/ships, armor, etc.
[0041] It should be appreciated that any face sheets (or any desired or required components or structures) may be attached to the core (or in communication with the core or other structure or components) by any suitable means, including but not limited to brazing, transient liquid phase bonding, welding, diffusion bonding, or adhesive bonding after construction (or any other available adhesion process). In some embodiments, if the materials are constructed of a polymer they are attached together by an adhesive. In some embodiments, if the materials are constructed of a metal, they are attached through welding or brazing.
[0042] By way of example and not limitation, the lattice structures and arrays shown in the figures of the present disclosure as resting on a flat surface. In some embodiments a lattice structure or array may be curved, such that it does not rest on a flat surface. For example, a lattice structure might take the shape of an arc or be used to form the shell of a cylinder. Thus, since in some embodiments the lattice structure may be curved, any face sheet applied to such an embodiment will also be curved. In some embodiments, the lattice structure might be used to form a rocket or jet fuel nozzle. For example, the core or lattice (with or without panels) may be circular or at least semi-circular to provide an opening or nozzle for a jet or rocket. Similar designs may be implemented to provide a conduit or structure for any medium transfer there through. This application of the lattice structure is facilitated by the structure's high strength and thermal conductivity.
[0043] The core or lattice (with or without panels) may be implemented for walls or floors for housings, compartments, buildings, floors, vehicles, or infrastructure.
[0044] The lattice structures described above have many applications including use as the cores of sandwich panel structures. Utilizing embodiments of the present disclosure, sandwich panels with ultra-light and high specific stiffness and strength lattice cores can be designed to outperform competing load supporting structures made with honeycomb or other conventional cores. These sandwich panels may be used in minimum weight structural applications, including many forms of mechanized transportation. Embodiments of the present disclosure can also be used to construct materials with improved impact or blast load mitigation. For example, these materials can sustain larger compressive forces along their struts before truss buckling occurs and they can suffer larger face sheet deformations before face sheet tearing is initiated. Embodiments of the present disclosure also enable materials with superior cross flow heat exchange, since the hollow structure allows coupling of a fluid coolant driven between the struts to heat transported through the struts by conduction. The hollow structure also enables the placement of other elements within the core. Embodiments of the present disclosure may also be used to create armors that have high ballistic resistance, in other words the strength of the structure increases the force needed to crush the material. Embodiments of the present disclosure may also be used to create armors, storage or buildings that mitigate blast impact.
[0045] An embodiment of this present disclosure can be designed to control the collapse of the first order cells during an impact with a rigid object, making it a preferred material system for impact or blast energy absorption. The increased surface area of a structure with a multiplicity of cell sizes can also be used as a support system for catalysts where the large cell size regions provide easy transport of reactants and products of the reaction enhanced at the catalytically coated surfaces of the trusses. When cells are arranged in this way, a high surface energy is enabled upon which other materials can be added for a wide range of applications. For example, an embodiment of the present disclosure could be used for the deposition of thin film batteries resulting in a load supporting, easily cooled structure with a very high energy storage density.
[0046] In some embodiments of the present disclosure, arrays of unit cells (unit cell arrays) can be fabricated from thermoformable materials through the use of an injection molding process. FIG. 8 schematically depicts an injection molding process for fabricating a unit cell of a cellular lattice by use of an injection molding apparatus 500 and a mold 510 . In an embodiment, a granular thermoplastic polymer 502 is fed into a cylinder 504 , where the polymer is heated by heater 506 into a liquid form before being propelled through nozzle 508 into a mold 510 by rotating screw 512 . The injection apparatus 500 is then separated from the mold 510 and the liquid polymer is allowed to cool and harden. After cooling, the respective parts of the mold 510 are separated and unwanted portions of the cooled polymer may be cropped ( FIG. 8B ). This process results in the formation of a unit cell 514 .
[0047] In certain embodiments, the polymer 502 may be polypropylene, but alternative embodiments may use any other suitable thermoplastic polymer capable of being heated into a liquid state and then cooled to a solid state. By way of example and not limitation, polystyrene and polyethylene could also be used. One skilled in the art will recognize that in other embodiments, many different methods for injecting liquid into a mold could be used. Other embodiments may use any suitable injection apparatus to propel two or more polymers into a mold to form a unit cell in a process known as reaction injection molding. Still other embodiments may use any suitable injection apparatus to propel liquid metal into a mold to form a unit cell in a process known as metal injection molding. Still other embodiments may use any suitable injection apparatus to inject ceramic materials mixed with thermoplastic binders into a mold to form a unit cell in a process known as ceramic injection molding.
[0048] FIG. 9 schematically depicts a perspective view of a mold 600 used to form an array of unit cells 602 by an injection molding process.
[0049] A cell array 602 formed by an injection molding process may be used in various applications to provide support in structural materials. A cell array 602 formed by an injection molding process may also be used as a template in further processing, as shown in FIG. 10 and FIG. 11 .
[0050] FIG. 10 schematically depicts a cell array 602 being used as a template for the deposition of other materials. In some embodiments, after formation through injection molding using polymers, the cell array 602 is heated in a furnace without air, resulting in a carbonized unit cell array 702 comprised of graphite, or other suitable material as desired or required. This carbonized cell array 702 has a higher melting temperature than a normal cell array 602 . The carbonized unit cell array is then placed in a heated chamber 700 . Various gases are supplied to the chamber and interact with each other to form solids. This process results in a solid coating over the carbonized unit cell array 702 . Waste gases flow out of the chamber through an outlet. As an example, and not by way of limitation, FIG. 10 depicts the deposition of silicon carbide (SiC) on the carbonized unit cell array 702 . This is accomplished by placing the carbonized unit cell array 702 in the heated chamber 700 and feeding argon 704 , hydrogen 706 , and methyltrichlorosilane (CH 3 SiCl 3 ) 708 into the chamber 700 . The gases will react, leaving a coating of SiC on the carbonized unit cell array 702 . The waste gases of hydrogen, argon, and hydrogen chloride flow through an outlet of the chamber 700 . Other embodiments may substitute any gases capable of interacting with each other to form a deposition on the carbonized unit cell array 702 . Deposition may occur by any suitable means capable of permitting vapor transport to all surfaces of the carbonized unit cell array 702 , including but not limited to, chemical vapor deposition, and directed vapor deposition.
[0051] If a hollow truss structure is desired, the inner material of the coated carbonized unit cell array 702 can be removed by the process of burnout, by which the coated carbonized unit cell array 702 is subjected to a temperature that exceeds the melting point of the inner material of the coated carbonized unit cell array 702 but not the deposited material, thus leaving the deposited material in tact in the same shape as the original unit cell array 602 . While the preceding example involves a carbonized polymeric unit cell array used as a template for deposition, other embodiments may utilize unit cell arrays made from other types of materials, including but not limited to metals, metal alloys, inorganic polymers, organic polymers, ceramics, glasses, and all composite derivatives, or any combination thereof.
[0052] FIG. 1 schematically depicts a polymeric unit cell array 602 being used as a template for investment casting of a unit cell array. In an embodiment, the process begins with a unit cell array 602 with uncropped risers 802 made from a polymer material 804 ( FIG. 11A ). The unit cell array 602 is then immersed in liquid casting slurry 806 or other suitable material or process ( FIG. 11B ). After the casting slurry dries, the unit cell array 602 is composed of the polymer material 804 and the slurry coating 808 . The unit cell array 602 is then placed in furnace 810 and the polymer material core 804 is burned out, leaving a hollow negative template comprised of the slurry coating 808 ( FIG. 11C ). Molten metal 811 or other suitable liquid material is then poured into this template ( FIG. 11D ). After cooling, the unit cell array 602 is comprised of a solid metal core 812 and a slurry coating 808 . This slurry coating 808 is then removed ( FIG. 11E ), leaving a unit cell array comprised of solid metal 812 . The solid metal unit cell array can then be tested for structural soundness. By way of example and not limitation, the electrical resistivity of the solid metal unit cell array in FIG. 11F may be measured with an ohmmeter or by applying a current to the unit cell array and measuring a voltage drop across the unit cell array with a voltmeter.
[0053] FIG. 12 depicts a method of manufacture of an embodiment of tetrahedral unit cells of the present disclosure. Referring to FIG. 12A , individual hexagons 160 with tabs 162 extending in both directions from every other vertex may be die cast, stamped from sheet goods, or cut from an extruded profile. Each piece is then deformed with a die 156 and punch 154 tool assembly to form unit cell 110 . Similarly, referring to FIG. 12B , individual hexagons 170 with tabs 172 extending in both directions from every other vertex may also be die cast, stamped from sheet goods, or cut from an extruded profile and then deformed with a die 152 and punch 150 tool assembly to form unit cell 120 . Unit cell 120 may be nested with unit cell 110 . After nesting, these unit cells may be held in place via a resistance weld, or other suitable means at the lower portion of each major ligament. Collections of these individual units may be subsequently joined in rows and placed in a packed array between face sheets that may (or may not) have channels or indentations to provide for correct alignment. The assembly is subjected to a joining process such as, but not limited, to brazing, transient liquid phase bonding, welding, diffusion bonding, or adhesive bonding depending on the materials used. The result is a sandwich panel that contains a hierarchical truss core network and exhibits significant improvements in strength.
[0054] A person skilled in the art would recognize that the lattice structures described in the present disclosure could be manufactured in other ways including lattice block construction, constructed metal lattice, and metal textile lay-up techniques.
[0055] It should be appreciated that various aspects of embodiments of the present method, system, devices, article of manufacture, and compositions may be implemented with the following methods, systems, devices, article of manufacture, and compositions disclosed in the following U.S. patent applications, U.S. patents, and PCT International patent applications and are hereby incorporated by reference herein and co-owned with the assignee:
[0056] International Application No. PCT/US2009/034690 entitled “Method for Manufacture of Cellular Structure and Resulting Cellular Structure,” filed Feb. 20, 2009.
[0057] International Application No. PCT/US2008/073377 entitled “Synergistically-Layered Armor Systems and Methods for Producing Layers Thereof,” filed Aug. 15, 2008.
[0058] International Application No. PCT/US2008/060637 entitled “Heat-Managing Composite Structures,” filed Apr. 17, 2008.
[0059] International Application No. PCT/US2007/022733 entitled “Manufacture of Lattice Truss Structures from Monolithic Materials,” filed Oct. 26, 2007.
[0060] International Application No. PCT/US2007/012268 entitled “Method and Apparatus for Jet Blast Deflection,” filed May 23, 2007.
[0061] International Application No. PCT/US04/04608, entitled “Methods for Manufacture of Multilayered Multifunctional Truss Structures and Related Structures There from,” filed Feb. 17, 2004, and corresponding U.S. application Ser. No. 10/545,042, entitled “Methods for Manufacture of Multilayered Multifunctional Truss Structures and Related Structures There from,” filed Aug. 11, 2005.
[0062] International Application No. PCT/US03/27606, entitled “Method for Manufacture of Truss Core Sandwich Structures and Related Structures Thereof,” filed Sep. 3, 2003, and corresponding U.S. application Ser. No. 10/526,296, entitled “Method for Manufacture of Truss Core Sandwich Structures and Related Structures Thereof,” filed Mar. 1, 2005.
[0063] International Patent Application Serial No. PCT/US03/27605, entitled “Blast and Ballistic Protection Systems and Methods of Making Same,” filed Sep. 3, 2003.
[0064] International Patent Application Serial No. PCT/US03/23043, entitled “Method for Manufacture of Cellular Materials and Structures for Blast and Impact Mitigation and Resulting Structure,” filed Jul. 23, 2003.
[0065] International Application No. PCT/US03/16844, entitled “Method for Manufacture of Periodic Cellular Structure and Resulting Periodic Cellular Structure,” filed May 29, 2003, and corresponding U.S. application Ser. No. 10/515,572, entitled “Method for Manufacture of Periodic Cellular Structure and Resulting Periodic Cellular Structure,” filed Nov. 23, 2004.
[0066] International Application No. PCT/US02/17942, entitled “Multifunctional Periodic Cellular Solids and the Method of Making Thereof,” filed Jun. 6, 2002, and corresponding U.S. application Ser. No. 10/479,833, entitled “Multifunctional Periodic Cellular Solids and the Method of Making Thereof,” filed Dec. 5, 2003.
[0067] International Application No. PCT/US01/25158 entitled “Multifunctional Battery and Method of Making the Same,” filed Aug. 10, 2001, U.S. Pat. No. 7,211,348 issued May 1, 2007 and corresponding U.S. application Ser. No. 11/788,958, entitled “Multifunctional Battery and Method of Making the Same,” filed Apr. 23, 2007.
[0068] International Application No. PCT/US01/22266, entitled “Method and Apparatus For Heat Exchange Using Hollow Foams and Interconnected Networks and Method of Making the Same,” filed Jul. 16, 2001, U.S. Pat. No. 7,401,643 issued Jul. 22, 2008 entitled “Heat Exchange Foam,” and corresponding U.S. application Ser. No. 11/928,161, “Method and Apparatus For Heat Exchange Using Hollow Foams and Interconnected Networks and Method of Making the Same,” filed Oct. 30, 2007.
[0069] International Application No. PCT/US01/17363, entitled “Multifunctional Periodic Cellular Solids and the Method of Making Thereof,” filed May 29, 2001, and corresponding U.S. application Ser. No. 10/296,728, entitled “Multifunctional Periodic Cellular Solids and the Method of Making Thereof,” filed Nov. 25, 2002.
[0070] It should be appreciated that various aspects of embodiments of the present method, system, devices, article of manufacture, and compositions may be implemented with the following methods, systems, devices, article of manufacture, and compositions disclosed in the following U.S. patent applications, U.S. patents, and PCT International patent applications, and scientific articles, and are hereby incorporated by reference herein:
1. Lakes, R., “Materials with Structural Hierarchy”, Nature, Vol. 361, Feb. 11, 1993, Pages 511-515. 2. U.S. Patent Application Publication No. 2005/0126106 A1, Murphy, et al., “Deployable Truss Having Second Order Augmentation”, Jun. 16, 2005. 3. U.S. Patent Application Publication No. 2007/0256379 A1, Edwards, C., “Composite Panels”, Nov. 8, 2007. 4. U.S. Pat. No. 4,722,162, Wilensky, J., “Orthogonal Structures Composed of Multiple Regular Tetrahedral Lattice Cells”, Feb. 2, 1988. 5. U.S. Pat. No. 6,644,535 B2, Wallach, et al., “Truss Core Sandwich Panels and Methods for Making Same”, Nov. 11, 2003. 6. U.S. Pat. No. 6,931,812 B1, Lipscomb, “Wet Structure and Method for Making the Same”, Aug. 23, 2005.
[0077] Of course it should be understood that a wide range of changes and modifications could be made to the preferred and alternate embodiments described above. It is therefore intended that the foregoing detailed description be understood that it is the following claims, including all equivalents, which are intended to define the scope of this invention.
[0078] In summary, while the present invention has been described with respect to specific embodiments, many modifications, variations, alterations, substitutions, and equivalents will be apparent to those skilled in the art. The present invention is not to be limited in scope by the specific embodiment described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those of skill in the art from the foregoing description and accompanying drawings. Accordingly, the invention is to be considered as limited only by the spirit and scope of the following claims, including all modifications and equivalents.
[0079] Still other embodiments will become readily apparent to those skilled in this art from reading the above-recited detailed description and drawings of certain exemplary embodiments. It should be understood that numerous variations, modifications, and additional embodiments are possible, and accordingly, all such variations, modifications, and embodiments are to be regarded as being within the spirit and scope of this application. For example, regardless of the content of any portion (e.g., title, field, background, summary, abstract, drawing figure, etc.) of this application, unless clearly specified to the contrary, there is no requirement for the inclusion in any claim herein or of any application claiming priority hereto of any particular described or illustrated activity or element, any particular sequence of such activities, or any particular interrelationship of such elements. Moreover, any activity can be repeated, any activity can be performed by multiple entities, and/or any element can be duplicated. Further, any activity or element can be excluded, the sequence of activities can vary, and/or the interrelationship of elements can vary. Unless clearly specified to the contrary, there is no requirement for any particular described or illustrated activity or element, any particular sequence or such activities, any particular size, speed, material, dimension or frequency, or any particularly interrelationship of such elements. Accordingly, the descriptions and drawings are to be regarded as illustrative in nature, and not as restrictive. Moreover, when any number or range is described herein, unless clearly stated otherwise, that number or range is approximate. When any range is described herein, unless clearly stated otherwise, that range includes all values therein and all sub ranges therein. Any information in any material (e.g., a United States/foreign patent, United States/foreign patent application, book, article, etc.) that has been incorporated by reference herein, is only incorporated by reference to the extent that no conflict exists between such information and the other statements and drawings set forth herein. In the event of such conflict, including a conflict that would render invalid any claim herein or seeking priority hereto, then any such conflicting information in such incorporated by reference material is specifically not incorporated by reference herein. | A sandwich panel core that may be comprised of a lattice structure utilizing a network of hierarchical trusses, synergistically arranged, to provide support and other functionalities disclosed herein. Since this design results in a generally hollow core, the resulting structure maintains a low weight while providing high specific stiffness and strength. Sandwich panels are used in a variety of applications including sea, land, and air transportation, ballistics, blast impulse mitigation, impact mitigation, thermal transfer, ballistics, load bearing, multifunctional structures, armors, construction materials, and containers, to name a few. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/549,949, filed Mar. 4, 2004.
FIELD OF THE INVENTION
This invention relates to a method of mechanically activating the shape recovery of a deformed shape memory material. The invention also relates to a device comprising a mechanically activated shape memory material.
BACKGROUND OF THE INVENTION
Shape memory is the ability of a material to remember its original shape, either after mechanical deformation, which is a one-way effect, or by cooling and heating, which is a two-way effect. This phenomenon is based on a structural phase transformation.
Materials known to have these properties are shape memory alloys (SMAs), for example TiNi, CuZnA 1 , and FeNiA 1 alloys. The structure phase transformation of these materials is known as a martensitic transformation. These materials have been proposed for various applications such as vascular stents, medical guidewires, orthodontic wires, vibration dampers, pipe couplings. However, these materials have not been widely used, in part due to their relatively high costs and their limited range of mechanical properties.
Shape memory polymers (SMPs) have been under active development as a replacement or augmentation to SMAs. SMPs enjoy many advantages, among which are low density, high recoverable strain (up to several hundred percent compared to less than 8% for SMA), tailorability of the transition temperature and rubbery modulus according to the application, easy processability, and economy of materials and manufacturing. In the literature, several classes of polymers have been shown to allow SMP behavior, including highly entangled amorphous polymers, crosslinked amorphous polymers (including castable SMPs), melt-miscible blends of semicrystalline and amorphous polymers, crosslinked semicrystalline polymers and their blends with rubber (shape memory rubber), and multiblock copolymers. The latter SMP class consists of phase-segregated linear block co-polymers having a hard segment and a soft segment. The hard segment is typically crystalline, with a defined melting point, and the soft segment is typically amorphous, with a defined glass transition temperature. In some embodiments, the hard segment is amorphous and has a glass transition temperature rather than a melting point. In other embodiments, the soft segment is crystalline and has a melting point or glass transition temperature. The melting point or glass transition temperature of the soft segment is substantially lower than the melting point or the glass transition temperature of the hard segment.
When the SMP is heated above the melting point or glass transition temperature of the hard segment, the material can be shaped with complete relaxation of internal stress. This original shape can be memorized by cooling the SMP below the melting point or glass transition temperature of the hard segment. When the shaped SMP is cooled below the melting point or glass transition temperature of the soft segment while the shape is deformed, that temporary shape is fixed. The original shape is recovered by heating the material above the melting point or glass transition temperature of the soft segment but below the melting point or glass transition temperature of the hard segment. In another method for setting a temporary shape, the material is deformed at a temperature lower than the melting point or glass transition temperature of the soft segment. When the material is heated above the melting point or glass transition temperature of the soft segment, but below the melting point or glass transition temperature of the hard segment, the stresses and strains are relieved and the materials return to their original shape. The recovery of the original shape, which is induced by an increase in temperature, is called the thermal shape memory effect.
The shape memory effects are intimately linked to the polymer's structure and morphology and exist in many polymers, copolymers and cross-linked polymers. Examples of polymers used to prepare hard and soft segments of SMPs include various polyethers, polyacrylates, polyamides, polysiloxanes, polyurethanes, polyethers amides, polyurethane/ureas, polyether esters (U.S. Pat. No. 5,506,300 to Ward et al., U.S. Pat. No. 5,145,935 to Hayashi, and U.S. Pat. No. 5,665,822 to Bitler et al), polynorborene (Japanese Patent Publication No. JP 59-53528 (Nippon Zeon Co. Ltd)) cross-linked polymers such as cross-linked polyethylene and cross-linked poly(cyclooctene) (C. Liu, S. B. Chun, P. T. Mather, L. Zheng, E. H. Haley, and E. B. Coughlin, Macromolecules , volume 35, number. 27, pages 9868–9874 (2002)), inorganic-organic hybrid polymers (H. G. Leon, P. T. Mather, and T. S. Haddad, Polymer International , volume 49, number 5, pages 453–457 (2000)), and copolymers such as urethane/butadiene copolymers, styrene-butadiene copolymers (M. Irie, Chapter 9: Shape Memory Polymers, in K. Otsuka and C. M. Wayman, eds., “Shape Memory Materials,” Cambridge University Press: Cambridge, UK, 1998).
As described above, the recovery of the original shape of a SMP or SMA is triggered by the application of heat that increases the temperature of the SMP or SMA beyond the critical temperature, be it a melting point or glass transition temperature. To date, application of heat has been primarily from external sources, such as heat guns, or hot water. However, new applications of shape memory materials would be possible if the heat necessary to allow shape recovery in a shape memory material were generated within or immediately adjacent to the shape memory article itself.
BRIEF DESCRIPTION OF THE INVENTION
The invention comprises a device combining the advantages of a shape memory material and a super-cooled liquid containing heat pack provided with a crystallization trigger or activator. The super-cooled liquid and its crystallization activator/trigger provide mechanical activation of shape or strain recovery in shape memory materials that avoids the use of external heating at the time of the shape recovery, thereby greatly extending the range of applications available for the device.
SMP or SMA is used in fabricating the container or as an integral element of the container for the super-cooled liquid. Preferably the device, i.e., the container portion thereof is made of an SMP. Mechanical activation of the super-cooled liquid to allow initiation of heat-generating crystallization results in the triggering of strain recovery of the SMP toward a deployed shape that is rigid and stationary until later heated for simultaneous liquification of the super-cooled liquid and softening of the SMP for strain fixing in a temporary (generally compact) shape.
The device is suitable as a reusable warmer, as a dental mold material, in medical applications where reusable heat packs are indicated, particularly for application to difficult contours, and for large deployable structures such as satellite antennae and temporary shelters
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE shows an embodiment in which a shape memory article comprising a super-cooled liquid within a shape memory polymer is heated to soften the shape memory polymer and melt the previously crystallized super-cooled liquid, reshaped to a nonequilibrium shape, cooled to harden the shape-memory polymer into the nonequilibrium shape, and mechanically activated to trigger crystallization of the super-cooled liquid thereby softening the shape memory polymer and allowing recovery of the equilibrium shape and concomitant hardening of the super-cooled liquid.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a means for shape or strain recovery in shape memory materials using heat generated from the crystallization of a super-cooled liquid. The use of super-cooled liquid eliminates the need to use an external heating source, such as a heat gun, electrical heating element, and the like. Without the necessity of an external heating element, the portability of the device and the ease of using it are greatly enhanced.
A particular source of heat, heat pack, has been used for many years by sportsmen and others to warm parts of the human body for therapeutic purposes or simply fending off the cold. One particularly favored embodiment of the heat pack is the reusable heat pack employing a super-cooled liquid and an activator. A super-cooled liquid is a liquid that can cool well below the normal liquid-to-solid phase change temperature, but still remain in the liquid phase. Normally the super-cooled liquid is prepared so that it remains stable at ambient temperature found in homes, hospitals and their related storage areas. When the pack is to be used, crystallization in the solution is initiated. Thus, when an activator embedded in the super-cooled liquid is triggered, conditions are created in the liquid that cause the material to change very rapidly, in wave like manner from the activation site, from the liquid phase to the solid phase, thus quickly giving up the heat of crystallization to the surroundings. The super-cooled liquid can be made from many different materials, including aqueous solutions of sodium acetate, calcium nitrate, lead acetate, sodium borate, sodium phosphate, sodium pyrophosphate, sodium thiosulfate, trimethylol ethane (U.S. Pat. No. Re. 35,586 to Manker, and U.S. Pat. No. 6,537,309 to Sharma et al.) and their hydrates, and the melt or supersaturated solution xylitol (U.S. Pat. No. 4,296,801 to Guex). The aqueous solution of sodium acetate is typically preferred because it is generally harmless to humans.
The salt solution is made by dissolving the salt in the desired amount of water. The amount of salt to be utilized should permit the salt solution to be super-cooled to at least the ambient temperature at which the heat pack is intended to be utilized. Additionally, the amount of the salt should not be so great that the resulting solution is activated unintentionally by shaking, etc., when at ambient or use temperature. However, a sufficient amount of salt should be used to enable the super-cooled solution to be readily crystallized when the trigger is activated and to release sufficient heat to serve the desired function. In particular, the amount of water present in the salt solution will vary depending upon the heat pack temperature desired. As the amount of water increases relative to the amount of salt, the temperature to which the container contents are raised when the salt crystallizes decreases. This means that the maximum temperature of a heat pack can be controlled by appropriate adjustment of the water/salt ratio (U.S. Pat. No. 5,305,733 to Walters).
Optionally, various gelling agents can be added to prevent the super-cooled aqueous solution from freely flowing (also known as “saddlebagging”) giving rise to uneven heating (U.S. Pat. No. Re. 35,586 to Manker, and U.S. Pat. No. 5,058,563 to Manker). Various other compounds can also be added to the super-cooled solution to impart desirable properties, such as the addition of aniline to increase the shelf life of the product (U.S. Pat. No. 6,537,309 to Sharma et al), the addition of viscosity enhancing compounds for improved smoothness to the crystallized solution (U.S. Pat. No. 6,537,309 to Sharma et al.), and the like.
The triggering of the super-cooled solution to activate the crystallization has been accomplished in a number of ways. Puncturing devices can be used in the presence (U.S. Pat. No. 5,915,461 to Panhehco) or absence (U.S. Pat. No. 5,305,733 to Walters) of salt crystals. U.S. Pat. No. 5,275,156 to Milligan et al. and U.S. Pat. Nos. 4,460,546, 4,580,547, and 4,899,727 all to Kapralis et al. disclose various trigger devices that float free in the super-cooled salt solution, which is activated by mechanically stressing the devices. U.S. Pat. No. 5,056,589 to Hettel et al. discloses the use of a metallic spring mechanism for crystallizing a super-cooled salt solution, and U.S. Pat. No. 5,143,048 to Cheney discloses a disc or ampoule containing crystals of the salt used to form the super-cooled salt solution. U.S. Pat. No. 4,077,390 to Stanley et al., U.S. Pat. Nos. 4,379,448 and 4,460,546 and 4,532,110 to Kapralis et al., and U.S. Pat. No. 4,572,158 to Fiedler disclose the use of strips with slits or openings in contact with the super-cooled solution wherein the bending or flexing of the strips initiates the crystallization. U.S. Pat. No. 4,829,980 to Smith discloses the use of nested helically-coiled resilient metallic filament as a trigger.
The shape memory material used in this invention can be of any suitable shape memory polymer or alloy formulations as described above, such as castable shape memory formulations, shape memory rubber, amorphous/crystalline blends, and/or nanostructured biodegradable SMP polyurethanes. The preferred materials are shape memory polymers, particularly a cured blend of poly(cyclooctene) and styrene-butadiene rubber.
The super-cooled liquid can be selected from the ones described above. The preferred super-cooled liquid is an aqueous sodium acetate solution (preferably about 40 to about 60 weight percent, more preferably roughly 50 weight percent) prepared by dissolving sodium acetate or its hydrates in an appropriate amount of water. The purity of the sodium acetate and water should be such that no impurity, such as dust, is present to trigger an unintentional premature crystallization.
It is within the spirit of the invention to add various agents into the super-cooled salt solution to impart desirable properties, such as the addition of gelling agents (U.S. Pat. Nos. Re. 35,586 and 5,058,563 to Manker) to prevent uneven heating, and/or the addition of shelf life enhancement agents (U.S. Pat. No. 6,537,309 to Sharma et al.), and viscosity adjusting compounds (U.S. Pat. No. 6,537,309 to Sharma et al.).
The trigger/activator can be selected from the ones described above. The preferred embodiment uses a fissure-containing stainless steel strip, such as that disclosed in U.S. Pat. No. 4,077,390 to Stanley et al.
An illustrative procedure for making the mechanically activated shape memory device of the invention is shown in the Figure. A shape memory device 10 in its equilibrium conformation comprises walls having a hardened, unstrained shape memory polymer 20 (such as a slender tube from a cured blend of poly(cyclooctene) and styrene-butadiene rubber), a saturated salt solution 30 (e.g., a saturated, aqueous solution of sodium acetate), solid salt crystals 40 (e.g., sodium acetate crystals), and a trigger strip 50 in contact with the saturated salt solution. The opening in the tube through which the salt solution is introduced is subsequently vacuum sealed. The shape memory device 10 is heated to a temperature above the melting point or glass transition temperature of the shape memory polymer and also above a temperature sufficient to dissolve the salt crystals 40 . This heating softens the hardened shape memory polymer 20 to yield a shape memory device comprising softened shape memory polymer 70 and a solution 80 into which the solid solute particles 40 have dissolved. For example, heating to about 65° C. or higher is sufficient to soften the poly(cyclooctene) fixing phase of the blend of poly(cyclooctene) and styrene-butadiene rubber and to melt the crystallized aqueous sodium acetate solution. The shape memory device is then reshaped (e.g., by twisting, stretching, folding, rolling, etc.; reshaping process not shown) to yield a shape memory device 60 in its temporary, nonequilibrium conformation. Cooling the shape memory device 60 (e.g., with air or water) yields shape memory device 90 in which the shape memory polymer 100 has hardened in a strained conformation and the salt solution 110 is super-cooled. When maintained at room temperature, the super-cooled liquid in the device is metastable against crystallization and remains as a liquid, while the shape memory polymer is in a temporary (deformed) shape and is stable against strain recovery. Activation of the trigger strip 50 (e.g., as described in U.S. Pat. No. 4,077,390 to Stanley et al.) initiates crystallization in the super-cooled solution, generating heat that temporarily softens the hardened and strained shape memory 90 to yield a softened shape memory polymer (not shown) and allows the shape memory device to reassume its equilibrium conformation. For example, when the super-cooled solution is a supersaturated sodium acetate solution, crystallization will release about 190 Joules per gram of energy at a crystallization temperature that varies with the water content, but is in the range 35<T cryst <58° C. The sodium acetate concentration in the supercooled solution may therefore be selected so that the crystallization temperature is greater than the critical temperature for the onset of shape recovery T cryst (about 40 to 50° C. for this example). Energetically, the work performed by the shape memory polymer upon shape/strain recovery may be derived from the mechanical work done in performing the original shape fixing, but some additional energy may be derived from the heat released from the crystallization of the super-cooled liquid. The crystallization may progress as a front and thus the shape recovery may occur as a smooth propagation ideal for deployment of a complex structure. Alternatively, deployment of the structure could commence from at least two sites simultaneously or sequentially as dictated by the locations of at least two mechanical triggering sites.
The amount of water utilized with super-cooled liquid, as described above, can influence the temperature the device can heat up to upon crystallization, with a lower water concentration leading to a higher temperature. Therefore, depending on the kind of shape memory material employed in making the device, the amount of water (or the kind of super-cooled liquid) can be varied to provide a temperature suitable for the triggering the shape recovery of the SMP. A particular advantage of using low water content is that the final deployed device (after crystallization and shape recovery) is more robust due to the presence of rigid solid crystals.
The devices of the invention are suitable as reusable warmers, as molding materials for making impressions as for example of dental tissue and in numerous medical applications where reusable heat packs are indicated particularly for application to difficult contours. Additionally, large expandable structures, including satellite antennae and temporary shelter, are envisioned with the possibility of remote radio-frequency (RF) activation of the mechanical trigger that, in this case, would feature a small motor and RF antenna.
All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. | A device and method are provided combining the thermal and mechanical attributes of two distinct materials: shape memory materials and super-cooled liquids (SCLs). In one example of the invention, the super-cooled liquid is contained within a shape memory polymer (SCL liquid is filled into a shape memory polymer tube), so that the heat released by the SCL when it is mechanically triggered to crystallize itself triggers the shape change of the shape memory polymer. The device is suitable as a reusable warmer, as a dental mold material, in medical applications where reusable heat packs are indicated, particularly for application to difficult contours, and for large deployable structures such as satellite antennae and temporary shelters. | 0 |
FIELD OF THE INVENTION
The present invention relates to a device and a method for operating a vehicle using a vehicle controller for individually adjusting braking forces of the wheels of at least one axle of the vehicle and using a yawing moment compensator to at least partially compensate for a yawing moment of the vehicle due to different braking forces of individual wheels of the at least one axle by intervening in a steering of the vehicle.
BACKGROUND INFORMATION
Today, braking systems such as hydraulic, electrohydraulic, pneumatic, electropneumatic, or electromechanical braking systems may be increasingly electrically controllable. The electrical control may permit a pressure build-up in the wheel brakes independent of the driver's braking intent, i.e. of the brake pedal operation by the driver. Such electrical controls of braking systems may be used, for example, for implementing an anti-lock control (ABS, i.e., anti-lock (braking) system) or an electronic stability program (FDR or ESP).
A purpose of an anti-lock (braking) system (ABS) may include to prevent the vehicle from slipping due to its wheels locking while braking, in particular on a slippery surface. For this purpose, when the driver operates the brake pedal for an extended period of time, sensors determine whether the individual wheels are locked, and whenever this is the case, the brake pressure on the corresponding wheel brakes is reduced. In such an anti-lock (braking) system, the front wheels of the vehicle may be (but not necessarily) separately and consequently differently controlled, while the rear wheels are controlled together.
An electronic stability program (FDR or ESP) is used to monitor steering, braking, and gas pedal inputs by the driver in order to prevent the vehicle from slipping as a result of false inputs. In this context, false inputs are intercepted by targeted braking actions at the individual wheels.
Similar to braking systems controlled by electrical controls, steering systems may also be controlled by motor-driven steering systems. In this context, the power of a power source of an electromotor, for example, is able to be superimposed on the steering-wheel power applied by the driver, e.g. using a control element for the superimposed steering action. On the one hand, an effect supporting the steering-wheel power of the driver is able to be achieved. On the other hand, steering signals that increase the driving safety and/or the driving comfort are able to be applied to the steering systems of the vehicle. Such a motor-driven steering system is described in German Published Patent Application No. 40 31 316, for example.
A combination of a control of a braking system and of a steering system of a vehicle is described in European Published Patent Application No. 0 487 967 (vehicle having an anti-lock controller). Reference is made to this patent with respect to the entire content. In short, a yawing moment compensation (GMK) for a vehicle equipped with an anti-lock (braking) system (ABS) is described in European Published Patent Application No. 0 487 967. The yawing moment compensation determines a correction steering angle to compensate for the yawing moment of the vehicle occurring when braking on an inhomogeneous roadway (e.g. a μ-split) due to different braking forces on the left or right wheel(s).
SUMMARY
An object of the present invention may include providing an improved method and an improved device for controlling a braking system and a steering system of a vehicle as well as providing a vehicle having the corresponding device.
This objective may be achieved by an example method according to the present invention. In this context, for operating a vehicle using a vehicle controller to individually adjust braking forces of the wheels of at least one axle of the vehicle and using a yawing moment compensator to at least partially compensate for a yawing moment of the vehicle resulting from different braking forces of individual wheels of at least one axle by intervening in a steering of the vehicle, the action of the yawing moment compensator on the steering is not performed or only to a lesser degree while braking forces are being adjusted by the vehicle controller.
Hence, the action of the yawing moment compensator on the steering is not performed while the vehicle controller is active.
In particular, the vehicle controller may be part of an electronic stability program (FDR or ESP) as described, for example, in the article, FDR—The Operating Dynamics Regulation of Bosch, by A. van Zanten, R. Erhardt and G. Pfaff, Journal of Automobile Technology 96 (1994), 11 pages 674 to 689, and SAE paper 973184, Vehicle Dynamics Controller for Commercial Vehicles, by F. Hecker, S. Hummel, 0. Jundt, K. -D. Leimbach, I. Faye, and H. Schramm. In this context, the vehicle controller may be configured for adjusting the braking forces as a function of the yaw rate of the vehicle and a setpoint yaw rate of the vehicle, in particular as a function of the difference between the yaw rate of the vehicle and the setpoint yaw rate of the vehicle. In this context, the braking forces may be adjusted by calculating the setpoint slip values for the wheels that may be input quantities in secondary control loops.
The intervention of the yawing moment compensator in the steering may be reduced by at least one filter.
In a further example embodiment of the present invention, the axle may be the front and/or the rear axle.
In another example embodiment of the present invention, the action on a steering of the vehicle may be performed using a compensation steering angle determined as a function of the braking forces of individual wheels.
In a further example embodiment of the present invention, a compensation steering angle dependent on a difference of separately controlled braking pressures of the front and/or rear wheels may be adjusted at a rear-wheel steering system or may be superimposed on a front-wheel or rear-wheel steering angle in order to at least partially compensate for the yawing moment of the vehicle.
In this context, the braking pressures may be used as substitute quantities for the braking forces.
In another example embodiment of the present invention, the value of the compensation steering angle may be set to zero in a predefined or variable range of small braking pressure differences, i.e. within a dead zone, and to a value not equaling zero outside of the dead zone.
The values for the dead zone may be different for the front and rear axle.
In another example embodiment of the present invention, separate partial compensation steering angles may be determined in each case for the front wheels and the rear wheels, the compensation steering angle being determined as a function of the partial compensation steering angles.
In a further example embodiment of the present invention, the compensation steering angle may be determined by adding the partial compensation steering angles.
In another example embodiment of the present invention, at least one partial compensation steering angle may be determined after the dead zone is exceeded by adding the product of a constant and the initial value of the dead zone and the product of a variable amplification and the initial value of the dead zone.
In a further example embodiment of the present invention, the compensation steering angle may be stored when braking forces are adjusted by the vehicle controller.
In another example embodiment of the present invention, the stored compensation steering angle may be essentially continuously transferred after the completion of the adjustment of the braking forces via the vehicle controller to an instantaneous compensation steering angle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a technical field that may be improved by an example embodiment of the present invention.
FIG. 2 is a graph diagram for the block diagram in FIG. 1 .
FIG. 3 is a graph diagram for the block diagram in FIG. 1 .
FIG. 4 is a graph diagram for the block diagram in FIG. 1 .
FIG. 5 is a block diagram of a modified technical field that may be improved by an example embodiment of the present invention.
FIG. 6 is a block diagram of an example embodiment of the present invention.
FIG. 7 is a diagram of the example embodiment in FIG. 6 .
DETAILED DESCRIPTION
In the following, a technical field, which may be improved by an example embodiment of the present invention, is first explained via an example on the basis of FIGS. 1 through 5 . An example embodiment of the present invention is then described on the basis of FIGS. 6 and 7 .
The present example of a technical field in FIG. 1 explains the compensation for the brake yawing moment by a rear axle steering for a select-low braked rear axle.
The braking pressures in the front wheels supply, in a first approximation, a measure of the used braking force, the difference Δp of the pressures consequently supplies a measure for the brake yawing moment. Rear-axle steering angle δ produces an opposing moment about vertical vehicle axle that compensates for the brake yawing moment given a suitable configuration. The steady-state relationship between δ and Δp is described by proportionality factor k p .
Since the brake pressures may be constantly modulated during an ABS braking, a rear axle steering control having only the abovementioned proportionality may react very irregularly. Therefore, a filtering may be provided before the pressure difference is calculated. This difference first overcomes a significant threshold (dead zone) before the control becomes active; this measure may also be intended to prevent steering irregularity in the case of small disturbances.
Measured braking pressures P vl and P vr are filtered in two stages.
Disturbances caused by measuring noise (peaks, A/D errors) are to be suppressed in pre-filter 1 , 1 ′ by variably restricting the pressure change rate. The increase limit remains at smaller values when there is frequent change of pressure build-up and decrease. Given a change having the same sign over a longer period of time, the increase limit is continuously increased to a maximum value.
Decay filters 2 and 2 ′ may be configured for the relationships between ABS control cycles (ABS control cycles with series of pulses) and rear-wheel steering. So that the rear-wheel steering angle does not directly follow the pressure jumps in particular in the pressure reduction phases, a decrease of the filtered braking pressures is only allowed very slowly during the first pressure reduction after a pressure increase phase. After a predefined time (e.g. 100 ms) elapses, the time constant of the low pass filter is switched over so that the filtered value (output of block 2 or 2 ′) approaches the output quantities of pre-filter 1 ( 1 ′) more quickly.
The measured pressure as well as the intermediate value and the filtered pressure are shown in FIG. 2 .
According to this, the difference of the output quantities of filters 2 and 2 ′ is formed from filtered braking pressures P vlf and P vrf in a subtracter circuit 3 , the difference supplying after a dead zone 4 is exceeded input quantities f(Δp) for control amplifiers 5 and 6 whose output signals are added in adder 7 to form steering angle Δ.
The control may be made up of a constant proportion
δ p =f (Δ p )· k p (Block 5 ).
As a result of the filtering, the dead zone, and the dynamic response (characteristic) of the steering controller, a yawing motion first builds up which is also maintained in the case of an ideal configuration of amplification k p . Therefore, a time-variable proportion is also calculated at the start of the control action:
δ v =f (Δ p )· k v (Block 6 )
Factor k v is set to a certain value when the difference of the filtered pressures exceeds the dead zone and then continually decays.
Therefore, when the control is switched in, the rear-wheel steering angle is noticeably increased, so that the yaw rate changes its sign and the yaw angle is consequently reduced again. In this case, the driver may no longer need to intervene. Viewed over the entire braking action, the yaw rate only assumes very small values, i.e., the irregularities are largely compensated for by the ABS control cycles.
The yawing moment compensation prevents the vehicle from breaking away at low speeds as well as at high speeds. Its support may become clearer as the speed increases.
In tests with a fixedly held steering wheel, the track displacement remains quite small, and a yaw angle builds very slowly.
As already said above, the measurement used to date of the front wheel brake pressures may also be replaced by an estimation algorithm. One is described in patent application P 4030724.7, which is included in European Published Patent Application No. 0 486 967 as an appendix. In this context, the filtering of the braking pressures is able to be simplified such that blocks 1 , 1 ′ are eliminated.
The front-wheel steering angle may be influenced according to the same principle. Only quantitative differences arise.
Given different friction coefficients on different vehicle sides, introducing the time-variable amplification may result in desirable features yet may cause an oversteering behavior of the vehicle when fully braking in a curve. To prevent this, the transversal acceleration of the vehicle may also be taken in to account. However, considering the transversal acceleration as described does not presuppose acquiring the steering angle according to the top branch in FIG. 1 .
A correction factor K by , which is multiplicatively linked to the rear-wheel angle (in 12 ), is first determined from measured transversal acceleration b y via the characteristic curve (block 8 ) shown in FIG. 3 .
This characteristic curve causes the compensation to not be influenced (K by =1) in the case of low transversal accelerations, e.g. less than 2 m/s 2 , thereby resulting in a reduction proportional to the transversal acceleration, and causes the compensation to be completely suppressed (K by =0) in the case of a very high transversal acceleration, e.g. above 8 m/s 2 . This characteristic curve is based on the knowledge that in the case of μ-split braking, the occurring transversal accelerations are approximately in the range of +/−2 m/s 2 .
Only this characteristic curve may not be sufficient. Fluctuations in the transversal acceleration for values b y >2 m/s 2 (e.g. sign change of b y during lane change while braking) result in proportional fluctuations of the correction factor and consequently of the rear-wheel steering angle that may be noticeable as an irregularity. In addition, it may be undesirable that these steering-angle fluctuations then effect the b y signal. A suitable filtering of the correction factor may therefore be required. However, it may be required to ensure that when building up a transversal acceleration, the GMK is quickly reduced. However, during certain driving maneuvers, e.g. lane changes, an intervention may not be performed again too quickly. This may be achieved using two alternative low pass filters 10 and 11 having very different time constants. As such, the transversal acceleration-dependent steering angle correction may have the form shown in FIG. 1 in blocks 8 , 9 , 10 , and 11 .
Example values for the time constants of the two alternative low pass filters may be 10 ms and 1000 ms, respectively.
Blocks 9 , 10 , and 11 are to symbolize the following situation. If the transversal acceleration increases and Kb y becomes smaller, low pass filter 10 having the small time constant becomes active, i.e., output value Kb y quickly follows the input from block 8 and decreases the steering angle. If however the transversal acceleration decreases and Kb y consequently increases, Kb y follows the input value from block 8 but in a delayed manner.
These measures may reduce the yawing moment compensation when braking on curves and changing lanes while braking on surfaces having high coefficients of friction. The remaining portions of rear-wheel steering angle δ GMK from the compensation may no longer have a negative effect on the vehicle performance.
The measured transversal acceleration may be replaced by a quantity subsequently formed from the steering angles and the vehicle speed (e.g. tacho signal). When considered in a steady-state manner, the following relationship for the transversal acceleration is able to be derived from the conventional linear single-track model:
b y , stat = V x 2 ( δ v - δ h ) l o 1 1 + ( V X / V ch ) 2
where:
V x
longitudinal vehicle speed
δv
front-wheel steering angle
δh
rear-wheel steering angle
l o
wheel base
V ch
characteristic speed
B y.stat
estimated steady-state acceleration
In this context V ch is made up of the model parameters as follows:
V ch = 1 m l 0 2 ( l h C v - l v C h )
where
m
Vehicle weight
l v
Distance from center of gravity - front axle
l h
Distance from center of gravity - rear axle
C v
Slip angle rigidity - front axle
C h
Slip angle rigidity - rear axle
Using the parameters of a certain model may result in a value of V ch of about 20 m/s.
In the case of a transient driving maneuver (changing lanes while braking), it turns out that steady-state equation (1), which is adjusted to cornering, may deliver transversal accelerations that are too high. For this reason, a dynamic member (low pass filter having time constant T bys ), which takes the vehicle dynamics into consideration, is connected in series (block 13 ).
When implementing equation (1) in the computing device, it offers itself to store the portion
V x 2 l o 1 1 + ( V X / V ch ) 2
as a speed-dependent characteristic curve (block 14 ). Equation (1) is consequently reduced to the interpolation of a characteristic curve (in block 14 ) as well as the multiplication of the result by the difference (δ v −δ h ) (in block 15 ). The total transversal acceleration correction consequently may have the form shown in the middle branch in FIG. 1 .
When estimating the transversal acceleration as shown above, rear-wheel steering angle δ h is included as an input quantity. At the same time, the estimation has a reciprocal effect on part of the rear-wheel steering angle, namely the GMK part. So that no feedback effects are able to occur in this context, only the portion of the rear-wheel steering angle coming from another rear-wheel steering control is taken into consideration as an input quantity of the transversal acceleration estimation.
To suppress the amplified turning-in at the end of a curve braking by the yawing moment compensation, an amplification factor K Vx dependent on the vehicle speed is multiplicatively superimposed.
Its example characteristic curve is stored in block 16 and shown in FIG. 4 . Over 50 km/h, for example, the amplification factor remains unchanged at one, and in the range of 50 km/h to 20 km/h, for example, it is continuously reduced to zero. This measure may be less important for μ-split braking, since vehicles having ABS may not show any manageability problems in lower speed ranges.
This additional factor K Vx is multiplicatively considered in multiplier 12 . Therefore, the steering angle for the yawing moment compensation as a whole is:
δ GMX =K by ·K vx ·δ.
A variable dead zone 4 ′ differentiates the block diagram of a modified technical field in FIG. 5 from that in FIG. 1 . In this context, filtered braking pressures P vlf and P vrf are multiplied together by a multiplier 20 . The product of P vlf and P vrf is multiplied by a correction factor K th and added to a predefined limiting value P to to form a corrected limiting value P toth .
The example of a technical field described using FIGS. 1 through 5 that may be improved by an example embodiment of the present invention starts out from a vehicle having an anti-lock (braking) system (ABS) in which the braking pressures of the rear wheels are not individually regulated. This may often be sufficient for the purposes of a simple anti-lock (braking) system (ABS) so that provision may not be made for an individual control of the braking pressures of the rear wheels for commercially available anti-lock (braking) systems (ABS). Consequently, braking pressure differences may only occur at the wheels of the front axle and may only need to be considered there.
Something different may be true for vehicles equipped with an electronic stability program (FDR or ESP). In this instance, within the framework of the electronic stability program, braking pressures of the wheels of both axles may be individually regulated at least intermittently. In this context, different braking pressures may be set in a targeted manner at each wheel of an axle in order to influence the vehicle motion.
These conditions are considered in the example embodiment of the present invention shown in FIG. 6 . In this context, the variant from FIG. 5 having a variable dead zone 4 ′ is presupposed. The present invention may also be used for the variant from FIG. 1 having a fixed dead zone. In this manner, it may be achieved that yawing moment compensation (GMK) only reacts to braking pressure differences in an anti-lock braking system (ABS) and may not also be dependent on a vehicle controller of a electronic stability program (FDR or ESP).
In comparison with the variant in FIG. 5 , yawing moment compensation (GMK) is expanded in FIG. 6 by two parts:
The first expansion, which is shown in the upper left portion of FIG. 6 , is used for considering the braking pressure differences of the wheels of the rear axle. For this purpose, another branch was added to the block diagram that may correspond to the top branch in FIG. 5 (or FIG. 1 ). Therefore, the same components in the representation are designated by the same reference numerals, and only “h” for the rear axle and “v” for the front axle were added.
The braking pressures of rear wheels P hl and P hr are able to be measured or estimated as described above for the braking pressures of front wheels P vl , P vr . They may then be treated in the same manner as the braking pressures of front wheels P vl , P vr . Consequently, they are filtered in pre-filters and decay filters 1 h , 1 h ′, 2 h , 2 h ′. The difference of filtered braking pressures P hlf , P hrf is determined in a subtracter circuit 3 h . If the difference of filtered pressures P hlf , P hrf exceeds a dead zone 4, which is dependent on the total pressure level or is predefined in a fixed manner, a partial compensation steering angle δ GMKh is determined. A steering angle determined from the braking pressures of the wheels of the front axle as described above is added as an additional partial compensation steering angle δ GMKv to partial compensation steering angle δ GMKh of the braking pressures of the wheels of the rear axle to form a rear and/or front axle steering angle δ ideal .
Mainly the following points differentiate the treatment of braking pressures P hl , P hr of the rear wheels from the treatment of braking pressures P vl , P vr of the front wheels: Other parameters may be selected for the filters and the dead zone as well as another value for the constant amplification. Such different parameters may take into account e.g. the different configuration or the different size of the brakes, i.e., a different connection between braking pressure and braking force at the front or rear axle. Furthermore, such different parameters may take into account a possibly different track width of the front and rear axle or different ABS strategies.
Moreover, the time-variable amplification of the braking pressure difference (block 6 in FIGS. 1 and 5 ) may be eliminated. This may be possible since in the case of an ABS action within a electronic stability program (FDR), the braking pressure difference of the rear wheels is regularly controlled such that it only increases slowly. On the other hand, a time-variable amplification of the braking pressure difference of the rear wheels may also be useful and used accordingly.
Due to the indicated differences when treating the rear and front braking pressures P hl , P hr , and P vl , P vr , it may be desirable to first form each difference separately as shown in FIG. 6 . Subsequently, partial compensation steering angles δ GMKv , δ GMKv are added to form total rear or front axle steering angle intervention δ ideal .
The thus obtained rear or front axle steering angle intervention δ ideal may generally correspond to the steering angle for the yawing moment compensation. However, as described above, transversal acceleration b y and the speed of the vehicle may also be considered. For this purpose, specified correction factors K by and K vx are applied to front or rear axle steering angle δ ideal . The thus obtained instantaneous compensation steering angle δ A is set for yawing moment compensation at the rear axle or is superimposed on a steering angle of the front or rear axle.
The second expansion may be used to ensure that yawing moment compensation (GMK) only reacts to braking pressure differences from an anti-lock braking system (ABS) and not as a function of a driving dynamics controller. A signal indicating when interventions of the vehicle controller occur is provided for this purpose. The feature that interventions of the vehicle controller exist may be indicated in electronic stability programs in the form of a flag that is able to assume the values zero and one, for example. Therefore, it may only need to be transmitted to the control of yawing moment compensation (GMK). A selector 50 is provided for processing signal F.
This expansion may cause yawing moment compensation (GMK) to be switched off when interventions of the vehicle controller occur. An already applied compensation steering angle δ A is maintained during a subsequent intervention of the vehicle controller and is then essentially continuously transferred to an instantaneous compensation steering angle δ A .
For this purpose, a factor K H is first formed from flag F of the vehicle controller via a block 52 by a switching-off filter 30 . The value of factor K H always equals one when flag F is set, i.e. equals one. If flag F zeros, the value of factor K H tends to zero with a predefined time response. Such a relationship is shown via an example in FIG. 7 . In this example, the value of factor K H tends to zero in a linear manner in a time Δt. Alternatively, an exponential transition may also be used.
With the help of thus obtained factor K H , the front-axle steering angle δ GMK to be ultimately applied at the steered axle for yawing moment compensation is determined by a block 53 in accordance with the following equation:
δ GMK =(1 −K H )·δ A +K H ·δ H
where
δ A =
the intantaneous compensation steering angle in each
case
δ H =
a compensation steering angle maintained during an
intervention of the vehicle controller.
A controllable sample-and-hold member 51 is used to obtain constant compensation steering angle δ H . It is switched such that it assumes in each case instantaneous compensation steering angle δ A (sample). As long as factor K H equals zero, sample-and-hold member 51 also outputs this instantaneous compensation steering angle δ A in each case as an output value (i.e. δ A =δ H ). However, as soon as factor K H is greater than zero, the value of compensation steering angle δ A applied last is frozen (hold) and constant compensation steering angle δ H is consequently generated and output. As soon as factor K H again assumes the value zero, constant compensation steering angle δ H is no longer maintained, etc.
As long as factor K H equals zero, i.e., as long as there are no interventions of the vehicle controller, the above equation simplifies to:
δ GMK =(1−0)·δ A +0·δ H =δ A
Therefore, the yawing moment compensations required in each case are performed unchanged in accordance with the above description.
As soon as there is an intervention of the vehicle controller, factor K H equals one. Consequently, the above equation becomes:
δ GMK =(1−1)·δ A +1·δ H =δ H
i.e., the compensation angle δ A last applied before the intervention of the vehicle controller is maintained as a constant compensation angle δ H and continues to be applied during the intervention.
As soon as the intervention of the vehicle controller is finally completed, factor K H is continuously transferred rear to the value zero during a time Δt. During this time, constant compensation angle δ H continues to be maintained and resulting compensation angle δ GMK is calculated as explained above:
δ GMK =(1 −K H )·δ A +K H ·δ H
In this manner, the compensation angle δ H maintained during the intervention of the vehicle controller and also applied during this time as resulting compensation angle δ GMK is continuously transferred to the value of the instantaneous compensation angle δ A actually needed in each case after the intervention of the electronic stability program (FDR or-ESP) to compensate for the yawing moment.
Another possibility for preventing yawing moment compensation (GMK) from counteracting its vehicle controller is to significantly filter instantaneous intervention angle δ A of yawing moment compensation (GMK) as long as the interventions of the vehicle controller are occuring. Consequently, the driving dynamics interventions in the higher frequency range are not affected by yawing moment compensation (GMK).
In comparison with the exemplarily described technical field, the described example embodiment may provide that yawing moment reductions (GMA) to be considered by the anti-lock (braking) system (ABS) integrated in the electronic stability program (FDR or ESP) according to the related art are able to be significantly reduced at the front axle as well as at the rear axle. A transition may also be made to individual ABS interventions at the rear axle already at a higher speed. This may result in a shorter braking distance. Furthermore, other steering actions may superimpose the yawing moment compensation interventions. Measured or estimated braking pressures that may already be available from the electronic stability program (FDR or ESP) may be used as input information for the yawing moment compensation.
The above-described example embodiments are only used to improve the understandability of the present invention. They are not intended as a restriction. Therefore, it may be understood that all additional possible example embodiments are within the framework of the present invention. In particular, it may be understood that the present invention also includes a device for implementing the described method and a vehicle equipped with such a device.
LIST OF REFERENCE NUMERALS
δδ ideal Rear-axle and/or front-axle steering angle
Δ A Compensation steering angle
δ GMKv , δ GMKv Partial compensation steering angle
ΔP Pressure difference
k p Proportionality factor
k v Factor
P vl , P vr Braking pressures of the front wheels
P vlf , P vrf Filtered braking pressures of the front wheels
P hl , P hr Braking pressures of the rear wheels
P hlf , P hrf Filtered braking pressures of the rear wheels
b y Transversal acceleration
K by Correction factor
K by Amplification factor
P tot Predefined limiting value
K th Correction factor ,
P toth Corrected limiting value
F Flag
K H Weight factor
S/H Sample-and-hold member
1 , 1 ′ Pre-filter
2 , 2 ′ Decay filter
3 Subtracter circuit
4 Dead zone or dead zone
4 ′ Variable dead zone or dead zone
5 , 6 Control amplifiers or block
7 Adder
8 Characteristic curve of block
9
10 , 11 Alternative low pass filters
12 Multiplier
13 Dynamic member
14 Speed-dependent characteristic curve
20 Multiplier
30 Triggering filter | Device and method are described for operating a vehicle using a vehicle controller to individually adjust braking forces of the wheels of at least one axle of the vehicle and using a yawing moment compensator to at least partially compensate for a yawing moment of the vehicle resulting from different braking forces of individual wheels of at least one axle by intervening in a steering of the vehicle, the action of the yawing moment compensator on the steering not being performed or only to a lesser degree while the vehicle controller is adjusting braking forces. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/064,692, filed Feb. 23, 2005, which is a divisional of U.S. patent application Ser. No. 09/957,216, filed Sep. 19, 2001, now U.S. Pat. No. 6,863,683 issued Mar. 8, 2005, the contents of each of which are incorporated by reference in their entireties, and to each of which priority is claimed.
FIELD OF THE INVENTION
[0002] The present invention relates to a cold-molding process for loading a stent onto a stent delivery system. More specifically, the present invention relates to a method of loading a stent onto a balloon having creases that extend non-uniformly into the interstices of the stent without the use of a heating step.
BACKGROUND OF THE INVENTION
[0003] A stent is commonly used alone or in conjunction with angioplasty to ensure patency through a patient's stenosed vessel. Stents overcome the natural tendency of the vessel walls of some patients to restenose after angioplasty. A stent is typically inserted into a vessel, positioned across a lesion, and then expanded to create or maintain a passageway through the vessel, thereby restoring near-normal blood flow through the vessel.
[0004] A variety of stents are known in the art, including self-expandable and expandable stents, as well as wire braid stents. One such stent is described, for example, in U.S. Pat. No. 4,733,665 to Palmaz. Expandable stents are typically delivered to treatment sites on delivery devices, such as balloon catheters or other expandable devices. Balloon catheters may comprise a balloon having a collapsed delivery configuration with wings that are wrapped and folded about the catheter. An expandable stent is then disposed in a collapsed delivery configuration about the balloon by compressing the stent onto the balloon. The stent and balloon assembly may then be delivered, using well-known percutaneous techniques, to a treatment site within the patient's vasculature, for example, within the patient's coronary arteries. Once the stent is positioned across a lesion at the treatment site, it is expanded to a deployed configuration by inflating the balloon. The stent contacts the vessel wall and maintains a path for blood flow through the vessel.
[0005] Significant difficulties have been encountered during stent delivery and deployment, including difficulty in maintaining the stent on the balloon and in achieving symmetrical expansion of the stent when deployed. Several techniques have been developed to more securely anchor the stent to the balloon and to ensure more symmetrical expansion. These include plastically deforming the stent so that it is crimped onto the balloon, and sizing the stent such that its internal diameter provides an interference fit with the outside diameter of the balloon catheter. Such techniques have several drawbacks, including less than optimal securement of the stent to the balloon. Consequently, the stent may become prematurely dislodged from the balloon during advancement of the stent delivery system to the treatment site.
[0006] Stent delivery systems utilizing a removable sheath disposed over the exterior surface of the stent, which is removed once the stent is positioned at the treatment site, have also been proposed, for example, in U.S. Pat. No. 5,690,644 to Yurek et al. Such systems may be used with or without retainer rings and are intended to protect the stent during delivery and to provide a smooth surface for easier passage through the patient's vasculature. However, the exterior sheath increases the crossing profile of the delivery system while decreasing flexibility, thereby decreasing the ability of the device to track through narrowed and tortuous anatomy.
[0007] U.S. Pat. No. 6,106,530 to Harada describes a stent delivery device comprising a balloon catheter having stoppers disposed proximal and distal of a balloon on to which a stent is affixed for delivery. The stoppers are separate from the balloon and maintain the stent's position in relation to the balloon during delivery. As with the removable sheaths discussed previously, the stoppers are expected to increase delivery profile and decrease flexibility of the stent/balloon system.
[0008] U.S. Pat. No. 6,110,180 to Foreman et al. provides a catheter with a balloon having pre-formed, outwardly-extending protrusions on the exterior of the balloon. A stent may be crimped onto the balloon such that the protrusions extend into the gaps of the stent, thereby securing the stent about the balloon for delivery. A drawback to this device is the added complexity involved in manufacturing a balloon with pre-formed protrusions. Additionally, if the protrusions are not formed integrally with the balloon, there is a risk that one or more of the protrusions may detach during deployment of the stent. The protrusions may also reduce flexibility in the delivery configuration, thereby reducing ability to track through tortuous anatomy.
[0009] U.S. Pat. No. 5,836,965 to Jendersee et al. describes a hot-molding process for encapsulating a stent on a delivery system. Encapsulation entails placement of the stent over a balloon, placement of a sheath over the stent on the balloon, and heating the pressurized balloon to cause it to expand around the stent within the sheath. The assembly is then cooled while under pressure to cause the balloon to adhere to the stent and to set the shape of the expanded balloon, thereby providing substantially uniform contact between the balloon and the stent. This method also provides a substantially uniform delivery profile along the surface of the encapsulated balloon/stent assembly.
[0010] A significant drawback of Jendersee's encapsulation method is the need to heat the balloon in order to achieve encapsulation. Such heating while under pressure may lead to localized plastic flows resulting in inhomogeneities along the length of the balloon including, for example, varying wall thickness. Varying wall thickness may, in turn, yield areas of decreased strength that are susceptible to rupture upon inflation of the balloon during deployment of the stent. Additionally, heating and cooling increases the complexity, time, and cost associated with affixing the stent to the balloon.
[0011] U.S. Pat. No. 5,976,181 to Whelan et al. provides an alternative technique for stent fixation involving the use of solvents to soften the balloon material. In this method, the stent is disposed over an evacuated and wrapped balloon while in its compact delivery configuration. A rigid tube is then placed over the stent and balloon assembly, and the balloon is pressurized while the balloon is softened by application of a solvent and/or heating. The rigid tube prevents the stent from expanding but allows the balloon to deform so that its surface projects through either or both of the interstices and ends of the stent. Softening under pressure molds the balloon material such that it takes a permanent set into the stent. Once pressure is removed, the stent is interlocked with the surface of the balloon, providing substantially uniform contact between the balloon and the stent and a substantially uniform delivery profile.
[0012] As with the technique in the Jendersee patent, the technique in the Whelan patent has several drawbacks. Chemically softening the balloon material under pressure is expected to introduce inhomogeneities along the length of the balloon, such as varying wall thickness, which again may lead to failure of the balloon. Additionally, chemical alteration of the balloon, via application of a solvent to the surface of the balloon, may unpredictably degrade the mechanical characteristics of the balloon, thereby making accurate and controlled deployment of a stent difficult. Softening also adds cost, complexity, and time to the manufacturing process.
[0013] In view of the drawbacks associated with previously known methods and apparatus for loading a stent onto a stent delivery system, it would be desirable to provide methods and apparatus that overcome those drawbacks.
[0014] It would be desirable to provide methods and apparatus for loading a stent onto a stent delivery system that enhance positional stability of the stent during delivery.
[0015] It would further be desirable to provide methods and apparatus for loading a stent onto a stent delivery system wherein the delivery system comprises a crossing profile and flexibility suitable for use in tortuous and narrowed anatomy.
[0016] It would still further be desirable to provide methods and apparatus for loading a stent onto a stent delivery system that provide a substantially symmetrical expansion of the stent at deployment.
[0017] It would also be desirable to provide methods and apparatus for loading a stent onto a stent delivery system that do not unpredictably modify the mechanical characteristics of the balloon during fixation of the stent to the balloon.
SUMMARY OF THE INVENTION
[0018] In view of the foregoing, it is an object of the present invention to provide methods and apparatus for loading a stent onto a stent delivery system and deployment that overcome drawbacks associated with previously known methods and apparatus.
[0019] It is an object to provide methods and apparatus for loading a stent onto a stent delivery system that enhance positional stability of the stent during delivery.
[0020] It is an object to provide methods and apparatus for loading a stent onto a stent delivery system wherein the delivery system comprises a crossing profile and flexibility suitable for use in tortuous and narrowed anatomy.
[0021] It is also an object to provide methods and apparatus for loading a stent onto a stent delivery system that provide a substantially symmetrical expansion of the stent at deployment.
[0022] It is an object to provide methods and apparatus for loading a stent onto a stent delivery system that do not unpredictably modify the mechanical characteristics of the balloon during fixation of the stent to the balloon.
[0023] These and other objects of the present invention are achieved by providing methods and apparatus for cold-molding a stent to the balloon of a stent delivery system so that the balloon extends non-uniformly into the interstices of the stent. In a preferred embodiment, the stent is a balloon expandable stent and is manufactured in a fully-expanded state or in an intermediate-expanded state (i.e., having a diameter smaller than its fully-expanded, deployed diameter, but larger than its compressed delivery diameter).
[0024] The stent is disposed on the balloon of a delivery catheter, and the balloon and stent are placed within an elastic crimping tube. The balloon/stent/crimping tube assembly is then placed in a crimping tool, and the balloon is inflated, preferably only partially. The crimping tool is actuated to compress the stent on the outside of the partially inflated balloon and to cause creases of the balloon to extend non-uniformly into the interstices of the stent. Crimping occurs at a substantially constant temperature, without the use of chemicals. The balloon is then deflated, and the elastic crimping tube is removed.
[0025] Optionally, pillows or bumpers may be formed in the proximal and/or distal regions of the balloon during crimping that, in conjunction with the non-uniform creases of the balloon, prevent longitudinal movement of the stent with respect to the balloon during intravascular delivery.
[0026] Furthermore, one or more additional, secondary crimping steps may be performed to achieve a smoother delivery profile, in which a semi-rigid crimping tube is disposed over the stent delivery system, and the assembly is again disposed within the crimping tool. During secondary crimping, the crimping tool is actuated to further compress the stent onto the unpressurized balloon. Secondary-crimping may alternatively be performed with the balloon partially or completely pressurized/inflated.
[0027] Apparatus of the present invention may be used with a variety of prior art stents, such as balloon expandable stents, and may include tubular slotted stents, connected stents, articulated stents, multiple connected or non-connected stents, and bi-stable stents. In addition to methods of production, methods of using the apparatus of the present invention are provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Further features of the invention, its nature and various advantages will be more apparent from the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts throughout, and in which:
[0029] FIGS. 1A-1C are, respectively, a side view of a stent delivery system in accordance with the present invention, a cross-sectional view of the system along section line A-A in FIG. 1A , and a detail view of the balloon of the system non-uniformly extending within the interstices of the stent;
[0030] FIG. 2 is a flow chart showing the steps of the cold-molding process of the present invention;
[0031] FIGS. 3A-3C are, respectively, a side view of the distal end of the delivery catheter of the system of FIG. 1 in an expanded configuration, and cross-sectional views of the catheter along section line B-B in FIG. 3A , showing the balloon evacuated to form radially extended wings and in a contracted configuration with the radially extended wings wrapped about the catheter;
[0032] FIGS. 4A-4C are, respectively, a side view, partially in section, of the wrapped delivery catheter of FIG. 3C having the stent of FIG. 1 and an elastic crimping tube disposed thereover, the entire assembly disposed within a crimping tool; a cross-sectional view of the same along section line C-C in FIG. 4A ; and a detail view of the expandable structure of the stent;
[0033] FIGS. 5A and 5B are, respectively, a cross-sectional view along section line C-C in FIG. 4A of the apparatus upon pressurization of the balloon, and a detail view of the expandable structure of the stent;
[0034] FIG. 6 is a cross-sectional view along section line C-c in FIG. 4A during crimping after pressure has been removed;
[0035] FIG. 7 is a cross-sectional view along section line C-C in FIG. 4A of a possible configuration of the stent delivery system after crimping and removal of the elastic crimping tube;
[0036] FIG. 8 is a side view, partially in section, of the stent delivery system disposed within a semi-rigid crimping tube and within the crimping tool for optional secondary crimping; and
[0037] FIGS. 9A-9D are side views, partially in section, of the stent delivery system of FIG. 1 disposed within a patient's vasculature, depicting a method of using the apparatus in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] The present invention comprises methods and apparatus for cold-molding a stent onto a stent delivery system. More specifically, the present invention provides methods and apparatus for obtaining a balloon having creases that extend non-uniformly into the interstices of a stent loaded onto the exterior of the balloon, without the use of a heating or chemical process.
[0039] With reference to FIG. 1 , apparatus in accordance with the present invention is described. As seen in FIG. 1A , stent delivery system 10 , illustratively shown in a collapsed delivery configuration, comprises balloon expandable stent 20 loaded on balloon 14 of delivery catheter 12 . Stent 20 comprises an illustrative balloon expandable stent and may be replaced with other stents known in the art. As seen in FIGS. 1B and 1C , balloon 14 has creases 16 that extend non-uniformly into interstices 22 of stent 20 .
[0040] In FIG. 1B , creases 16 are shown with varying slope and height about the circumference of stent delivery system 10 . FIG. 1C depicts creases 16 as shaded areas and illustrates that creases 16 extend along the length of stent 20 within interstices 22 . Line L indicates the longitudinal axis of stent 20 in FIG. 1C . It should be understood that creases 16 typically do not extend within every interstice 22 of stent 20 .
[0041] Delivery catheter 12 preferably includes markers 17 disposed distal of and proximal to stent 20 that facilitate placement of stent 20 on balloon 14 , and that facilitate positioning of stent delivery system 10 at a treatment site within a patient's vasculature. Markers 17 are preferably radiopaque and fabricated from a radiopaque material, such as platinum or gold. Catheter 12 preferably also comprises guide wire lumen 13 and inflation lumen 15 , which is coupled to balloon 14 . As described hereinbelow, during the cold-molding process of the present invention, proximal and/or distal pillows 19 optionally may be formed in balloon 14 during pressurized crimping. As with creases 16 , pillows 19 act to reduce or prevent longitudinal movement of the stent on the balloon during intravascular delivery.
[0042] Balloon 14 is expandable by injection of a suitable medium, such as air or saline, via inflation lumen 15 . Balloon 14 preferably expands stent 20 to a deployed configuration under application of pressure in the range of about 6-9 atm. Additionally, balloon 14 preferably has a rated burst pressure above 10 atm, and even more preferably between about 12-14 atm. Balloon 14 may be fabricated from a variety of materials, including Nylon, polyethylene terephalate, polyethylene, and polyether/polyamide block copolymers, such as PEBAX.
[0043] Additionally, balloon 14 may be fabricated from an elastomeric polyester block copolymer having an aromatic polyester hard segment and an aliphatic polyester soft segment, such as “Pelprene,” which is marketed by the Toyobo Corporation of Osaka, Japan. Balloon 14 also may be fabricated from a copolymer having a polybutylene terephalate hard segment and a long chain of polyether glycol soft segment, such as “Hytrel” from the DuPont Corporation of Wilmington, Del.
[0044] Illustrative stent 20 may be fabricated from a variety of materials, including polymers and metals, and may comprise any of a variety of prior art stents, such as balloon expandable stents, including tubular slotted stents, connected stents, articulated stents, multiple connected or non-connected stents, and bi-stable stents. Stent 20 also may include external coating C configured to retard restenosis or thrombus formation in the vessel region surrounding the stent. Alternatively, coating C—may—deliver therapeutic agents into-the-patient's blood stream or vessel wall.
[0045] Referring now to FIGS. 2-8 , a method of producing stent delivery system 10 is described. FIG. 2 provides an overview of the cold-molding process of the present invention, while FIGS. 3-8 provide detailed views of these process steps.
[0046] As depicted in FIG. 2 , the cold-molding process of the present invention involves steps of: obtaining a stent, step 102 ; obtaining a balloon catheter, step 103 ; disposing the stent on the balloon of the balloon catheter, step 104 ; and disposing an elastic crimping sleeve over the stent and balloon, step 105 . In accordance with the method of the present invention, the balloon is then inflated—preferably only partially—with an inflatable medium, such as air, at step 106 . The sleeve/stent/balloon assembly is then crimped within a crimping tool that compresses the stent onto the balloon, step 107 , while the balloon is pressurized.
[0047] As described hereinbelow, this step causes the balloon to bulge into the interstices of the stent, and in addition, to form pillows 19 , proximal of, and distal to, the ends of the stent to retain the stent in place during transluminal delivery. At step 108 , the balloon is depressurized, and the elastic sleeve is removed to complete the stent loading process.
[0048] If desired, a semi-rigid sleeve optionally may be disposed over the stent/balloon assembly, and one or more additional crimping steps may be performed, steps 109 and 110 of FIG. 2 .
[0049] Referring now to FIGS. 3-8 , additional details of a preferred embodiment of the process of the present invention are illustrated and described. In FIG. 3 , balloon 14 of delivery catheter 12 —preferably is folded prior to placement of stent 20 about balloon 14 . Balloon 14 is first expanded, as in FIG. 3A , and then evacuated to form radially extended wings 18 , as seen in FIG. 3B . Balloon 14 is illustratively depicted with four wings 18 , but it should be understood that any number of wings may be provided, for example, two, three or five wings. In FIG. 3C , wings 18 are wrapped about the shaft of delivery catheter 12 to dispose catheter 12 in a contracted configuration. It should be understood that balloon 14 may alternatively be folded and/or disposed in a collapsed delivery configuration by other techniques, for example, with techniques that do not utilize wings.
[0050] With reference to FIG. 4 , stent 20 and elastic crimping tube 30 are disposed about balloon 14 , preferably with stent 20 positioned between markers 17 of delivery catheter 12 (steps 102 - 105 , FIG. 2 ). The balloon/stent/crimping tube assembly is inserted within crimping tool 40 , as seen in FIG. 4A . Crimping tool 40 is preferably positioned between markers 17 to facilitate formation of optional pillows 19 during pressurization of balloon 14 . Crimping tool 40 may be any of a variety of crimping tools known in the art. An illustrative crimping tool is described, for example, in U.S. Pat. No. 6,082,990 to Jackson et al., which is incorporated herein by reference.
[0051] Referring to FIG. 4B , stent 20 may be directly placed about balloon 14 , and elastic crimping tube 30 then may be loaded over the stent/balloon assembly. Alternatively, stent 20 may be placed within elastic crimping tube 30 , and then the stent/tube assembly disposed surrounding balloon 14 . As yet another alternative, crimping tube 30 , or crimping tube 30 and stent 20 , may be positioned within crimping tool 40 ; then, balloon 14 , with or without stent 20 loaded thereon, may be positioned within crimping tool 40 .
[0052] As depicted in FIG. 4C , stent 20 preferably is manufactured in an intermediate-expanded state having a diameter smaller than its expanded deployed diameter, but larger than its compressed delivery diameter, thereby facilitating positioning of stent 20 about balloon 14 . When stent 20 is initially disposed surrounding balloon 14 , the balloon does not substantially extend into interstices 22 of stent 20 . It should be understood that stent 20 alternatively may be manufactured in a fully-expanded state.
[0053] In FIG. 5 , once stent 20 and crimping tube 30 are disposed about balloon 14 of delivery catheter 12 , and once the entire assembly is disposed within crimping tool 40 , balloon 14 is pressurized, for example, via an inflation medium delivered through inflation lumen 15 of catheter 12 (step 106 , FIG. 2 ). Pressure application causes balloon 14 to enter a portion of interstices 22 of stent 20 in a non-uniform manner, as seen in the cross section of FIG. 5A and in the detail view of FIG. 5B . Crimping tube 30 and crimping tool 40 prevent expansion of stent 20 during partial or complete pressurization of balloon 14 , as depicted in FIG. 5A .
[0054] The inflation medium is preferably delivered at a pressure in the range of about 6-8 atm. This pressure range is below the preferred rated burst pressure of balloon 14 , which is above 10 atm, and even more preferably between about 12-14 atm, and thus ensures that the balloon does not puncture. The elasticity of crimping tube 30 allows the tube to expand slightly upon application of pressure, and to contract slightly during crimping. Tube 30 may be fabricated from any suitable—elastic material, for example, a polymer, such as PEBAX. Elastic crimping tube 30 preferably has a hardness of between about 30 and 40 Shore Hardness, and more preferably a hardness of about 35 Shore Hardness.
[0055] With reference to FIG. 6 , in conjunction with FIG. 4A , crimping tool 40 is actuated to crimp stent 20 onto balloon 14 (step 107 , FIG. 2 ). Crimping tool 40 applies an inwardly-directed stress, σ crimp , to the assembly. Initially, balloon 14 is still pressurized. Stent 20 is compressed onto the outside of balloon 14 , causing the balloon to further bulge non-uniformly into interstices 22 of the stent. Crimping preferably proceeds along the length of the balloon/stent/tube assembly all at once but may alternatively proceed in sections, so that the assembly is gradually crimped along its length.
[0056] Balloon 14 is then depressurized, allowing crimping tool 40 to further compress stent 20 onto balloon 14 , as seen in FIG. 6 (step 108 , FIG. 2 ), which forms creases 16 of balloon 14 that extend non-uniformly within interstices 22 of the stent. Creases 16 are most clearly seen in FIGS. 1B and 1C . Optional pillows 19 of stent delivery system 10 are also formed. Since many prior art crimping tools 40 apply an inwardly-directed stress, σ crimp , that is not uniform about the radius of balloon 14 , elastic crimping tube 30 acts to more uniformly distribute the stress about the circumference of the balloon/stent assembly.
[0057] Stent delivery system 10 is removed from elastic crimping tube 30 and crimping tool 40 (step 108 , FIG. 2 ). Stent delivery system 10 has a low-profile delivery configuration adapted for percutaneous delivery within a patient's vasculature, as described hereinbelow with respect to FIG. 9 . Creases 16 , as well as pillows 19 , secure stent 20 to balloon 14 between markers 17 of delivery catheter 12 .
[0058] In contrast to prior art techniques described hereinabove, crimping in accordance with the present invention occurs at a substantially constant temperature, without the use of chemicals. In the context of the present invention, substantially constant temperature during crimping should be understood to include minor fluctuations in the actual temperature due to frictional losses, etc.
[0059] Importantly, the system of the present invention is not actively heated to thermally remodel the balloon, as described in U.S. Pat. No. 5,836,965 to Jendersee et al. Likewise, no solvents are added to soften and mold the balloon, as described in U.S. Pat. No. 5,976,181 to Whelan et al. As described previously, both heating and solvents have significant potential drawbacks, including inhomogeneities along the length of the balloon, such as varying wall thickness. Varying wall thickness may yield areas of decreased strength that are susceptible to rupture upon inflation of the balloon during deployment of the stent. Additionally, heating and cooling, as well as addition of solvents, increases the complexity, time, and cost associated with affixing the stent to the balloon.
[0060] Theoretical bounds for the radial stress that may be applied to balloon 14 during crimping, while the balloon is pressurized, may be estimated by modeling balloon 14 as an idealized tube and assuming crimping tool 40 applies an evenly distributed, inwardly-directed radial stress, σ crimp . Stent 20 and elastic crimping tool 30 , meanwhile, theoretically resist the crimping stress with an outwardly-directed radial stress, σ resistance . Thus, the composite inwardly-directed radial stress, σ in , applied to balloon 14 may be idealized as:
[0000] σ in =σ crimp −σ resistance (1)
[0061] Pressurization/inflation of balloon 14 similarly may be modeled as an evenly distributed, outwardly-directed radial stress, σ o and it may be assumed that the rated burst pressure of balloon 14 is the yield stress of the balloon, σy . A stress balance provides:
[0000] σ in −σ out <σ y (2)
[0062] Thus, a theoretical upper bound for the radial stress, σ y that may be applied to balloon 14 is:
[0000] σ in <σ y +σ out (3)
[0063] A theoretical lower bound for σ y in also may be found by observing that, in order to compress stent 20 onto the exterior of balloon 14 , crimping tool 40 must apply a radial stress, σ crimp , that is greater than the net stress provided by resistance of stent 20 and crimping tube 30 , σ resistance , and by the inflation of balloon 14 , σ out :
[0000] σ crimp >σ out +σ resistance (4)
[0064] Combining Equation (1) and (4) provides a lower bound for σ in :
[0000] σ in >σ out (5)
[0065] Finally, combining Equations (3) and (5) provides a range for σ in :
[0000] σ out <σ in <σ y +σ out (6)
[0066] As an example, assuming a burst pressure, σ y , of 12 atm and a balloon pressurization, σ out , of 8 atm, the balloon will theoretically withstand an inwardly-directed stress, σ in , of up to 20 atm. Furthermore, in order to ensure that stent 20 is crimped onto balloon 14 , σ in must be greater than 8 atm. Thus, the inwardly-directed radial stress must be between 8 and 20 atm. Assuming, for example, a resistance stress, σ resistance , of 2 atm, crimping tool 40 must apply a crimping stress, σ crimp , between 10 and 22 atm. As one of ordinary skill will readily understand, the actual radial stress applied should be further optimized within this range to provide a safety factor, optimal crimping, etc. Since balloon 14 is not in reality an idealized tube, stresses applied to the balloon will have a longitudinal component in addition to the radial component, which may be, for example, accounted for in the safety factor.
[0067] With reference now to FIG. 7 , a possible configuration of the stent delivery system after crimping and removal of elastic crimping tube 30 is described. One or more struts 21 of stent 20 may be incompletely compressed against balloon 14 . Such a strut may potentially snag against the patient's vasculature during delivery, and thereby prevent positioning of stent delivery system 10 at a treatment site. Additionally, pressurized crimping may result in a delivery profile for delivery system 10 that is more polygonal than cylindrical, thereby applying undesirable stresses on the vessel wall during transluminal insertion. Accordingly, it may be desirable to perform an optional secondary crimping step after balloon 14 has been depressurized.
[0068] Referring to FIG. 8 , in order to reduce the potential for incompletely compressed individual struts 21 of stent 20 , and to provide a more uniform cylindrical delivery profile, one or more additional, secondary crimping steps may be performed on stent delivery system 10 . In FIG. 8 , stent delivery system 10 is disposed within semi-rigid crimping tube 50 , which is disposed within crimping tool 40 (step 109 , FIG. 2 ). Tube 50 may be fabricated from any suitable semi-rigid material. As with elastic crimping tube 30 , semi-rigid crimping tube 50 preferably comprises a polymer, such as PEBAX. Semi-rigid crimping tube 50 preferably has a hardness of between about 50 and 60 Shore Hardness, and more preferably a hardness of about 55 Shore Hardness.
[0069] With stent delivery system 10 disposed within semi-rigid tube 50 and crimping tool 40 , tool 40 is actuated to compress individual struts 21 against balloon 14 and to give delivery system 10 the substantially cylindrical delivery profile of FIG. 1B (step 110 , FIG. 2 ). As with elastic crimping tube 30 , semi-rigid tube 50 acts to evenly distribute crimping stresses applied by crimping tool 40 around the circumference of the stent/balloon assembly. Since balloon 14 is not pressurized, secondary crimping preferably proceeds in sections along the length of stent delivery system 10 . However, as will be apparent to those of skill in the art, secondary crimping may proceed in one step. Optionally, balloon 14 may be pressurized during secondary crimping.
[0070] Referring now to FIG. 9 , a method of using stent delivery system 10 of the present invention is described. Stent delivery system 10 is disposed in a contracted delivery configuration with stent 20 disposed over balloon 14 of delivery catheter 12 . Creases 16 of balloon 14 non-uniformly extend within interstices 22 of stent 20 . Creases 16 , in conjunction with optional pillows 19 , act to secure stent 20 to balloon 14 . As seen in FIG. 9A , the distal end of catheter 12 is delivered to a target site T within a patient's vessel V using, for example, well-known percutaneous techniques. Target site T may, for example, comprise a stenosed region of vessel V. The radiopacity of markers 17 may facilitate positioning of system 10 at the target site. Alternatively, stent 20 or other portions of catheter 12 may be radiopaque to facilitate positioning.
[0071] In FIG. 9B , balloon 14 is inflated, for example, via an inflation medium delivered through inflation lumen 15 of catheter 12 . Stent 20 expands to the deployed configuration in which it contacts the wall of vessel V at target site T. Expansion of stent 20 opens interstices 22 of the stent and removes the non-uniform creases of balloon 14 from within the interstices. Additionally, stent 20 has a diameter in the deployed configuration that is larger than the diameter of optional pillows 19 , thereby facilitating removal of stent 20 from delivery catheter 12 . Balloon 14 is then deflated, as seen in FIG. 9C , and delivery catheter 12 is removed from vessel V, as seen in FIG. 9D .
[0072] Stent 20 remains in place within vessel V in the deployed configuration in order to reduce restenosis and recoil of the vessel. Stent 20 also may comprise external coating C configured to retard restenosis or thrombus formation around the stent. Alternatively, coating C may deliver therapeutic agents into the patient's blood stream or a portion of the vessel wall adjacent to the stent.
[0073] Although preferred illustrative embodiments of the present invention are described hereinabove, it will be evident to those skilled in the art that various changes and modifications may be made therein without departing from the invention.
[0074] For example, stent delivery system 10 may be produced without using elastic crimping tube 30 . In this case, the stent/balloon assembly would be loaded directly into crimping tool 40 , which would limit expansion of balloon 14 during pressurization. Likewise, semi-rigid crimping tube 50 may be eliminated from the secondary crimping procedure. If crimping tubes are not used, crimping tool 40 preferably applies an inwardly-directed stress that is substantially evenly distributed about the circumference of the stent/balloon assembly.
[0075] Additionally, balloon 14 may be depressurized prior to crimping stent 20 onto the balloon. This may be particularly beneficial when crimping long stents, for example, stents longer than about 50 mm. Pressurization of balloon 14 may cause the balloon to increase in longitudinal length. When crimping a long stent 20 onto a correspondingly long balloon 14 , this increase in balloon length is expected to be more significant, for example, greater than about 1 mm.
[0076] If stent 20 is crimped onto balloon 14 while the balloon is pressured, significant stresses may be encountered along creases 16 after balloon 14 is depressurized, due to contraction of the balloon back to its shorter, un-inflated longitudinal length. These stresses may, in turn, lead to pinhole perforations of balloon 14 . Thus, since pressurization of balloon 14 causes the balloon to extend at least partially within interstices 22 of stent 20 in a non-uniform manner, as seen in FIG. 5A , it is expected that crimping after depressurization will still establish creases 16 of stent delivery system 10 , in accordance with the present invention. Obviously, crimping after depressurization may be done with stents 20 of any length, not just long stents.
[0077] It is intended in the appended claims to cover all such changes and modifications that fall within the true spirit and scope of the invention. | Stent delivery system having a contracted delivery configuration and an expanded deployed configuration is provided. The stent delivery system includes a stent having a plurality of expandable elements and a plurality of interstices disposed between adjacent expandable elements, and a delivery catheter having an inflatable balloon including creases extending non-uniformly within the interstices of the stent in the contracted delivery configuration. Each crease defines a maximum radial height within a corresponding interstice, and the maximum radial heights of the creases vary. A method for stenting at a target site within a patient's vessel including providing a stent delivery system is also provided. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY
[0001] The present application is related to and claims the benefit under 35 U.S.C. §119(a) of a Korean patent application filed in the Korean Intellectual Property Office on Nov. 4, 2015 assigned Serial No. 10-2015-0154526, the entire disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to an apparatus and method for controlling a connection interval (CI) in a wireless communication system supporting a Bluetooth scheme, and more particularly, to an apparatus and method for controlling a CI based on channel status in a wireless communication system supporting a Bluetooth scheme.
BACKGROUND
[0003] The Internet, which is a human centered connectivity network where humans generate and consume information, is now evolving to the internet of things (IoT) where distributed entities, such as things, exchange and process information without human intervention. The internet of everything (IoE), which is a combination of the IoT technology and the big data processing technology through connection with a cloud server, has emerged.
[0004] As technology elements, such as “sensing technology”, “wired/wireless communication and network infrastructure”, “service interface technology”, and “security technology” have been demanded for IoT implementation, a sensor network, a machine-to-machine (M2M) communication, machine type communication (MTC), and so forth have been recently researched.
[0005] Such an IoT environment may provide intelligent Internet technology services that create a new value to human life by collecting and analyzing data generated among connected things. IoT may be applied to a variety of fields including smart home, smart building, smart city, smart car or connected cars, smart grid, health care, smart appliances and advanced medical services through convergence and combination between existing information technology (IT) and various industrial applications.
[0006] Machine type communication is rapidly evolving from an M2M communication concept which supports communication between people and things, or between things, based on a mobile communication network into a concept of interacting with all information of real and virtual worlds as well as things while extending its area to the Internet. Namely, the M2M communication that enables the intelligent communication between people and things, or between things, at anytime and anywhere in real time in a stable and convenient manner is extending its area to IoT while connecting all surrounding things through the Internet.
[0007] The IoT refers to a technology of connecting various types of things, which have a sensor and a communication function embedded therein, to the Internet. Here, the things include various embedded systems (a computer system of an electronic device such as a smart phone), such as home appliances, a mobile device, wearable computers, etc. The things connected to the IoT have to be connected to an internet based on a unique internet protocol (IP) address by which the things can be identified, and may have sensors embedded therein for acquiring information from an external environment.
[0008] Recently, IoT has been rapidly developed, so a Bluetooth scheme, specially, a Bluetooth scheme which supports a Bluetooth low energy (BLE) mode has been attracted. Generally, a user may control devices to which a BLE mode is applied using a portable terminal, e.g., a smart phone, so devices to which a BLE mode is applied has been increased.
[0009] An operation for transmitting and receiving a data packet in a conventional wireless communication system supporting a BLE mode will be described with reference to FIG. 1 .
[0010] FIG. 1 schematically illustrates an operation for transmitting and receiving a data packet in a conventional wireless communication system supporting a BLE mode.
[0011] Referring to FIG. 1 , an initiator performs a scan operation based on a preset scan interval. The initiator is a master BLE device 111 , and the scan operation is performed during a preset scan window.
[0012] Upon detecting that traffic is arrived, an advertiser performs an advertising event operation based on an advertising interval. Here, the advertiser is a slave BLE device 113 .
[0013] Upon detecting the advertiser while performing the scan operation based on the scan interval, the initiator transmits a connection request message to the advertiser.
[0014] After the connection request message is received from the initiator, a connection is established between the initiator and the advertiser. According to the connection establishment, the initiator, i.e., the master BLE device 111 and the advertiser, i.e., the slave BLE device 113 performs a data transmitting operation and a connection maintaining operation corresponding to a preset CI TCI. Here, a CI TCI denotes an interval during which data transmission and data reception between two BLE devices are possible in a connection which is established between the two BLE devices.
[0015] A data transmitting operation and a connection maintaining operation which are performed between the master BLE device 111 and the slave BLE device 113 will be described below.
[0016] If a data packet to be transmitted occurs, the master BLE device 111 transmits the data packet through a preset data channel, so a connection event between the master BLE device 111 and the slave BLE device 113 is started. If a data packet to be transmitted occurs, the slave BLE device 113 also transmits the data packet through the data channel. If there is no data to be transmitted in the master BLE device 111 and the slave BLE device 113 , the connection event is terminated. In FIG. 1 , for convenience, it will be noted that a data packet, i.e., a master data packet which is transmitted in the master BLE device 111 is illustrated as “M”, and a data packet, i.e., a slave data packet which is transmitted in the slave BLE device 113 is illustrated as “S”.
[0017] In FIG. 1 , if there is no data to be transmitted in the master BLE device 111 and the slave BLE device 113 , the connection event is terminated. However, if a cyclic redundancy check (CRC) error successively occurs preset times, e.g., two times, the connection event may be terminated.
[0018] Meanwhile, a connection event does not occur in a specific CI. In this case, each of the master BLE device 111 and the slave BLE device 113 transmits a null packet to maintain a connection which is established between the master BLE device 111 and the slave BLE device 113 . In FIG. 1 , for convenience, it will be noted that the null packet is illustrated as “N”. A data channel which is used every CI may be hopped based on a preset channel hopping scheme.
[0019] Meanwhile, if null packets are successively lost between the master BLE device 111 and the slave BLE device 113 , supervision timeout may occur. The supervision timeout is used for checking whether a connection between two BLE devices is released. If the master BLE device 111 and the slave BLE device 113 do not receive any effective data packet during a preset supervision timeout period TST, supervision timeout occurs in the master BLE device 111 and the slave BLE device 113 .
[0020] If the supervision timeout occurs, a connection which is established between the master BLE device 111 and the slave BLE device 113 is released, so a connection reestablishing process for reestablishing a connection is performed between the master BLE device 111 and the slave BLE device 113 .
[0021] Meanwhile, a BLE mode proposed in the Bluetooth scheme is a mode which is proposed in a case assuming a channel which is not affected by an error, i.e., an error free channel. That is, since the Bluetooth scheme considers only a case that there is a need for short range connectivity such as a case that a wearable device is used, relatively good channel status, e.g., channel status corresponding to a relatively high received signal strength indicator (RSSI) may be maintained, so an operation in the BLE mode is performed based on stable and good link quality.
[0022] Recently, the Bluetooth has been actively used in a case that needs to support long range connectivity such as a smart home network, a mesh network, and the like, so efficiency of an operation in a BLE mode which is proposed by considering an error free channel may be decreased due to bad channel status between two BLE devices.
[0023] For example, as described in FIG. 1 , a connection which is established between two BLE devices in a BLE mode is maintained corresponding to a CI, and the CI in a BLE mode of the current BLE scheme is used as a preset value which is fixed corresponding to a system situation. Here, the CI is determined based on a BLE mode assuming an error-free channel. As described above, if long range connectivity needs to be supported like in a smart home network, a mesh network, and the like, an error-free channel may not be guaranteed. So, if an operation for transmitting and receiving a data packet is performed based on a CI which is determined in the BLE mode assuming the error-free channel, the operation may not be normally performed. This abnormal operation may degrade total system performance. That is, the CI may be an important parameter for determining performance of a wireless communication system in which the BLE mode is used. The reason will be described below.
[0024] Firstly, in the BLE mode, after establishing a connection, two BLE devices operates in a sleep state in order to decrease energy which is consumed for maintaining the established connection unless a connection event occurs. If the connection event occurs, the two BLE devices wake up based on a CI to transmit and receive a data packet. So, if the CI is set to a lengthy value, delay may occur in processing a connection event. Alternatively, if the CI is set to a value which is too short, power consumption due to unnecessary wake up may be increased. So, the CI becomes an important parameter for determining total system performance.
[0025] Currently, a Bluetooth scheme defines a scheme for determining a CI that the CI is determined as an arbitrary value within a range from 7.5 milliseconds to 10.24 milliseconds, and does not define any specific scheme for determining the CI. Specially, the CI which is determined as the arbitrary value within the range from 7.5 milliseconds to 10.24 milliseconds is based on an error free channel, and the current Bluetooth scheme does not define any scheme for determining a CI in a case that an error free channel is not guaranteed.
[0026] The above information is presented as background information only to assist with an understanding of the present disclosure. No determination has been made, and no assertion is made, as to whether any of the above might be applicable as prior art with regard to the present disclosure.
SUMMARY
[0027] To address the above-discussed deficiencies, it is a primary object to provide an apparatus and method for controlling a connection interval (CI) in a wireless communication system supporting a Bluetooth scheme.
[0028] Another aspect of the present disclosure is to propose an apparatus and method for adaptively controlling a CI in a wireless communication system supporting a Bluetooth scheme.
[0029] Another aspect of the present disclosure is to propose an apparatus and method for adaptively controlling a CI based on channel status in a wireless communication system supporting a Bluetooth scheme.
[0030] Another aspect of the present disclosure is to propose an apparatus and method for controlling a CI thereby decreasing power consumption of a BLE device which operates in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0031] Another aspect of the present disclosure is to propose an apparatus and method for controlling a CI thereby guaranteeing a seamless connection among BLE devices which operate in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0032] In accordance with an aspect of the present disclosure, a method for controlling a connection interval (CI) by a device in a wireless communication system supporting a Bluetooth scheme is provided. The method includes detecting channel status; and controlling a CI for a connection which is established between the device and other device based on the channel status, wherein the CI denotes an interval during which data packet transmission and data packet reception between the device and the other device are possible.
[0033] In accordance with another aspect of the present disclosure, a device in a wireless communication system supporting a Bluetooth scheme is provided. The device includes a processor configured to perform an operation of detecting channel status, and perform an operation of controlling a connection interval (CI) for a connection which is established between the device and other device based on the channel status, wherein the CI denotes an interval during which data packet transmission and data packet reception between the device and the other device are possible.
[0034] Other aspects, advantages, and salient features of the disclosure will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the disclosure.
[0035] Before undertaking the DETAILED DESCRIPTION below, it may be advantageous to set forth definitions of certain words and phrases used throughout this patent document: the terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation; the term “or,” is inclusive, meaning and/or; the phrases “associated with” and “associated therewith,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, or the like; and the term “controller” means any device, system or part thereof that controls at least one operation, such a device may be implemented in hardware, firmware or software, or some combination of at least two of the same. It should be noted that the functionality associated with any particular controller may be centralized or distributed, whether locally or remotely. Definitions for certain words and phrases are provided throughout this patent document, those of ordinary skill in the art should understand that in many, if not most instances, such definitions apply to prior, as well as future uses of such defined words and phrases.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts:
[0037] FIG. 1 schematically illustrates an operation for transmitting and receiving a data packet in a conventional wireless communication system supporting a BLE mode;
[0038] FIG. 2 schematically illustrates a channel environment in a case that a fixed CI is used in a wireless communication system supporting a BLE mode according to an embodiment of the present disclosure;
[0039] FIG. 3 schematically illustrates an inner structure of a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0040] FIG. 4 schematically illustrates an inner structure of a link layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0041] FIG. 5 schematically illustrates an inner structure of an L2CAP layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0042] FIG. 6 schematically illustrates a process for estimating a PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0043] FIG. 7 schematically illustrates relation between a retransmission count for a data packet and RTT for the data packet in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0044] FIG. 8 schematically illustrates an example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0045] FIG. 9 schematically illustrates another example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0046] FIG. 10 schematically illustrates a scheme for detecting an average supervision timeout period according to a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0047] FIG. 11 schematically illustrates power which is averagely consumed for maintaining a connection according to a CI in a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0048] FIG. 12 schematically illustrates an example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0049] FIG. 13 schematically illustrates another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0050] FIG. 14 schematically illustrates still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0051] FIG. 15 schematically illustrates relation between a measured PER and an estimated PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0052] FIG. 16 schematically illustrates still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure;
[0053] FIG. 17 schematically illustrates an inner structure of a master BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure; and
[0054] FIG. 18 schematically illustrates an inner structure of a slave BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0055] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION
[0056] FIGS. 2 through 18 , discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged system or device.
[0057] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of various embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.
[0058] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the present disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the present disclosure is provided for illustration purpose only and not for the purpose of limiting the present disclosure as defined by the appended claims and their equivalents.
[0059] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
[0060] Although ordinal numbers such as “first,” “second,” and so forth will be used to describe various components, those components are not limited herein. The terms are used only for distinguishing one component from another component. For example, a first component may be referred to as a second component and likewise, a second component may also be referred to as a first component, without departing from the teaching of the inventive concept. The term “and/or” used herein includes any and all combinations of one or more of the associated listed items.
[0061] The terminology used herein is for the purpose of describing various embodiments only and is not intended to be limiting. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “has,” when used in this specification, specify the presence of a stated feature, number, step, operation, component, element, or combination thereof, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, elements, or combinations thereof.
[0062] The terms used herein, including technical and scientific terms, have the same meanings as terms that are generally understood by those skilled in the art, as long as the terms are not differently defined. It should be understood that terms defined in a generally-used dictionary have meanings coinciding with those of terms in the related technology.
[0063] According to various embodiments of the present disclosure, an electronic device may include communication functionality. For example, an electronic device may be a smart phone, a tablet personal computer (PC), a mobile phone, a video phone, an e-book reader, a desktop PC, a laptop PC, a netbook PC, a personal digital assistant (PDA), a portable multimedia player (PMP), an mp3 player, a mobile medical device, a camera, a wearable device (e.g., a head-mounted device (HMD), electronic clothes, electronic braces, an electronic necklace, an electronic appcessory, an electronic tattoo, or a smart watch), and/or the like.
[0064] According to various embodiments of the present disclosure, an electronic device may be a smart home appliance with communication functionality. A smart home appliance may be, for example, a television, a digital video disk (DVD) player, an audio, a refrigerator, an air conditioner, a vacuum cleaner, an oven, a microwave oven, a washer, a dryer, an air purifier, a set-top box, a TV box (e.g., Samsung HomeSync™, Apple TV™, or Google TV™), a gaming console, an electronic dictionary, an electronic key, a camcorder, an electronic picture frame, and/or the like.
[0065] According to various embodiments of the present disclosure, an electronic device may be a medical device (e.g., magnetic resonance angiography (MRA) device, a magnetic resonance imaging (MRI) device, computed tomography (CT) device, an imaging device, or an ultrasonic device), a navigation device, a global positioning system (GPS) receiver, an event data recorder (EDR), a flight data recorder (FDR), an automotive infotainment device, a naval electronic device (e.g., naval navigation device, gyroscope, or compass), an avionic electronic device, a security device, an industrial or consumer robot, and/or the like.
[0066] According to various embodiments of the present disclosure, an electronic device may be furniture, part of a building/structure, an electronic board, electronic signature receiving device, a projector, various measuring devices (e.g., water, electricity, gas or electro-magnetic wave measuring devices), and/or the like that include communication functionality.
[0067] According to various embodiments of the present disclosure, for example, each of a master Bluetooth low energy (BLE) device and a slave BLE device may be an electronic device.
[0068] An embodiment of the present disclosure proposes an apparatus and method for controlling a connection interval (CI) in a wireless communication system supporting a Bluetooth scheme.
[0069] An embodiment of the present disclosure proposes an apparatus and method for adaptively controlling a CI in a wireless communication system supporting a Bluetooth scheme.
[0070] An embodiment of the present disclosure proposes an apparatus and method for adaptively controlling a CI based on channel status in a wireless communication system supporting a Bluetooth scheme.
[0071] An embodiment of the present disclosure proposes an apparatus and method for controlling a CI thereby decreasing power consumption of a BLE device which operates in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0072] An embodiment of the present disclosure proposes an apparatus and method for controlling a CI thereby guaranteeing a seamless connection among BLE devices which operate in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0073] A method and apparatus proposed in various embodiments of the present disclosure may be applied to various communication systems such as a long term evolution (LTE) mobile communication system, an LTE-advanced (LTE-A) mobile communication system, a licensed-assisted access (LAA)-LTE mobile communication system, a high speed downlink packet access (HSDPA) mobile communication system, a high speed uplink packet access (HSDPA) mobile communication system, a high rate packet data (HRPD) mobile communication system proposed in a 3rd generation project partnership 2 (3GPP2), a wideband code division multiple access (WCDMA) mobile communication system proposed in the 3GPP2, a code division multiple access (CDMA) mobile communication system proposed in the 3GPP2, an institute of electrical and electronics engineers (IEEE) 802.16m communication system, an IEEE 802.16e communication system, an evolved packet system (EPS), and a mobile internet protocol (Mobile IP) system and/or the like.
[0074] A channel environment in a case that a fixed CI is used in a wireless communication system supporting a BLE mode according to an embodiment of the present disclosure will be described with reference to FIG. 2 .
[0075] FIG. 2 schematically illustrates a channel environment in a case that a fixed CI is used in a wireless communication system supporting a BLE mode according to an embodiment of the present disclosure.
[0076] Referring to FIG. 2 , the wireless communication system assumes a smart home network which should support long range connectivity, and it will be assumed that there are a master BLE device and a plurality of slave BLE devices, e.g., four slave BLE devices, e.g., a slave BLE device 1 , a slave BLE device 2 , a slave BLE device 3 , and a slave BLE device 4 . For convenience, in FIG. 2 , it will be noted that the master BLE device is illustrated as “M”, and the slave BLE device 1 , the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 are illustrated as “S 1 ”, “S 2 ”, “S 3 ”, and “S 4 ”, respectively.
[0077] If there are the master BLE device, the slave BLE device 1 , the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 as illustrated in FIG. 2 , it will be understood that channel status 211 of the slave BLE device 1 is relatively good, and channel status 213 of the slave BLE device 3 is relatively bad. That is, the slave BLE device 1 is very close to the master BLE device, so the channel status 211 is relatively good, and the slave BLE device 3 is relatively far from the master BLE device, so the channel status 213 is relatively bad.
[0078] In FIG. 2 , a vertical axis in each of graphs indicating the channel status 211 of the slave BLE device 1 and the channel status 213 of the slave BLE device 3 indicates the number of times connection loss occurs during preset time, e.g., 30 minutes, i.e., the number of times connection release occurs and an average packet error rate (PER) during the preset time. In FIG. 2 , a horizontal axis in each of the graphs indicating the channel status 211 of the slave BLE device 1 and the channel status 213 of the slave BLE device 3 indicates time.
[0079] Further, it will be noted that the channel status 211 of the slave BLE device 1 and the channel status 213 of the slave BLE device 3 as described in FIG. 2 are acquired in a case that a supervision timeout interval TST is set to 6 seconds, and a CI T CI is set to 1.5 sec. Here, the CI T CI denotes an interval during which data transmission and data reception between two BLE devices are possible in a connection which is established between the two BLE devices. Further, supervision timeout is used for checking whether a connection between two BLE devices is released, and supervision timeout occurs in the two BLE devices if the two BLE devices do not receive any effective data packet during a preset supervision timeout interval TST.
[0080] In FIG. 2 , channel status is a PER, however, it will be understood by those of ordinary skill in the art that the channel status may be expressed using various parameters such as received signal code power (RSCP), reference signal received power (RSRP), reference signal received quality (RSRQ), a carrier-to-interference noise ratio (CINR), a signal-to-noise ratio (SNR), a block error rate (BLER), a received signal strength indicator (RSSI), and the like.
[0081] As described in FIG. 2 , a case that connection loss occurs, i.e., a case that a connection is released may frequently occur if slave BLE devices of which channel status is bad use a CI which is determined based on an error free channel, so the slave BLE devices frequently perform a connection reestablishing process. Power consumption for performing the connection reestablishing process is significantly large, so total system performance is degraded if a connection is maintained using a CI for a BLE mode which is based on an error free channel.
[0082] So, an embodiment of the present disclosure proposes a scheme for controlling a CI based on channel status, and this will be described below.
[0083] An inner structure of a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 3 .
[0084] FIG. 3 schematically illustrates an inner structure of a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0085] Referring to FIG. 3 , a BLE device denotes a device which operates in a BLE mode, and each of a master BLE device and a slave BLE device may be a BLE device.
[0086] A BLE device 300 includes an operating system (OS) part 310 and a BLE chipset part 320 .
[0087] The OS part 310 includes an application layer 311 , an attribute protocol (ATT) layer 313 , a security manager (SM) 315 , and a logical link control and adaptation protocol (L2CAP) layer 317 . The ATT layer 313 , the SM 315 , and the L2CAP layer 317 are included in a host part, and the L2CAP layer 317 may control a CI. This will be described below, so a detailed description will be omitted herein. A detailed description of each of the ATT layer 313 and the SM 315 will be omitted herein.
[0088] The BLE chipset part 320 includes a link layer 321 and a physical layer 323 . The link layer 321 and the physical layer 323 are included in a controller part, and the link layer 321 may control a CI. This will be described below, so a detailed description will be omitted herein. A detailed description of the physical layer 323 will be omitted herein.
[0089] Meanwhile, an interface between the L2CAP layer 317 and the link layer 321 is a host controller interface (HCI).
[0090] While the OS part 310 and the BLE chipset part 320 are described in the BLE device 300 as separate units, it is to be understood that this is merely for convenience of description. In other words, the BLE device 300 may be implemented with one processor.
[0091] While the application layer 311 , the ATT layer 313 , the SM 315 , and the L2CAP layer 317 are described in the OS part 310 as separate units, it is to be understood that this is merely for convenience of description. In other words, two or more of the application layer 311 , the ATT layer 313 , the SM 315 , and the L2CAP layer 317 may be incorporated into a single unit. The OS part 310 may be implemented with one processor.
[0092] While the link layer 321 and the physical layer 323 are described in BLE chipset part 320 as separate units, it is to be understood that this is merely for convenience of description. In other words, the BLE chipset part 320 may be implemented with one processor.
[0093] An inner structure of a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 3 , and an inner structure of a link layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 4 .
[0094] FIG. 4 schematically illustrates an inner structure of a link layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0095] Referring to FIG. 4 , a link layer 400 includes a PER measuring unit 411 and a CI determiner 413 . The link layer 400 is included in a controller part included in a BLE device.
[0096] The PER measuring unit 411 may detect the number of data packets which are actually transmitted in a Bluetooth chipset and the number of data packets for which acknowledgements (ACKs) will be received. So, the PER measuring unit 411 measures a PER of a current channel based on the number of data packets which are actually transmitted in the Bluetooth chipset and the number of data packets for which the ACKs will be received, and outputs the measured PER to the CI determiner 413 .
[0097] The CI determiner 413 determines a CI for decreasing average power consumption of a related BLE device in a current channel corresponding to a preset scheme for determining a CI based on the PER output from the PER measuring unit 411 . For example, the CI determiner 413 may determine a CI for minimizing average power consumption of a related BLE device in a current channel corresponding to a preset scheme for determining a CI based on the PER output from the PER measuring unit 411 . The scheme for determining the CI will be described below, so a detailed description will be omitted herein.
[0098] While the PER measuring unit 411 and the CI determiner 413 are described in the link layer 400 as separate units, it is to be understood that this is merely for convenience of description. In other words, the link layer 400 may be implemented with one processor.
[0099] In FIG. 4 , the PER measuring unit 411 and the CI determiner 413 are included in the link layer 400 , however, it will be understood by those of ordinary skill in the art that the measuring unit 411 and the CI determiner 413 may be located at any part of a controller part included in the BLE device.
[0100] In a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure, channel status is determined based on a PER, so the CI determiner 413 determines a CI based on a measured PER in FIG. 4 , however, it will be understood by those of ordinary skill in the art that any parameter which may indicate channel status as well as the PER may be used for determining a CI.
[0101] An inner structure of a link layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 4 , and an inner structure of an L2CAP layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 5 .
[0102] FIG. 5 schematically illustrates an inner structure of an L2CAP layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0103] Referring to FIG. 5 , an L2CAP layer 500 includes a PER estimator 511 and a CI determiner 513 . The L2CAP layer 500 is included in a host part included in a BLE device.
[0104] Meanwhile, a controller part included in the BLE device does not inform information related to a retransmitting operation for a data packet which is performed in a link layer included in the controller part to the host part. So, the PER estimator 511 estimates a PER of a channel based on round trip time (RTT) of a data packet which may be estimated in the host part.
[0105] The PER estimator 511 outputs the estimated PER to the CI determiner 513 .
[0106] The CI determiner 513 determines a CI for decreasing average power consumption of a related BLE device in a current channel corresponding to a preset scheme for determining a CI based on the PER output from the PER estimator 511 . For example, the CI determiner 513 may determine a CI for minimizing average power consumption of the related BLE device in the current channel corresponding to the preset scheme for determining the CI based on the PER output from the PER estimator 511 . The scheme for determining the CI will be described below, so a detailed description will be omitted herein.
[0107] While the PER estimator 511 and the CI determiner 513 are described in the L2CAP layer 500 as separate units, it is to be understood that this is merely for convenience of description. In other words, the L2CAP layer 500 may be implemented with one processor.
[0108] In FIG. 5 , the PER estimator 511 and the CI determiner 513 are included in the L2CAP layer 500 , however, it will be understood by those of ordinary skill in the art that the PER estimator 511 and the CI determiner 513 may be located at any part of a host part included in the BLE device.
[0109] In a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure, channel status is determined based on a PER, so the CI determiner 513 determines a CI based on an estimated PER in FIG. 5 , however, it will be understood by those of ordinary skill in the art that any parameter which may indicate channel status as well as the PER may be used for determining a CI.
[0110] An inner structure of an L2CAP layer in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 5 , and a scheme for determining a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described below.
[0111] Firstly, it will be assumed that power which is consumed for null packet transmission is P Null , and power which is consumed for reestablishing a connection, i.e., power which is consumed for a connection reestablishing process is P Re-conn .
[0112] In this case, a CI T CI should be appropriately determined for decreasing power P(T CI ) which is consumed during the CI T CI , and an optimization issue for minimizing the power P(T CI ) may be expressed as Equation (1).
[0000]
min
T
CI
P
(
T
CI
)
=
min
T
CI
{
P
Null
(
T
CI
)
+
P
Re
-
conn
(
T
CI
)
}
=
min
T
CI
{
E
Null
T
CI
+
E
Re
-
conn
ST
avg
(
T
CI
)
}
Equation
(
1
)
[0113] In Equation (1), each of the P Null and the P Re-conn may be expressed as a function of a CI, and it will be understood that the P Null is decreased if a CI is increased, and the P Re-conn is increased if the CI is increased.
[0114] In Equation (1), E Null denotes energy which is consumed for transmitting one null packet or receiving one null packet, and E Re-conn denotes energy which is consumed for reestablishing a connection, i.e., energy which is consumed for a connection reestablishing process. Each of the E Null and the E Re-conn may be a constant value according to a system situation in a wireless communication system supporting a Bluetooth scheme.
[0115] In Equation (1), ST avg denotes an average supervision timeout period. The ST avg may be expressed as a function of a CI. The smaller the CI is, the more frequently a null packet is transmitted. In this case, a probability that supervision timeout occurs may be decreased, so ST avg may be decreased. So, if the CI is decreased, P re-conn may be decreased.
[0116] In Equation (1), The CI min ≦T CI ≦CI max . The CI min denotes a minimum value of a CI requested for packet delivery performance, e.g., latency and throughput requested by an application which uses a BLE mode, and the CI max denotes a maximum value of the CI requested for the packet delivery performance which is requested by the application which uses the BLE mode.
[0117] As described above, a scheme for determining a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure may be used in each of a CI determiner 413 in FIG. 4 and a CI determiner 513 in FIG. 5 .
[0118] A scheme for determining a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described above, and a process for estimating a PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 6 .
[0119] FIG. 6 schematically illustrates a process for estimating a PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0120] Referring to FIG. 6 , as described in FIG. 5 , a controller part included in a BLE device does not inform information related to a retransmitting operation for a data packet which is performed in a link layer included in the controller part to a host part included in the BLE device. So, a PER estimator included in the host part estimates a PER of a channel based on RTT of a data packet which may be estimated in the host part.
[0121] A minimum value of RTT may be expressed as Equation (2).
[0000] RTT min =offset+ T CI Equation (2)
[0122] In Equation (2), offset denotes time from a timing point at which a packet occurs to a timing point at which an actual data packet is transmitted.
[0123] Further, RTT in a case that retransmission for a related data packet occurs one time may be expressed as Equation (3).
[0000] RTT=offset+2 *T CI =RTT min +1 *T CI Equation (3)
[0124] A process for estimating a PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 6 , and relation between a retransmission count for a data packet and RTT for the data packet in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 7 .
[0125] FIG. 7 schematically illustrates relation between a retransmission count for a data packet and RTT for the data packet in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0126] Referring to FIG. 7 , the more increased a retransmission count for a data packet is, the more increased RTT for the data packet is.
[0127] An RTT graph 711 in the inside of a door, e.g., in a slave BLE device 2 as described in FIG. 2 and an RTT graph 713 in the outside of the door, e.g., in a slave BLE device 3 as described in FIG. 2 are illustrated in FIG. 7 . A vertical axis in each of graphs in FIG. 7 indicates a cumulative density function (CDF) of RTT, and a horizontal axis denotes RTT at a related location. It will be noted that the RTT graphs 711 and 713 are RTT graphs of a related BLE device in a case that T CI is 1 second (T CI =1 sec).
[0128] Relation between a retransmission count for a data packet and RTT for the data packet in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 7 , and a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIGS. 8 and 9 .
[0129] FIG. 8 schematically illustrates an example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0130] Referring to FIG. 8 , it will be assumed that a process for controlling a CI in FIG. 8 is a process controlling a CI which is performed in a link layer included in a controller part of a BLE device.
[0131] A link layer detects that it reaches a CI updating interval T CIA as an interval during which a CI T CI should be updated at operation 811 . Here, a CIA scheme denotes a CI adaptation scheme, and denotes a scheme for updating a CI by updating a PER which indicates channel status. The CI T CI may be maintained or updated every T CIA .
[0132] The link layer measures a PER based on the number of data packets which are actually transmitted in a Bluetooth chipset and the number of data packets for which ACKs will be received to update the PER at operation 813 . A scheme for measuring the PER to update the PER has been described above, so a detailed description will be omitted herein. The link layer determines whether difference |PER−PER Pre | between a PER which is measured in a current T CIA and a PER which is measured in a previous T CIA is greater than a threshold PER PER thre at operation 815 . If the |PER−PER Pre | is not greater than the PER thre , that is, if the |PER−PER Pre | is equal to or less than the PER thre , the link layer awaits the next CI updating interval at operation 817 , and proceeds to operation 813 .
[0133] If the |PER−PER Pre | is greater than the PER thre , the link layer updates a CI T CI and a CI updating interval T CIA at operation 819 . A scheme for updating the CI T CI has been described above, so a detailed description will be omitted herein. The link layer sets the updated PER to a previous PER PER pre at operation 821 , and proceeds to operation 817 .
[0134] Although FIG. 8 illustrates an example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure, various changes could be made to FIG. 8 . For example, although shown as a series of operations, various operations in FIG. 8 could overlap, occur in parallel, occur in a different order, or occur multiple times.
[0135] An example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 8 , and another example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 9 .
[0136] FIG. 9 schematically illustrates another example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0137] Referring to FIG. 9 , it will be assumed that a process for controlling a CI in FIG. 9 is a process controlling a CI which is performed in an L2CAP layer included in a host part of a BLE device.
[0138] An L2CAP layer detects that it reaches a CI updating interval T CIA as an interval during which a CI T CI should be updated at operation 911 . The L2CAP layer estimates a PER of a channel based on RTT of a data packet which may be measured in the host part to update the PER at operation 913 . A scheme for estimating the PER to update the PER has been described above, so a detailed description will be omitted herein. The L2CAP layer determines whether difference |PER−PER Pre | between a PER which is estimated in a current T CIA and a PER which is estimated in a previous T CIA is greater than a threshold PER PER thre at operation 915 . If the |PER−PER Pre | is not greater than the PER thre , that is, if the |PER−PER Pre | is equal to or less than the PER thre , the L2CAP layer awaits the next CI updating interval at operation 917 , and proceeds to operation 913 .
[0139] If the |PER−PER Pre | is greater than the PER thre , the L2CAP layer updates a CI T CI and a CI updating interval T CIA at operation 919 . A scheme for updating the CI T CI has been described above, so a detailed description will be omitted herein. The L2CAP layer sets the updated PER to a previous PER PER pre at operation 921 , and proceeds to operation 917 .
[0140] Although FIG. 9 illustrates another example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure, various changes could be made to FIG. 9 . For example, although shown as a series of operations, various operations in FIG. 9 could overlap, occur in parallel, occur in a different order, or occur multiple times.
[0141] Another example of a process for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 9 , and a scheme for detecting an average supervision timeout period according to a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 10 .
[0142] FIG. 10 schematically illustrates a scheme for detecting an average supervision timeout period according to a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0143] Referring to FIG. 10 , ST avg (T CI ) denotes an average supervision timeout period for a CI T CI , and denotes the average number of state transitions until supervision timeout according to the CI T CI occurs.
[0144] Further, P denotes a PER, and n denotes the number of packet errors due to supervision timeout. Here,
[0000]
n
=
⌊
T
ST
T
CI
⌋
.
[0145] A scheme for detecting the ST avg (T CI ) will be described below.
[0146] Firstly, in a state diagram in FIG. 10 , n denotes a null packet transmission count which may be tried until a supervision timeout occurs, and an index of each state denotes a count of null packet transmissions which are successively failed. That is, it reaches a state n when null packet transmission fails consecutively n times. In this case, supervision timeout occurs. Here, the ST avg (T CI ) becomes state transition count which should be averagely passed until it reaches a state n from a state 0*CI.
[0147] However, there are many cases that it may reach a state n from a state 0, so a state transition count which should be averagely passed until it reaches the state n from the state 0 may become significantly increased.
[0148] So, in an embodiment of the present disclosure, a CI determiner may calculate ST avg (T CI ) as expressed in Equation (4).
[0000]
ST
avg
(
T
CI
)
=
∑
k
=
0
∞
(
T
F
+
kT
S
)
p
F
p
S
k
=
T
F
+
T
S
P
(
1
-
P
S
)
Equation
(
4
)
[0149] In Equation (4), p F , P S , T F , and T S may be expressed as Equation (5).
[0000]
p
F
=
P
n
,
p
S
=
1
-
P
n
T
F
=
T
ST
,
T
S
=
T
CI
{
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
}
(
1
-
P
n
)
(
1
-
P
)
Equation
(
5
)
[0150] In Equation (4) and Equation (5), a case S indicates a case that packet transmission by a BLE device is successful before supervision timeout occurs, and a case F indicates a case that packet transmission by the BLE device is failed before the supervision timeout occurs. That is, the case S denotes a case that it starts from a state 0 before supervision timeout occurs, and succeeds in null packet transmission before it reaches a state n to return to the state 0, and the case F denotes a case that it starts from the state 0 before the supervision timeout occurs and reaches the state n.
[0151] So, the CI determiner calculates average time which is consumed in each of a case that the case S occurs and a case that the case F occurs, and a probability that each of the case S and the case F occurs, and calculates time which is averagely consumed until supervision timeout occurs based on the average time which is consumed in each of the case that the case S occurs and the case that the case F occurs, and the probability that each of the case S and the case F occurs.
[0152] That is, the case S may be one of various cases including a case that it starts from a state 0 and succeeds in the first null packet transmission to return to the state 0, a case that it starts from the state 0, fails in up to n−1 null packet transmissions, and succeeds in the last null packet transmission to return to the state 0, and the like. So, the CI determiner multiplies time which is consumed in a case that each case occurs and a probability that each case occurs in order to calculate time which is averagely consumed in a case that the case S occurs, and sums the multiplied values to calculate average time which is consumed in the case S, and the average time which is consumed in the case S may be expressed as Equation (6).
[0000]
T
S
=
∑
k
=
1
n
(
k
*
T
CI
)
*
P
k
-
1
*
(
1
-
P
)
P
S
=
T
CI
*
(
1
-
P
)
P
S
*
∑
k
=
1
n
(
k
*
P
k
-
1
)
Equation
(
6
)
[0153] Further, average time which is consumed in a case S as expressed in Equation (6) may be expressed as Equation (8) using definition in Equation (7).
[0000]
X
=
∑
k
=
1
n
(
k
*
P
k
-
1
)
=
1
+
2
P
+
3
P
2
+
⋯
+
nP
n
-
1
PX
=
P
+
2
P
2
+
3
P
3
+
⋯
+
nP
n
(
1
-
P
)
X
=
1
+
P
+
P
2
+
⋯
+
P
n
-
1
-
nP
n
=
1
-
P
n
1
-
P
-
nP
n
X
=
1
-
(
N
+
1
)
P
n
+
nP
n
+
1
(
1
-
P
)
2
Equation
(
7
)
T
S
=
T
CI
*
(
1
-
P
)
P
S
*
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
(
1
-
P
)
2
=
T
CI
{
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
}
(
1
-
P
n
)
(
1
-
P
)
Equation
(
8
)
[0154] As a result, power which is averagely consumed for maintaining a connection according to a T CI in a LE device may be expressed as Equation (9).
[0000]
Equation
(
9
)
P
(
T
CI
)
=
E
null
T
CI
+
E
re
-
conn
ST
avg
(
T
CI
)
=
E
null
T
CI
+
E
re
-
conn
T
ST
+
T
CI
{
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
}
(
1
-
P
)
P
n
=
E
null
T
CI
+
E
re
-
conn
T
ST
+
T
CI
{
1
-
(
⌊
T
ST
T
CI
⌋
+
1
)
P
⌊
T
ST
T
CI
⌋
+
⌊
T
ST
T
CI
⌋
P
⌊
T
ST
T
CI
⌋
+
1
}
(
1
-
P
)
P
⌊
T
ST
T
CI
⌋
[0155] In Equation (9), each of E null , E re-conn , P, and ST may be a given constant value, and T CI may be a variable.
[0156] Meanwhile, power which is averagely consumed for maintaining a connection in a BLE device according to a CI TCI as expressed in Equation (9) may be expressed as Equation (10).
[0000]
P
(
T
CI
)
=
E
null
T
CI
+
E
re
-
conn
ST
avg
(
T
CI
)
=
E
null
T
CI
+
E
re
-
conn
T
ST
+
T
CI
{
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
}
(
1
-
P
)
P
n
Equation
(
10
)
[0157] In Equation (10),
[0000]
n
=
⌊
T
ST
T
CI
⌋
.
[0158] If power P(T CI ) which is averagely consumed for maintaining a connection according to a CI T CI as expressed in Equation (10) in a BLE device is expressed in a form of graph, the power P(T CI ) may be illustrated as FIG. 11 .
[0159] FIG. 11 schematically illustrates power which is averagely consumed for maintaining a connection according to a CI in a BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0160] Referring to FIG. 11 , it will be noted that a graph indicating power which is averagely consumed for maintaining a connection according to a CI in a BLE device in FIG. 11 is a graph which is generated based on power P(T CI ) which is averagely consumed for maintaining a connection according to a CI T CI as expressed in Equation (10) in a BLE device. In FIG. 11 , a vertical axis indicates power P(T CI ), and a horizontal axis indicates a CI T CI .
[0161] The graph in FIG. 11 has a stair form, i.e., a non-convex form due to
[0000]
n
=
⌊
T
ST
T
CI
⌋
[0000] as expressed in Equation (10).
[0162] So, due to the non-convex form, a BLE device may detect an optimal T CI in a case that all possible T CI values, i.e., all values which are multiples of 1.25 milliseconds, and are from 7.5 milliseconds to ST/2 are substituted in Equation (10). This may be expressed as Equation (11).
[0000]
{
T
CI
|
T
CI
=
T
ST
n
where
n
is
positive
integer
and
⌊
T
ST
CI
max
⌋
≦
n
≦
⌊
T
ST
CI
min
⌋
}
.
Equation
(
11
)
[0163] An optimal value of the CI T CI is determined as T CI included in a set as expressed in Equation (11), and should be determined thereby minimizing P(T CI ). This will be proved below.
[0164] Firstly, in T CI which satisfies a criterion
[0000]
T
ST
n
+
1
<
T
CI
≦
T
ST
n
,
⌊
T
ST
T
CI
⌋
[0000] is n.
[0165] Meanwhile, a CI T CI which uses a fixed value n and a monotone decreasing function according to P may be expressed as Equation (12).
[0000]
P
(
T
CI
)
=
E
null
T
CI
+
E
re
-
conn
ST
+
T
CI
{
1
-
(
n
+
1
)
P
n
+
nP
n
+
1
}
(
1
-
P
)
P
n
Equation
(
12
)
[0166] So, the optimal value of the CI T CI is
[0000]
T
ST
n
[0000] within a range
[0000]
T
ST
n
+
1
<
T
CI
≦
T
ST
n
.
[0167] Meanwhile, an embodiment of the present disclosure may relax n which should have an integer to a real number. That is, an embodiment of the present disclosure may relax n to a real number from an integer.
[0000]
n
=
⌊
T
ST
T
CI
⌋
=
T
ST
T
CI
Equation
(
13
)
[0168] After n is relaxed to a real number from an integer, P may be expressed as a function of n, and may be expressed as Equation (14).
[0000]
min
n
P
(
n
)
=
E
null
T
ST
n
+
E
re
-
conn
T
ST
*
n
(
1
-
p
)
p
n
1
-
p
n
Equation
(
14
)
[0169] As expressed in Equation (14), it will be understood that P has a convex form for n.
[0170] Meanwhile, if P(n) as expressed in Equation (14) is differentiated for n two times, this may be expressed as Equation (15).
[0000]
P
″
(
n
)
=
E
re
-
conn
T
ST
(
1
-
P
)
P
n
{
2
ln
P
+
n
(
ln
P
)
2
-
2
ln
PP
n
+
n
(
ln
P
)
2
P
n
}
(
1
-
P
n
)
3
Equation
(
15
)
[0171] As expressed in Equation (15), if P(n) as expressed in Equation (14) is differentiated for n two times, it will be understood that a second derivative of P(n), i.e., a value of P″(n) is always greater than 0.
[0172] So, a scheme for detecting an optimal TCI based on a result as expressed in Equation (15) will be described below.
[0173] Firstly, a BLE device detects an optimal value of n.
[0174] The BLE device may relatively easily detect an optimal value of n using the fact that P(n) is a convex function. That is, the BLE device may detect the optimal value of n by increasing n by 1 from a starting point
[0000]
⌊
T
ST
CI
max
⌋
[0000] until P(n+1) is greater than P(n).
[0175] So, if P(n+1) is greater than P(n), that is, if P(n+1)>P(n), a value of n at a related timing point becomes an optimal value of n.
[0176] Secondly, the BLE device may detect an optimal value of a CI T CI , and this may be expressed as Equation (16).
[0000]
T
CI
opt
=
T
ST
n
opt
Equation
(
16
)
[0177] Meanwhile, constraint for the CI T CI is that the CI T CI should be multiples of 1.25 milliseconds.
[0178] If
[0000]
T
ST
n
opt
[0000] is not multiples of 1.25 milliseconds, the BLE device may select an optimal value of the CI T CI as expressed in Equation (17).
[0000]
T
CI
opt
=
1.25
m
sec
*
⌊
T
ST
/
n
opt
1.25
m
sec
⌋
Equation
(
17
)
[0179] Complexity of each of a scheme for detecting an optimal value of a CI T CI after calculating power consumption using all possible values for the CI T CI and a scheme for detecting an optimal value of a CI T CI after relaxing a value of n to a real number from an integer will be described below.
[0180] Firstly, the scheme for detecting the optimal value of the CI T CI after calculating the power consumption using all possible values for the CI T CI may be expressed as Equation (18).
[0000] T CI =1.25 msec* n Equation (18)
[0181] In Equation (18), all values of n as expressed in
[0000]
CI
min
1.23
m
sec
≦
n
≦
CI
max
1.25
m
sec
[0000] are considered for a CI T CI . So, as expressed in Equation (18), complexity of the scheme for detecting the optimal value of the CI T CI after calculating the power consumption using all possible values for the CI T CI is linearly increased according to a maximum CI, i.e., T CImax . That is, in the scheme for detecting the optimal value of the CI T CI after calculating the power consumption using all possible values for the CI T CI , it will be understood that a range of a value of usable CI T CI is linearly increased according to a value of ST.
[0182] Secondly, in the scheme for detecting the optimal value of the CI T CI after relaxing the value of n to the real number from the integer, P is a convex function of n. So, in a case that a value of P(n) is calculated while a value of n is sequentially increased from 1 by 1, a value of n at a timing point at which P(n+1) is greater than P(n) at the first time is the optimal value of the CI T CI . Here, n denotes a null packet transmission count which may be tried before supervision timeout occurs.
[0183] So, in the scheme for detecting the optimal value of the CI T CI after relaxing the value of n to the real number from the integer, the number of values of n which should be discovered by a BLE device may be significantly decreased. At this time, in a case that a value of └ST/CI┘ is fixed to n, power which is consumed for reestablishing a connection in P(T CI ) and power which is consumed for transmitting a null packet is decreased if T CI is increased. So, the BLE device determines a value of T CI which satisfies a criterion └ST/CI┘=n and is maximum as the optimal value of the CI T CI .
[0184] Next, performance according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described below.
[0185] An example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 12 .
[0186] FIG. 12 schematically illustrates an example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0187] Referring to FIG. 12 , it will be noted that a simulation result according to a scheme for controlling a CI according to an embodiment of the present disclosure is a simulation result in a case that it will be assumed that all BLE channels have the same PER and the PER is not changed.
[0188] In FIG. 12 , a vertical axis denotes average power consumption, and a horizontal axis denotes a channel PER. Further, it will be noted that a simulation result in FIG. 12 is a simulation result in a case that simulation time is one hour, and T ST is 6 seconds (T ST =6 sec).
[0189] In FIG. 12 , it will be noted that a simulation result in a case that a scheme for controlling a CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA, and a simulation result in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is used is illustrated as CIA. Here, a CI TCI which is used in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is not used is separately marked in parenthesis. For example, a simulation result in a case that a CI TCI is 2 seconds and the scheme for controlling the CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA (2.0 sec).
[0190] For convenience, a scheme in which a scheme for controlling a CI according to an embodiment of the present disclosure, that is, a conventional scheme in which a fixed CI T CI is used will be referred to as a NoCIA scheme. In the NoCIA scheme, a CI T CI which achieves minimum power consumption according to a PER is used as a fixed CI T CI .
[0191] For convenience, a scheme for controlling a CI according to an embodiment of the present disclosure will be referred to as a CIA scheme. Further, a scheme for controlling a CI T CI thereby optimizing power P(T CI ) which is consumed during a CI T CI , that is, a scheme for controlling a CI T CI thereby minimizing power P(T CI ) which is consumed during a CI T CI , according to an embodiment of the present disclosure will be referred to as a CIA opt scheme.
[0192] In the CIA scheme, a CI TCI is adaptively updated thereby minimum power consumption is guaranteed at all PERs.
[0193] As illustrated in FIG. 12 , it will be understood that a CI T CI is changed in each of a NoCIA scheme, a CIA scheme, and a CIA opt scheme according to change in a PER of a channel. However, it will be understood that power consumption according to a CIA opt scheme according to an embodiment of the present disclosure is minimized at all PERs.
[0194] An example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 12 , and another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 13 .
[0195] FIG. 13 schematically illustrates another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0196] Referring to FIG. 13 , it will be noted that a simulation result according to a scheme for controlling a CI according to an embodiment of the present disclosure in FIG. 13 is a simulation result in a case that it will be assumed that trace is changed every preset time, e.g., every five minutes, that is, in a case that it will be assumed that a channel environment is changed according to time.
[0197] In FIG. 13 , a vertical axis indicates average power consumption and a horizontal axis indicates each scheme. Further, it will be noted that a simulation result in FIG. 13 indicates a simulation result in a case that simulation time is one hour, and T ST is 6 seconds (T ST =6 sec).
[0198] In FIG. 13 , it will be noted that a simulation result in a case that a scheme for controlling a CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA, and a simulation result in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is used is illustrated as CIA. Here, a CI T CI which is used in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is not used is separately marked in parenthesis. For example, a simulation result in a case that a CI T CI is 2 seconds and the scheme for controlling the CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA (2.0 sec).
[0199] As illustrated in FIG. 13 , in a NoCIA scheme, if a lengthy CI T CI is used, a connection is frequently released, so energy which is consumed for reestablishing a connection may be great. Further, in the NoCIA scheme, if a CI T CI which is too short is used, a null packet is frequently transmitted, so energy which is consumed for transmitting a null packet may be great. As illustrated in FIG. 13 , in the NoCIA scheme, it will be understood that power consumption is minimal if a CI T CI is set to 0.5 second. However, even though the CI T CI is set to 0.5 second, a channel situation is continuously changed, so an optimal issue in power consumption may be still not solved.
[0200] Meanwhile, in the CIA scheme, a CI TCI is adjusted thereby being appropriate to a channel situation which is changed real time, so power consumption which is less than minimum power consumption in a case that the NoCIA scheme is used may be achieved.
[0201] Another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 13 , and still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 14 .
[0202] FIG. 14 schematically illustrates still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0203] Referring to FIG. 14 , it will be noted that a simulation result according to a scheme for controlling a CI according to an embodiment of the present disclosure in FIG. 14 is a simulation result in a case that it will be assumed that trace is changed every preset time, e.g., every five minutes, that is, in a case that it will be assumed that a channel environment is changed according to time.
[0204] In FIG. 14 , a vertical axis denotes connection establishment count, and a horizontal axis denotes each scheme. Further, it will be noted that a simulation result in FIG. 14 is a simulation result in a case that simulation time is one hour, and T ST is 6 seconds (T ST =6 sec).
[0205] In FIG. 14 , it will be noted that a simulation result in a case that a scheme for controlling a CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA, and a simulation result in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is used is illustrated as CIA. Here, a CI T CI which is used in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is not used is separately marked in parenthesis. For example, a simulation result in a case that a CI T CI is 2 seconds and the scheme for controlling the CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA (2.0 sec).
[0206] As illustrated in FIG. 14 , it will be understood that the number of times a connection is released may be decreased ( 1411 ), but the number of times a null packet is transmitted may be increased ( 1413 ), if a value of a CI T CI is decreased.
[0207] So, in a case that a value of a CI T CI is adjusted based on a CIA scheme according to an embodiment of the present disclosure, the number of times a connection is released may be decreased and the number of times a null packet is transmitted may be increased, so power consumption during the CI T CI may be decreased.
[0208] Still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 14 , and relation between a measured PER and an estimated PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 15 .
[0209] FIG. 15 schematically illustrates relation between a measured PER and an estimated PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0210] Referring to FIG. 15 , it will be noted that a simulation result according to a scheme for controlling a CI according to an embodiment of the present disclosure is a simulation result in a case assuming a smart home network as environment which should support connectivity with a long range. It will be assumed that there are a master BLE device and a plurality of slave BLE devices, e.g., four slave BLE devices, e.g., a slave BLE device 1 , a slave BLE device 2 , a slave BLE device 3 , and a slave BLE device 4 in the smart home network. Here, it will be assumed that location of the master BLE device is fixed. For convenience, it will be noted that the master BLE device is illustrated as “M”, and the slave BLE device 1 , the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 are illustrated as “S 1 ”, “S 2 ”, “S 3 ”, and “S 4 ”, respectively.
[0211] If there are a master BLE device, and a slave BLE device 1 , a slave BLE device 2 , a slave BLE device 3 , and a slave BLE device 4 as illustrated in FIG. 15 , it will be understood that channel status of the slave BLE device 1 is relatively good, and channel status of each of the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 is relatively bad. That is, the slave BLE device 1 is very close to the master BLE device, so the channel status of the slave BLE device 1 is relatively good, and each of the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 is far from the master BLE device, so the channel status of each of the slave BLE device 2 , the slave BLE device 3 , and the slave BLE device 4 is relatively bad.
[0212] Meanwhile, as illustrated in FIG. 15 , it will be understood that a PER which is measured in an actual channel situation is almost similar to an estimated PER, i.e., a PER which is estimated based on RTT. So, it will be understood that performance which is almost similar to performance which is acquired in a case that an actual measured PER is used may be acquired even though a PER which is estimated in a CIA scheme and a CIAopt scheme according to an embodiment of the present disclosure is used.
[0213] Relation between a measured PER and an estimated PER in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 15 , and still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 16 .
[0214] FIG. 16 schematically illustrates still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0215] Referring to FIG. 16 , it will be assumed that a simulation result according to a scheme for controlling a CI according to an embodiment of the present disclosure is a simulation result in a case that a smart home network environment is assumed like in FIG. 15 .
[0216] In FIG. 16 , a vertical axis indicates average power consumption and a horizontal axis indicates each slave BLE device. Further, a simulation result in FIG. 16 denotes average power consumption of each slave BLE device during one day.
[0217] In FIG. 16 , it will be noted that a simulation result in a case that a scheme for controlling a CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA, and a simulation result in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is used is illustrated as CIA. Here, a CI T CI which is used in a case that the scheme for controlling the CI according to an embodiment of the present disclosure is not used is separately marked in parenthesis. For example, a simulation result in a case that a CI T CI is 2 seconds and the scheme for controlling the CI according to an embodiment of the present disclosure is not used is illustrated as NoCIA (2.0 sec).
[0218] As illustrated in FIG. 16 , it will be understood that power which is consumed in a case that a CIA scheme according to an embodiment of the present disclosure is used is less than power which is consumed in a case that NoCIA schemes are used in all slave BLE devices.
[0219] Further, as described in FIG. 16 , it will be understood that variability of channel status and a performance gain of a CIA scheme are increased if a distance between a master BLE device and a slave BLE device is increased.
[0220] Still another example of a simulation result according to a scheme for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 16 , and an inner structure of a master BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 17 .
[0221] FIG. 17 schematically illustrates an inner structure of a master BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0222] Referring to FIG. 17 , a master BLE device 1700 includes a transmitter 1711 , a controller 1713 , a receiver 1715 , and a storage unit 1717 .
[0223] The controller 1713 controls the overall operation of the master BLE device 1700 . More particularly, the controller 1713 controls the master BLE device 1700 to perform an operation related to an operation for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure. The operation related to the operation for controlling the CI in the wireless communication system supporting the Bluetooth scheme according to an embodiment of the present disclosure is performed in the manner described with reference to FIGS. 2 to 16 , and a description thereof will be omitted herein.
[0224] The transmitter 1711 transmits various signals and various messages, and the like to other devices, e.g., a slave BLE device, and the like included in the wireless communication system under a control of the controller 1713 . The various signals, the various messages, and the like transmitted in the transmitter 1711 have been described in FIGS. 2 to 16 and a description thereof will be omitted herein.
[0225] The receiver 1715 receives various signals, various messages, and the like from other devices, e.g., a slave BLE device, and the like included in the wireless communication system under a control of the controller 1713 . The various signals, the various messages, and the like received in the receiver 1715 have been described in FIGS. 2 to 16 and a description thereof will be omitted herein.
[0226] The storage unit 1717 stores a program related to the operation related to the operation for controlling the CI in the wireless communication system supporting the Bluetooth scheme according to an embodiment of the present disclosure which is performed by the master BLE device 1700 under a control of the controller 1713 , various data, and the like.
[0227] The storage unit 1717 stores the various signals and the various messages which are received by the receiver 1715 from the other devices, and the like.
[0228] While the transmitter 1711 , the controller 1713 , the receiver 1715 , and the storage unit 1717 are described in the master BLE device 1700 as separate units, it is to be understood that this is merely for convenience of description. In other words, two or more of the transmitter 1711 , the controller 1713 , the receiver 1715 , and the storage unit 1717 may be incorporated into a single unit. The master BLE device 1700 may be implemented with one processor.
[0229] An inner structure of a master BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure has been described with reference to FIG. 17 , and an inner structure of a slave BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure will be described with reference to FIG. 18 .
[0230] FIG. 18 schematically illustrates an inner structure of a slave BLE device in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure.
[0231] Referring to FIG. 18 , a slave BLE device 1800 includes a transmitter 1811 , a controller 1813 , a receiver 1815 , and a storage unit 1817 .
[0232] The controller 1813 controls the overall operation of the slave BLE device 1800 . More particularly, the controller 1813 controls the slave BLE device 1800 to perform an operation related to an operation for controlling a CI in a wireless communication system supporting a Bluetooth scheme according to an embodiment of the present disclosure. The operation related to the operation for controlling the CI in the wireless communication system supporting the Bluetooth scheme according to an embodiment of the present disclosure is performed in the manner described with reference to FIGS. 2 to 16 , and a description thereof will be omitted herein.
[0233] The transmitter 1811 transmits various signals and various messages, and the like to other devices, e.g., a master BLE device, and the like included in the wireless communication system under a control of the controller 1813 . The various signals, the various messages, and the like transmitted in the transmitter 1811 have been described in FIGS. 2 to 16 and a description thereof will be omitted herein.
[0234] The receiver 1815 receives various signals, various messages, and the like from other devices, e.g., a master BLE device, and the like included in the wireless communication system under a control of the controller 1813 . The various signals, the various messages, and the like received in the receiver 1815 have been described in FIGS. 2 to 16 and a description thereof will be omitted herein.
[0235] The storage unit 1817 stores a program related to the operation related to the operation for controlling the CI in the wireless communication system supporting the Bluetooth scheme according to an embodiment of the present disclosure which is performed by the slave BLE device 1800 under a control of the controller 1813 , various data, and the like.
[0236] The storage unit 1817 stores the various signals and the various messages which are received by the receiver 1815 from the other devices, and the like.
[0237] While the transmitter 1811 , the controller 1813 , the receiver 1815 , and the storage unit 1817 are described in the slave BLE device 1800 as separate units, it is to be understood that this is merely for convenience of description. In other words, two or more of the transmitter 1811 , the controller 1813 , the receiver 1815 , and the storage unit 1817 may be incorporated into a single unit. The slave BLE device 1800 may be implemented with one processor.
[0238] As is apparent from the foregoing description, an embodiment of the present disclosure enables to control a CI in a wireless communication system supporting a Bluetooth scheme.
[0239] An embodiment of the present disclosure enables to adaptively control a CI in a wireless communication system supporting a Bluetooth scheme.
[0240] An embodiment of the present disclosure enables to adaptively control a CI based on channel status in a wireless communication system supporting a Bluetooth scheme.
[0241] An embodiment of the present disclosure enables to control a CI thereby decreasing power consumption of a BLE device which operates in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0242] An embodiment of the present disclosure enables to control a CI thereby guaranteeing a seamless connection among BLE devices which operate in a BLE mode in a wireless communication system supporting a Bluetooth scheme.
[0243] Certain aspects of the present disclosure may also be embodied as computer readable code on a non-transitory computer readable recording medium. A non-transitory computer readable recording medium is any data storage device that can store data, which can be thereafter read by a computer system. Examples of the non-transitory computer readable recording medium include read only memory (ROM), random access memory (RAM), CD-ROMs, magnetic tapes, floppy disks, optical data storage devices, and carrier waves (such as data transmission through the Internet). The non-transitory computer readable recording medium can also be distributed over network coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. In addition, functional programs, code, and code segments for accomplishing the present disclosure can be easily construed by programmers skilled in the art to which the present disclosure pertains.
[0244] It can be appreciated that a method and apparatus according to an embodiment of the present disclosure may be implemented by hardware, software and/or a combination thereof. The software may be stored in a non-volatile storage, for example, an erasable or re-writable ROM, a memory, for example, a RAM, a memory chip, a memory device, or a memory integrated circuit (IC), or an optically or magnetically recordable non-transitory machine-readable (e.g., computer-readable), storage medium (e.g., a compact disk (CD), a digital video disc (DVD), a magnetic disk, a magnetic tape, and/or the like). A method and apparatus according to an embodiment of the present disclosure may be implemented by a computer or a mobile terminal that includes a controller and a memory, and the memory may be an example of a non-transitory machine-readable (e.g., computer-readable), storage medium suitable to store a program or programs including instructions for implementing various embodiments of the present disclosure.
[0245] The present disclosure may include a program including code for implementing the apparatus and method as defined by the appended claims, and a non-transitory machine-readable (e.g., computer-readable), storage medium storing the program. The program may be electronically transferred via any media, such as communication signals, which are transmitted through wired and/or wireless connections, and the present disclosure may include their equivalents.
[0246] An apparatus according to an embodiment of the present disclosure may receive the program from a program providing device which is connected to the apparatus via a wire or a wireless and store the program. The program providing device may include a memory for storing instructions which instruct to perform a content protect method which has been already installed, information necessary for the content protect method, and the like, a communication unit for performing a wired or a wireless communication with a graphic processing device, and a controller for transmitting a related program to a transmitting/receiving device based on a request of the graphic processing device or automatically transmitting the related program to the transmitting/receiving device.
[0247] Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as fall within the scope of the appended claims. | The present disclosure relates to a sensor network, machine type communication (MTC), machine-to-machine (M2M) communication, and technology for internet of things (IoT). The present disclosure may be applied to intelligent services based on the above technologies, such as smart home, smart building, smart city, smart car, connected car, health care, digital education, smart retail, security and safety services. The present disclosure includes a method for controlling a connection interval (CI) by a device in a wireless communication system supporting a Bluetooth scheme. The method includes detecting channel status and controlling a CI for a connection that is established between the device and other device based on the channel status, wherein the CI denotes an interval during which data packet transmission and data packet reception between the device and the other device are possible. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to a multiple pattern sewing machine, particularly a sewing machine with a trouble warning device for giving a warning of trouble in the machine to the operator.
When some troubles or faults occur, in sewing machines, such as over heating of the drive motor, faulty generation of a needle position detecting signal, wire-breakage in the foot controller, etc., there is a likelihood of developing into more serious trouble, if the situation is left unnoticed by the machine operator. This may result in injury to the operator. It is therefore necessary as well as desirable that the operator be given a warning of the occurrence of a trouble as quickly as possible, so that he or she may take appropriate steps such as checking or repair.
It has been conventionally practiced that a trouble is noticed to the operator by lightening or sometimes by blinking a trouble warning lamp (alarm lamp). Disposition of such an exclusive warning lamp is likely to be accompanied by some disadvantages, such as increasing the number of component parts or requiring a difficult mounting of other operating or indicating devices which are positioned on the front surface of the machine frame which has limited space for this purpose.
Such a warning lamp must be positioned so as to be easily and most likely to be noticeable by the operator when it is lighted. It is not preferable on the other hand that such a rarely used member be disposed at the most conspicuous position of the machine from the standpoint of the general appearance thereof.
SUMMARY OF THE INVENTION
It is therefore a primary object of this invention to provide a multiple pattern sewing machine with a trouble warning device which is composed of as few component parts as possible, does not detract from the machine appearance, and is capable of reliably giving a warning of the occurrence of a trouble.
It is another object of this invention to provide a multiple pattern sewing machine with a trouble warning device which is constructed and functions to assure the operator will not overlook the indication of the occurrence of trouble.
As to this invented trouble warning device, a pattern indicator, which is disposed on the front of the machine for indicating a desired stitch pattern selected from predetermined plural stitch patterns, is skilfully utilized as a combined or double-purposed device, i.e., a device for indicating a selected stitch pattern and the occurrence of trouble as well.
The pattern indicator should be primarily disposed at the best noticeable position, on the front, of a machine for indicating the selected pattern when the operator has selected his or her desired pattern by manipulating an operational button. It is therefore constructed and arranged to constantly indicate any one selected pattern during the operation period of the machine; and the operator looks at the indicator out of habit of confirming the selection of the desired pattern.
Characteristic feature of this invention resides in that the indicator does not indicate any one of the plural stitch patterns when some trouble has taken place in the machine. Thereby, a warning of the occurrence of a trouble is given to the operator.
This invention is applicable to a multiple pattern sewing machine having stitch forming instrumentalities, manually operable means for selecting a desired stitch pattern from among a plurality of predetermined stitch patterns, pattern displaying means on the front side of the machine for indicating each of the stitch patterns, and supplying means responsive to the operation of the manually operable means for supplying an indication signal to the pattern displaying means so as to indicate the selected stitch pattern. Such a sewing machine should have detecting means for detecting occurrence of trouble in the machine and generating a trouble signal and interrupting means responsive to the trouble signal for interrupting the supply of the indication signal to the pattern displaying means, and the disappearance of all the stitch patterns per se functions as a warning for an operator of the occurrence of trouble.
The interrupting means preferably includes gate means disposed between the supplying means and the pattern displaying means for passing the indication signal toward the pattern displaying means, and the gate means is adapted to interrupt passage of the indication signal during the generating time of the trouble signal.
A preferable multiple pattern sewing machine of this invention comprises stitch forming instrumentalities, a manual switch for selecting a desired stitch pattern from among a plurality of predetermined stitch patterns, a plurality of light emitting diodes disposed correspondingly to the stitch patterns on the front side of the machine for indicating each of the stitch patterns, supplying means for circularly supplying indication signals of a constant frequency to the diodes during the closure of the manual switch and keeping on supplying an indication signal to the diode corresponding to the stitch pattern which is indicated while the manual switch is opened, the supplying means including a plurality of first output terminals and a second output terminal, one terminal of each of the diodes being individually connected with each of the first output terminals, the other terminals of the diodes being adapted to be connected in common with the second output terminal, a detector for detecting occurrence of trouble in the machine and generating a trouble detecting signal, and a gate circuit disposed between the second output terminal and a common connection part of the diodes for interrupting the supply of the indication signals to the diodes during the generating time of the trouble detecting signal.
As stated above, when the operator begins sewing operation, he or she confirms by watching the pattern indicator whether the selection of the desired stitch pattern has been completed. It is quite convenient and advantageous that the watch of the indicator naturally leads him or her to habitually ascertain whether a trouble is present or not. There can be no other more certain trouble warning device, because he or she can not actually ascertain whether the machine is in a prepared state to form a desired stitch pattern or not while the pattern indicator is not lighted.
In this way the overlooking by the operator of a trouble occurrence can be prevented, which naturally reduces the probability of a possible developing of the trouble into a more serious one or further an injurious one to the operator. What is important in this respect is that the effect can be realized economically and without detracting from the appearance of the machine.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multiple pattern sewing machine with a trouble warning device of this invention;
FIG. 2 is a block diagram showing an embodiment of the multiple pattern sewing machine;
FIG. 3 is a timing diagram for explaining the operation mode of the embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In a sewing machine in FIG. 1 in which this invention is preferably applied, a bracket arm 1 is provided on either end thereof with a head portion 2 and a standard 3, the lower end of the latter being carried by a bed 4.
On the front surface, facing the operator, are disposed a push button 11, which is a manually operated member for the operator to use when he or she wishes to select a desired stitch pattern from a plurality of predetermined patterns (16 kinds in this embodiment) and a display panel 12 on which indicia of the above-mentioned 16 patterns are displayed. Above each of the indicia a light emitting diode (LED) 43 is disposed.
The LED 43 is lighted (illuminated) by a circuit shown in FIG. 2. An oscillator 21 is for generating a pulse signal of specific frequency, which is connected, via a normal open switch 23 which is closed only while the push button 11 is depressed, to a counter (octal) 41 which counts in order, whenever a pulse signal input from the oscillator 21 rises, from "0" to "7" for outputting the significance as a digit of binary scale with three bits. Upon reaching "7" the counter 41 returns to "0" again. The counter 41 is connected to a decoder 42; the latter produces a signal of high level from only a specific terminal out of the eight output terminals based on the signal input from the counter 41. To each of the terminals of the decoder 42 are connected a pair of LEDs 43 out of the 16 LEDs corresponding to each stitch pattern on the display panel 12. That is to say, one out of a first group containing eight from the first to the eighth of the 16 LEDs 43, starting from right to left, and one out of a second group containing another eight from the ninth to the sixteenth are connected to the same terminal of the decoder 42, and the remainder in the two groups of the 16 LEDs are similarly connected, forming seven pairs respectively, to each same terminal of the decoder 42.
The counter 41 is provided with a CR terminal which produces a carry signal Pc (see FIG. 3) which falls from high level to low level in response to the falling of a pulse signal Pa (see FIG. 3) for changing the significance to "7" and rises from low level to high level in response to the rising of a pulse signal Pb (see FIG. 3) for changing the significance from "7" to "0". The CR terminal is connected to a C terminal of a J-K flip-flop circuit 44. To a J terminal and a K terminal of this J-K flip-flop circuit 44 is respectively applied a high level voltage. To a Q terminal of the flip-flop circuit 44 the eight LEDs 43, from the first to the eighth, are connected through a lead wire 46 and a NAND circuit 33, and to a Q terminal of the same the other eight LEDs 43, from ninth to sixteenth, are connected through a lead wire 47 and a NAND circuit 34. The flip-flop circuit 44 is so built as to alternately change its holding state at every receiving of a rising of a carry signal output from the counter 41.
The oscillator 21 is connected, via a normal open switch 23, to an address generator 51, which memorizes starting (initial) addresses corresponding to various stitch patterns. Each starting address is sequentially selected in response to a pulse signal from the oscillator 21. The address generator 51 is connected to a data generator 52, which generates data required for forming stitches of each desired pattern. An actuator 53 for operating a mechanism regulating lateral oscillation of a sewing needle 5 (see FIG. 1) and another mechanism adjusting feed amount as well as feed direction of a feed dog 6 makes it possible to form a specific desired stitch pattern. A stitch forming system of this type is well known, being disclosed in, for example, U.S. Pat. No. 3,872,808 published on Mar. 25, 1975, which justifies omission of a further description. Besides, all of the counter 41, the flip-flop circuit 44, and the address generator 51 are reset, when electric power is supplied, by a signal input to each terminal R of them.
A detector 31 is disposed where detection of a trouble is desired, which is expected to generate a high level signal in case of a trouble occurring such as overheat of the drive motor, late producing or non-producing of a detection signal in a needle position detector for halting the needle at a desired position, or producing a excessive value of speed command for the drive motor due to a fault in a foot controller for controlling the drive motor. The detector 31 is connected, via a NOT circuit 32, to the NAND circuits 33 and 34.
The operation mode of the embodiment having the above-mentioned construction will be described next.
When electric power is supplied, the counter 41, the flip-flop circuit 44, and the address generator 51 are reset. Due to the resetting of the address generator 51, the data generator 52 is placed in a state wherein information (data) for forming a first stitch pattern (usually straight line stitch) is prepared to be generated, and the decoder 42 is placed in a state wherein a high level signal is output to the top lead wire 45 (see FIG. 2) and low level signals to the other lead wires. When the flip-flop circuit 44 is reset the Q terminal will be made low level and the Q terminal high level; unless the detector 31 outputs a high level signal because of there being no trouble in the machine, the output from the NOT circuit 32 will be high level and consequently the lead wire 46 will be low level and the lead wire 47 high level. Therefore the first (extreme right in FIG. 2) LED 43 is energized to be luminescent for indicating the first stitch pattern. If and when the operator wishes to change stitch patterns, he or she has only to depress the push button 11; then the normally open switch 23 is closed to consecutively input pulse signals from the oscillator 21 to the counter 41, and the luminescent LEDs 43 will be shifted leftwardly one by one at each pulse, with a result of sequentially changing the indicated stitch patterns. Due to the above-mentioned process the address generator 51 is changed, in the way of address selection, to place the data generator 52 in a state wherein information corresponding to the presently indicated stitch pattern can be generated. When the operator releases the depressing of the push button 11 upon noticing the indication of the desired stitch pattern the machine is consequently ready to form the same. The actuator 53 will act as predetermined according to the data produced from the data generator 52, and assures formation of the indicated stitch pattern on a work fabric.
The foregoing paragraph describes is the operation of a machine while no trouble is present. Once a trouble occurs the output from the detector 31 becomes high level, which is inverted in the NOT circuit 32 to be supplied to the input terminals of the NAND circuits 33 and 34 as a low level signal. The output terminals of the NAND circuits 33 and 34 consequently become high level, irrespective of the state of the Q and Q terminals of the flip-flop circuit 44. None of the LEDs 43 will be luminescent, even when any one of the output terminals of the decoder 42 generates a high level signal. The operator can not under this condition recognize from the LEDs which stitch pattern is now prepared to be formed, and it necessarily makes the operator notice there being something wrong in the machine.
As clearly understood from the above description, the manually operable means for the operator to select the desired stitch pattern is composed of the push button switch (11, 23), the indicating means for indicating the selected stitch patterns is composed of the LEDs 43 and the indicia designating the realizable stitch patterns, the indication signal supplying means is composed of the oscillator 21, the counter 41, the decoder 42, the flip-flop circuit 44, etc., and the restraining means for the indication signals is composed of the NAND circuits 33 and 34, in this embodiment. The above-mentioned means may be respectively substituted by other means as a matter of course, which is obvious to those skilled in the art. This invention should be interpreted to include all those substitutive means, although individual exemplification have been omitted. | A multiple pattern sewing machine with a trouble warning device. The sewing machine is provided with a pattern displaying device for indicating a selected stitch pattern from among a plurality of stitch patterns. The trouble warning device comprises a trouble detector disposed where detection of a trouble is desired in the sewing machine and a device for interrupting the supply of the indication signal to the pattern displaying device, in response to the trouble detecting signal from the trouble detector. Disappearing of the stitch pattern indication per se warns an operator of trouble occurrence. | 3 |
OBJECT OF THE INVENTION
The present invention consists of a compound tile with a natural stone visible face, preferably marble, of the type comprising a plate of natural stone of reduced thickness and firmly fixed by adhesive means to a rigidification and strengthening supporting sheet, said support having a particular composition which is adapted to the physical characteristics of the natural stone plate.
The present invention also consists of a process for manufacturing the above-mentioned tiles, in which the union between the natural stone plate and the supporting plate is made by stacking and curing the adhesive between plate and sheet in an oven.
The compound tile with natural stone visible face of the present invention has a special application in all sectors which commonly use natural stone, mainly for decoration.
DESCRIPTION OF THE STATE OF THE ART
In the state of the art the use of sheets of different materials is known, which are joined to plates of natural stone, for example marble, to obtain a lighter more rigid and cheaper compound tile by replacing part of the stone by other materials which prevent the mineral from breaking due to its fragility. But the industrial manufacturing process has not been technically developed or solved effectively. In order to obtain thin plates of natural stone, which involve a good use of the material and a lower cost, a combination of natural stone and supporting sheet are subjected to cutting processes.
In U.S. Pat. No. 3,723,233, filed by P. T. Bourke et al., a process is disclosed which consists of sticking a 2-5 mm sheet of natural stone, specifically marble, to a metal sheet, preferably having a honeycomb panel structure, and a thickness of between 1 and 2 cm. Since the metal material is light in weight but resistant to compression, it is strengthened with thin layers of fibreglass, which increase its resistance to tension and which are situated at both ends of the metal plate. For sticking the different components together, an epoxy resin or polyurethane resin is used. In this process, the use of material having a honeycomb panel structure does not offer the guarantees necessary for its later use as a support since it is difficult to attach it to floors and especially to walls. Moreover, the manufacture of honeycomb panel structures requires the use of especially light materials which increase the cost of the finished product, not only due to the material but also to the greater volume, which affects material transport costs. In the described process, the compatibility between the physical and chemical features of the minerals and the supporting materials is not analysed in relation to different physical effects which would influence the features of the final product, making its use and assembly complicated and unreliable.
Another method for obtaining strengthened tiles of natural stone may be seen in U.S. Pat. No. 3,950,202 filed by W. Hodges, in which a block of mineral material for decoration (marble, onyx, granite, etc.) is cut using a machine with parallel cutting blades, obtaining plates of approximately 20 mm in thickness. Once cut, supporting honeycomb panel sheets are stuck to the two larger sides of said plates and another cut is later made, this time through the middle of the previous mineral sheet, reaching a thickness of 5 mm, supported by an adhering honeycomb panel sheet. The use of other minerals is mentioned, and in the event that these are translucent, colouring is used on the supporting plate to camouflage this, thus unifying the appearance of the tile. In addition to the supporting materials mentioned, fibre wood, cellular structures of fibreglass and asbestos and even derivatives of Portland cement may be used. In this process, with the natural stone sheets in vertical position, that is, supported on their side of least thickness, the applicant is able to separate them after cutting without falling and then to introduce a strengthening sheet between each sheet, preferably also made of light material and with a honeycomb panel structure, which carries with it the drawbacks mentioned above. Adhesion of these supporting sheets to the natural stone sheets is carried out in this position, although it is not clear how application of the adhesive is carried out since if it is done in a vertical position an even application of said adhesive will not be obtained, which will affect the characteristics of the final product.
The feasibility of the manufacturing process and the strength of the compound tiles with a natural stone visible face stems mainly from the correct composition of the strengthening support material whose physical and chemical features must conform as far as possible to those of the natural stone so that they react in a similar way to the same physical or chemical reactions so that the compound tile is as stable as possible. Several materials may be used as a support for the natural stone plate, and different patent applications disclose the use of fibre materials, EP0252434, Leis, or polyurethane, EP255795, Rigas.
With respect to what has been described in the foregoing, an object of the present application is to obtain a supporting sheet for the natural stone plate with particular composition and materials which provide said sheet with similar characteristics to those of the natural stone plate so that their behaviour will be as similar as possible and the resulting stone product will have greater strength and said supporting sheet will have less thickness, particularly using fibre cement. To achieve this, it is necessary to prevent the distortions which occur in the fibre cement sheets mentioned in the state of the art when they absorb and release humidity, and which cause the natural stone plate to curve, becoming functionally unacceptable as a result and even breaking. To increase the stability of the resulting tile, it is necessary to increase the stability of the supporting sheet, which mainly consists of reducing the movement of humidification. The supporting sheets which use fibre cement described in the state of the art as a support for natural stone plates absorb humidity and release it, causing size increases. Because the fibre cement sheet is stuck to the natural stone plate, said size increases affect the tile resulting from said adhesion, making the tile curve and even break or crack.
Another object of the present invention is to provide improvements in the manufacturing processes used up to the present time for obtaining compound tiles with a natural stone visible face by means of introducing new materials and conditions into the industrial process.
DESCRIPTION
The objects mentioned above are, in accordance with the present invention, achieved by using a supporting sheet made up of a light sheet of reduced thickness to configure the tile with natural stone visible face, the purpose of said sheet being to strengthen the natural stone plate. The problem described above has been resolved in accordance with the invention by proposing and testing different materials and means to achieve on the one hand a reduction in the movement of humidification and on the other a reduction in resistance to the usual bending of fibre cement, pressed and cured in an autoclave, which has been chosen to make up said supporting sheet.
The movement of humidification is proportional, among other variables, to the cement content, to the inverse of the particle size and to the inverse of the density, variables which it has been necessary to modify by means of many test runs to achieve a greater stability of size. To increase stability and therefore reduce the movement of humidification it has been found that the cement content should be decreased, the sand content should be increased and the average size of the particles of the mixture should also be increased and, at the same time, the fibre percentage should be reduced in order to increase density. The products subjected to treatment in autoclave undergo an increase in their movement of humidification as they age. To prevent this, stabilising elements have been introduced into the composition, such as kaolin, alumina and mixtures thereof, which produce doping of the mould, retarding and reducing the effect of ageing. Another important factor in achieving size stability is to retard as far as possible the size changes caused by the movement of humidification, caused by the absorption of water into the fibre cement. To do this water repellents are included either in the paste or on the surface, or advantageously in both, which retard the penetration of water into the fibre cement or prevent it if it does not reach a sufficient pressure. These water repellents may be organic, inorganic or mixed.
The reduction of resistance to bending in the fibre cement is necessary since the movement of humidification never reduces completely and therefore the fibre cement sheet will always undergo small size changes. According to the force which the fibre cement exerts upon the natural stone, the latter will distort or not. Therefore, the distortion of the compound tile depends upon the resistance of the fibre cement: the greater the resistance the greater the distortion. The effects of a reduction in the resistance of fibre cement which is pressed and cured in an autoclave, mainly by reducing the percentage of cement and cellulose in accordance with the invention to values of 32-34% and 4-5% respectively, causes a significant increase in density and a reduction in bending resistance from values which are typical of fibre cement which is pressed and cured in an autoclave of 22 Mpa to values of 12 Mpa.
A fibre cement is known in the state of the art, with a low fibre content as described in patent application EP484283 filed by Tappa. In said patent application a manufacturing process for asbestos-free fibre cement is described which uses a completely different technology, air curing, giving rise to a type of fibre cement of lower quality and reliability, whose application as a supporting sheet is neither mentioned nor suggested, not being appropriate for this purpose, but only as a covering. Said fibre cement is made up of cellulose fibres, Portland cement, flocculant and strengthening fibres of polyvinyl alcohol. After mixing the different components, the compound is introduced in controlled temperature conditions but without subjecting it to chemical treatment or pre-treatment, nor, in contrast to the type of fibre cement used, to the pressing and curing operations in autoclave necessary for the objects of the present invention.
As a result of the foregoing changes in accordance with the principles of this invention, a fibre cement sheet is obtained which fails to comply with the typical characteristics of the same for covering facades, and as such, when laid out in the form of a sheet is extremely weak and fragile, the decrease in cement and fibre being as great as possible, provided that it allows handling and cutting operations to be carried out, but when adhering to a natural stone plate it increases the strength of the latter, allowing thicknesses which are impossible to use without the sheet described above and with a minimum of distortion due to humidity or temperature.
The supporting sheet is made up of a light sheet of reduced thickness, comprising a mixture of cement (20-35%), silica (40-50%), sand (5-10%) and cellulose fibre (4-8%), similar to fibre cement but with mechanical and chemical features which are different from the standard ones of fibre cement, obtained by pressing and autoclave curing. As described above, in order to reduce the movement of humidification, sand and stabilising and water-repelling agents are added to the paste or to the surface of the exposed faces of the tile. The cement and fibre content is very low in comparison with the standard amounts of fibre cement which is pressed and cured in an autoclave, but high enough to allow cutting and handling operations of the light sheet so that it may be stuck to the natural stone plate as described below. The reduction in cement and fibre content provides a high density in relation to other fibre cements and, as described above, a reduction in bending resistance and a reduction in the movement of humidification. Another additive which may be added to the supporting sheet mixture is a pigment which is, for example, stable in light, with the possible purpose of differentiating some compound tiles from others so that they will withstand conditions out of doors.
As mentioned above, the compound tile consists of a supporting sheet and a natural stone plate, which adhere together by means of an epoxy resin with two components, which incorporates a percentage of micro-granules or micro-nodules with a determinate diameter.
The supporting sheet of the natural stone plate is used to manufacture compound tiles in a manufacturing process made up of different stages:
from a block of natural stone, plates are cut with a thickness of more than twice that of the final thickness of the natural stone plate of the tile to be obtained;
a firm union by means of adhesive and compression of a supporting sheet to each face of said plate cut in the previous stage, forming a module with a natural stone plate sandwiched between two layers of fibre cement and subsequent curing of the adhesive;
cutting of said natural stone plates of said module into two, through the middle plane, to obtain two compound tiles, maintaining said module held and subjected to compression of the supporting sheets against the intermediate plate of natural stone; and
shaving and polishing of the resulting natural stone visible face.
In order to carry out the process described above, the sheets of pressed and cured fibre cement are arranged in large sheets. From said sheets the sheets are obtained which will serve as a support for the natural stone plate by means of cutting according to the size of the natural stone plate. Said fibre cement sheets are to be dry and clean since in order to stick the natural stone to the supporting sheet, the faces which are to be stuck must, at the time they are joined, be clean, dry (by means of an appropriate prior process) and at a determinate temperature so that the application of glue as well as the subsequent sticking and permanent adhesion are optimal. An epoxy adhesive with two components is used for this operation. The supporting sheets or fibre cement stick to each one of the two faces of the natural stone plate, thus forming modules of fibre cement-natural stone-fibre cement.
For adhesion to be perfect, there must be a permanent gap or space between the two faces, as during the adhesive curing process several modules of fibre cement-natural stone-fibre cement are stacked and a certain pressure is exerted upon the same. In the event that this gap or space were not present, a large part of the adhesive would be expelled due to the pressure exerted by some modules upon others and due to the pressure exerted by additional means upon the whole stack. Said space is ensured by means of a fibreglass or cellulose mesh soaked in the adhesive and arranged between the supporting sheet and the natural stone plate or by means of micro-granules or micro-nodules incorporated by dispersion in the adhesive.
When the supporting sheet is superimposed on the natural stone plate, a relative movement occurs between both plates, enhanced by the presence of uncured adhesive. To prevent this movement holding means are provided between both plates.
As mentioned above, when pressure is applied on the stack of modules, the surplus adhesive used is expelled and may slide down the stack of modules, sticking not only the components of the same module, but also sticking components of different modules to each other, it being impossible or very difficult to separate them subsequently, or requiring machine work such as milling or sanding. To prevent this problem, the lower supporting sheet of each one of the modules has a larger surface size than the other sheet of fibre cement and larger than the natural stone plate, and is provided with additional shapes at its periphery which serve to retain the surplus resin when said pressure is applied to the stack of modules. Said additional shapes consist of peripheral channels and/or an adhering perimetric strip which prevent the surplus resin which is expelled when the modules are compressed from sliding down the stack of modules and causing the problem described above.
After stacking the modules and exerting permanent vertical pressure upon the stack, for example by means of bracing means which relate the upper sheet of fibre cement of the module situated at the highest position in the stack with the lower sheet of fibre cement of the module situated at the lowest position of the stack, the modules are introduced into an oven for curing the adhesive between the natural stone plates and the sheets of fibre cement at a determinate temperature and for a determinate time.
After curing the adhesive, the manufacturing process continues by cutting the natural stone plates of a module into two through a middle plane, thus obtaining two compound tiles, after which the visible face of each tile is shaved and polished.
DESCRIPTION OF THE DRAWINGS
To assist understanding of this invention which concerns a compound tile with a natural stone visible face and a manufacturing process, 7 drawings are attached to the present patent application, whose purpose is to promote a better understanding of the principles on which the present invention is based and a more complete understanding of the description of a preferred embodiment, taking into account that the nature of the drawings is illustrative and non-restrictive.
FIG. 1 shows a lower sheet of fibre cement with a section in which the strip retaining the adhesive may be observed.
FIG. 2 shows a lower sheet of fibre cement with channels for retaining adhesive.
FIG. 3 shows a stack of modules, fibre cement-marble-fibre cement, in which one may observe a detail of the lower sheet of fibre cement with retention channels.
FIG. 4 shows a detail of a finished compound tile.
FIG. 5 shows a detail of the glue contact points for placing the sheets of fibre cement upon and under the marble, thus preventing their relative movement.
FIGS. 6 and 7 show two consecutive operations of the cutting process of a module of fibre cement-marble-fibre cement into two tiles with a visible marble face.
DESCRIPTION OF A PREFERRED EMBODIMENT
The present invention will be better understood from the following detailed description showing the main characteristics of the compound tile with a visible natural stone face 3 and its manufacturing process.
The compound tile is made up of a natural stone plate 3 , preferably marble, and a supporting sheet 1 , 2 , a fibre cement compound whose composition is as follows:
silica, between 40 and 50% by weight with respect to the total composition,
cement, between 32 and 34% by weight with respect to the total composition,
sand, between 4 and 6% in weight with respect to the total composition, with a grain size of 0.1 mm.
cellulose fibre, less than 6% by weight and preferably between 4 and 5% by weight with respect to the total composition.
size stabilising agents, between 2 and 8% by weight with respect to the total composition, said agents being preferably alumina, kaolin and mixtures thereof.
water-repellents, between 1 and 3% by weight with respect to the total composition, belonging to the siliconate group, preferably potassium methyl siliconate at a 15% concentration dissolved in water and applied to the surface with a ratio of 0.3 and 0.4 l/m 2 .
Using these percentages, size stability of the fibre cement sheet 1 , 2 can be increased as the movement of humidification is reduced from 0.45% to 0.30% after an accelerated ageing process.
Another component which may be added to the mixture is a pigment of synthetic iron oxide which is useful in that it enables one tile to be distinguished from another, for example when a different pigment is used for each colour of the marble 3 or for protection against the elements.
For adhesion between the two materials, the marble plate 3 and the fibre cement sheet 1 , 2 , the compound tile uses an adhesive, preferably epoxy resin with two components 8 which has micro-granules or micro-nodules in its composition with a mean diameter of 0.1 mm. The purpose of said micro-granules is to ensure a space between the marble plate 3 and the supporting sheet in order to ensure a minimum adhesive layer, as this is necessary due to the processes explained below.
The manufacturing process of the compound tiles with marble visible face 3 is carried out in the following stages:
from a block of marble, plates are cut with a thickness of more than twice that of the final thickness of the marble plate 3 of the tile to be obtained;
a firm union by means of adhesive and compression of a supporting sheet 1 , 2 to each face of said plate cut in the previous stage, forming a module with a marble plate 3 sandwiched between two layers of fibre cement 1 , 2 and subsequent curing of the adhesive 8 ;
cutting 7 of said marble plates of said module into two, through a middle plane parallel to the strengthening sheets, to obtain two compound tiles, maintaining said module held and subjected to compression of the supporting sheets 1 , 2 against the intermediate plate of marble 3 ; and
shaving and polishing of the resulting marble visible face 3 .
The following description will focus on the process of sticking the marble plates 3 to the fibre cement. To do this, before adhesion the fibre cement sheets 1 , 2 must be clean, that is free from dust, dry (by means of an appropriate conventional prior process) and at a temperature between 20 and 40° C. to achieve optimal adhesion. After this treatment, the components are stacked to form modules. Each module is made up of a supporting lower sheet 2 with a larger surface size than the following ones, the marble plate 3 on the lower sheet 2 and a supporting upper sheet 1 on the marble plate 3 , forming modules of fibre cement-marble-fibre cement. These materials are stuck together, as mentioned above, by means of an epoxy resin with two components 8 , but when a plate of material is superimposed upon another, due to the presence of this adhesive 8 a relative movement between the two materials occurs, for which reason strips of fast contact glue 6 are used as auxiliary elements to ensure the position and subsequently the resin 8 undergoes curing. The adhesive 8 is provided with micro-granules so that during subsequent stacking it is not completely expelled by the effect of the pressure exerted; due to the micro-granules a sufficient amount of the adhesive 8 remains inside for sticking evenly.
The lower fibre cement sheet 2 of each module, having a greater surface area than the others, has means 4 , 6 to retain the resin 8 in each module, preventing said resin from making contact with the other modules. Said retention means consist of peripheral channels 4 with a depth of 1 to 1.2 mm or a peripheral strip 6 with a height of 3 mm, preferably made of wax.
Once the adhesive 8 is applied, between fifteen and thirty modules of fibre cement-marble-fibre cement are stacked and vertical pressure is applied which is maintained by means of, for example, braces which relate the lower fibre cement sheet 2 of the module situated at the base of the stack of modules with the upper fibre cement sheet 1 of the module situated uppermost in the stack.
When the foregoing pressure, variable between 1000 N/m 2 and 2000 N/m 2 , is applied (if it were greater the marble plate 3 would break), the resin 8 between a marble plate 3 and the fibre cement sheet spills out, and is trapped by the channels 4 or by the strip 6 . If these retention means did not exist, the resin 8 would descend the sides of the modules sticking different modules to each other.
After stacking, the stacks of modules are introduced into an oven with controlled humidity for curing the adhesive at a temperature ranging between 50 and 60° C. for approximately 1 to 2 hours.
In this way the module of fibre cement-marble-fibre cement is obtained and treated in one of the conventional machines in the natural stone industry, called a splitter, which by means of diamond discs separates this piece into two halves. In this way two compound marble tiles are obtained which are strongly stuck to a fibre cement sheet 1 , 2 .
The final product of this process is a square or rectangular tile whose usual formats are:
30×30 cm
30.5×30.5 cm (12″×12″)
33×33 cm
40×40 cm
40.6×40.6 cm
45.7×45.7 cm
30×60 cm
30.5×61 cm (12″×24″)
33×66 cm
50×50 cm
60×60 cm
61×61 cm (24″×24″)
The thicknesses based on the resulting plates of natural stone with a thickness of 7 mm, will be the result of adding the applied fibre cement sheet, according to the following variants:
Natural Stone
Fibre cement
Total
7 mm +
2 mm =
9 mm
7 mm +
2.5 mm =
9.5 mm
7 mm +
3 mm =
10 mm
7 mm +
3.5 mm =
10.5 mm
7 mm +
4 mm =
11 mm
7 mm +
4.5 mm =
11.5 mm
7 mm +
5 mm =
12 mm
After the processes of smoothing, calibration and polishing of the resulting tiles, the natural stone plate has a thickness of 6 mm, with a perfectly polished surface and a slight bevel on its four edges. The rest of the thickness corresponds to the adhesive and the supporting fibre cement sheet.
The following objects are thus basically achieved:
1) natural stone tiles which are very strong, manageable, more easy to position and reliable.
2) better use of the processed natural stone.
3) application of marble slabs with a thickness of 2 cm for these purposes. | Compound tile with natural stone visible side, preferably marble, of the type comprising a plate of natural stone having a reduced thickness and firmly fixed by adhesive means to a rigidification supporting sheet, said support having a particular composition which is adapted to the physical characteristics of the natural stone plate. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 07/891,591 by Richard S. Withers and Guo-Chun Liang filed Jun. 1, 1992.
FIELD OF THE INVENTION
This invention relates to a superconducting magnetic probe coil used to detect magnetic resonances. More particularly, it relates to designs for a superconducting coil suitable for use as a detector in a magnetic resonance imaging system for medical or other applications.
BACKGROUND OF THE INVENTION
For certain applications, it is desirable to have a magnetic loop sensor, tuned by the addition of capacitance to resonate in the frequency range of 1-1000 MHz. In order to detect very weak magnetic fields such a sensor must generate extremely low levels of noise and consequently must have extremely low resistance and hence low loss. The lowest loss sensors are made of superconductor materials. Until recently, all superconductor materials had to be cooled below 30 K. to operate as superconductors. This requirement added significantly to the cost and complexity of systems which relied on these materials. The sensor design described here is one appropriate to high temperature superconductors, i.e., superconductor materials whose superconducting transition temperature (critical temperature or T c ) is higher than 30 K. This latter class of materials, also known as cuprates, oxide superconductors and perovskites, is better suited to use in thin film form than in bulk forms. This physico-chemical difference necessitates new device and circuit designs to make these materials useful in superconducting applications. The design can also be fabricated using conventional superconductors, like niobium, which are available in thin film form.
For certain magnetic resonance imaging (MRI) applications, resonant frequencies of approximately 5 MHz and sufficiently low resistance that the coil has a resonant quality factor (Q) of not less than 10 4 , and even as high as 10 6 , are desired. The low resistances implied by these high values of Q ensure that the coil's internally generated thermal noise will be less than the noise generated by other noise sources within the imaging system, such as the tissue or object being imaged or the preamplifier coupled to the coil. To achieve such high Q, it is necessary that the equivalent series resistance of the LC resonator be less that approximately 100 μΩ to 1 mΩ. Such low resistance is achieved by the use of superconducting thin-film metallization in both the coil and the capacitor. A key advantage of this approach is that the sensor can be produced with a single superconductive film, and as a result it is more easily and reproducibly manufactured.
Several embodiments of this invention are disclosed herein. One embodiment of this invention consists of a multi-turn spiral coil (having inductance L) with an internal distributed interdigital capacitor (having capacitance C). The device operates in a self-resonant mode. One variation of this design has no connection between the inner end of the inductor coil and its outer end. Such a configuration is possible to fabricate in a single layer of superconductor with no crossover, that is, with no intervening dielectric layer.
An alternative design employs a single turn of interdigitated capacitor and has a crossover connection between the inner end of the inductor spiral and its outer end. This embodiment consists of a multi-turn spiral coil (having inductance L) connected to a surrounding interdigital capacitor (having capacitance C). It is useful for certain magnetic-resonance-imaging (MRI) applications, employing resonant frequencies of approximately 5 MHz, having an inductance of the order of 1 μH, and an equivalent series of 1 mΩ or less. The corresponding resonant quality factors (Qs) are 10 4 to 10 6 . Such low loss is achieved by the use of superconducting thin-film metallization in both the coil and the capacitor. Even the crossover (which connects to the inside end of the spiral coil and crosses over the other turns of the coil to reach one terminal of the capacitor) must be superconducting, which is achieved by the use of two thin films of superconductor with an intervening layer of insulating thin film. This design has a higher effective capacitance than does the single layer variant, which results in a lower resonant frequency. Because it does not require interdigital capacitors throughout the circuit, it can also be made with higher inductance than the single layer variant, allowing it to operate at lower frequencies at the expense of a crossover.
Other embodiments of the present invention employ two multi-turn spiral coils, placed in proximity to each other and with a sense of current flow such that their mutual inductance enhances their self inductances, coupled together by two annular capacitors at their inner and outer extremities in order to form a resonant circuit. Here the capacitance of the structure is increased in order to reduce the operating frequency. In these embodiments a key advantage is that the dielectric of the annular capacitors can be any suitable layer of material and can be made arbitrarily thin in order to reduce the resonant frequency.
DISCUSSION OF THE PRIOR ART
Previous resonant magnetic sensors for the detection of fields in the frequency range of 1 to 1000 MHz have been made using normal metals such as copper which are not superconducting. Because of the resistivity of copper, these sensors have been limited to resistances exceeding many mΩ and to quality factors of at most a few thousand. This is adequate for most applications, for example in MRI machines with very strong magnetic fields (approximately 1 Tesla or more), but not in applications in which the signal levels are low. Thin film versions of the sensors made with normal metals have even lower Qs, precluding the use of thin film technology.
This invention is different in that it uses superconducting materials to drastically improve the Q of the resonant sensor. High quality superconductors of the high temperature variety are most readily available in thin film (rather than bulk or wire) form. This requires a different physical design of inductor and capacitor than is used for a bulk, normal metal version. In the embodiment shown in FIG. 1, the inductor (which actually intercepts the magnetic signal) consists of a spiral of a few or several turns, and the capacitor consists of interdigitated combs distributed throughout the inductor. The spiral may be made of a true spiral, of spirally connected concentric circles, or of spirally connected line segments. The use of superconductive metallization is essential to achieving the low loss (and hence high Q) behavior of both the inductor and capacitor. Photolithographic techniques are utilized to pattern the circuit to dimensions of a few tens of micrometers, thereby precisely controlling the resonant frequency. Use of such techniques is not possible with the prior art bulk technology, nor is the prior art bulk technology applicable to these new high temperature superconductor materials.
While the embodiment of FIG. 1 shows a superconducting coil made from a single layer of superconductive material, it can also be advantageous to use a coil structure formed from two layers of superconductive material. When the two layers are separated by a dielectric layer the resonating capacitors of the device are formed through the dielectric layer by forming superconducting electrodes on opposite sides of the layer. Here the advantages of the superconductive material is preserved, while the design criteria for the capacitors are somewhat relaxed due to the more conventional geometry. For some applications it will be advantageous to fabricate two superconductive layers in order to enjoy more design flexibility for the capacitors.
OBJECTS AND ADVANTAGES
It is therefore an object of this invention to utilize a high temperature superconductor to obtain a very high quality factor magnetic resonance probe coil for use as a detector of small magnetic fields, either in medical applications or in other non-contact applications such as non-destructive evaluation (NDE). Not only does the use of a superconductor confer the advantage of low loss (high-Q) operation, but it offers a high Q in the relatively low frequency range, 1 to 1000 MHz, most useful for magnetic resonance imaging. The high critical temperature of the superconductor allows operation with much less stringent cooling requirements than earlier magnetic resonance detector systems, which were made with low critical temperature materials. Because earlier systems were unable to achieve the high quality factors of the current invention, very high magnetic fields were required for similar sensitivity. This necessitated the use of superconducting magnets, which were invariably cooled to less than 30 K. Such extreme cooling requirements resulted in large and ungainly systems in which the cooling subsystem was often larger than the detecting subsystem itself. The higher operating temperature of the current invention reduces the need for excessive real estate merely to house a refrigerator.
It is a further object of this invention to offer an easily manufacturable magnetic resonance probe coil. One embodiment, the interdigitated design, can be implemented in a single layer of superconducting material. It does not require two or more superconducting elements to pass each other without making electrical contact, and so it does not require the use of intermediate insulating layers. This elimination of a crossover reduces the number of required deposition steps to one, greatly increasing the manufacturing yield of the process. This design for manufacturability has never before been suggested for a magnetic resonance probe coil.
A second preferred embodiment, the dual-film design, also avoids a superconducting crossover, that is, an area in which two or more superconducting elements to pass each other without making electrical contact. In this design, two separate single layers of superconductive material are deposited, again profiting from simplicity of manufacturing. These layers are then placed on either side of an intermediate dielectric which can be chosen for optimal dielectric properties in this application, since there is no requirement for compatibility of the material with the superconductive layer or its processing steps. Furthermore, because the resonating capacitors are formed through the intermediate dielectric layer, the substrates onto which the superconductive layers are deposited need not have optimal dielectric properties since they are used only for mechanical support during crystal growth and subsequent processing.
Finally, a single layer design with a crossover is disclosed. This embodiment has a larger inductance, allowing it to operate at lower frequency. While the crossover adds processing complexity, the overall design remains simple and the lower frequency operation may be essential for some applications.
It is yet a further object of the invention to provide a broadened range of frequency of operation while maintaining acceptably low loss. The addition of a matching network, also made with superconducting material, allows operation over a frequency range up to 100 times the reciprocal of the quality factor of the probe coil, while adding only 13 dB of loss. It is the extremely small loss inherent in the superconducting coil and network that provide this flexibility.
SUMMARY
In brief, then, this application discloses a superconducting probe coil useful for detecting magnetic resonances in the 1 to 1000 MHz range. In one embodiment the coil is made from a single layer of high temperature superconductor, and operates at temperatures higher than 30 K. This coil is an interdigitated spiral and so does not require that the superconductor cross itself. Another embodiment employs two separately deposited layers of superconductor spaced apart by a dielectric layer. This coil also operates at temperatures above 30 K. and gives similar high-Q performance suitable for use in medical and other applications of low-signal MRI. Yet another embodiment is a coil with a crossover. The capacitor in this case is again interdigitated between turns of the inductive spiral, but here the digits are present only between the outer two turns of the spiral. The inner end of the spiral is then connected via a crossover to the outer end of the inductor.
We also disclose a superconductive matching network which couples the probe coil to an external preamplifier. This network broadens the bandwidth of the system by a factor of 100 or more while maintaining an acceptably low loss figure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a magnetic resonance probe coil with a five turn spiral inductor.
FIG. 2 is a schematic view of a magnetic resonance probe coil with a two turn spiral inductor made up of concentric arcs.
FIG. 3 is an enlargement of part of the probe coil of FIG. 2, showing more clearly the interdigitated capacitors.
FIG. 4 is the equivalent circuit diagram of the probe coil, with some of the repeated intermediate elements left out for clarity.
FIG. 5 is a detail of the equivalent circuit diagram of FIG. 4, showing some of the circuit parameters.
FIG. 6 is a simplified equivalent circuit diagram of the probe coil, where all of the capacitance of each turn is combined into a lumped capacitor.
FIG. 7 shows the frequency response of the probe coil of FIG. 2, when the substrate is LaAlO 3 and the coil is patterned in a thin film of YBa 2 Cu 3 O 7- δ.
FIG. 8 is a schematic view of the operating configuration of the probe coil in conjunction with a broadband matching network coupled to a preamplifier.
FIG. 9 is the equivalent circuit diagram of the matching network of FIG. 8.
FIG. 10 shows the calculated bandwidth response of the matching network of FIG. 9.
FIG. 11 is a schematic view of the pattern of superconductive material which forms one layer of the dual-film magnetic resonance probe coil.
FIG. 12 shows a schematic partial cross-section of the dual-film magnetic resonance probe coil showing the active parts of the coil.
FIG. 13 shows a schematic cross-section of the dual-film magnetic resonance probe coil showing the active parts of the coil supported by their respective substrates.
FIG. 14 is the equivalent circuit of the dual-film magnetic resonance probe coil. FIG. 14(a) is the equivalent circuit showing explicitly the mutual inductance of the two superconductive layers. FIG. 14(b) is a further simplified equivalent circuit in which the mutual inductance and the self-inductances have been lumped as have all the capacitances.
FIG. 15 is a schematic cross-section of the dual-film magnetic resonance probe coil where the substrates and superconductive films have been patterned to form an annulus.
FIG. 16 shows the frequency response of the probe coil of FIG. 13, when the substrates are LaAlO 3 , the coil is patterned in a thin film of YBa 2 Cu 3 O 7- δ, and the intermediate dielectric is a sapphire wafer 0.012" thick.
FIG. 17 is a schematic representation of a magnetic resonance probe coil employing the crossover design. FIG. 17(a) is a top view of the patterned superconductive layer while FIG. 17(b) is a schematic partial cross-sectional view.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The probe coil (20) of the first embodiment of this invention is illustrated in FIG. 1. The primary part of the resonant sensor is the spiral inductor (22), consisting of several turns of a superconducting film (24). These turns may be literally a spiral, or they may be concentric circles, slit over short parts of their circumference, and connected with primarily radial segments to effect a functional spiral, or they may even be straight line segments of decreasing length joined to effect a functional spiral. The particular embodiment illustrated in FIG. 1 is a spiral with five turns, while FIG. 2 shows a two-turn spiral made up of slit concentric circles.
Distributed throughout the inductor are interdigital capacitive elements (26). These elements may be formed, for example, by bringing narrow finger electrodes (28) from each turn of the spiral towards the neighboring turn(s) in an alternating fashion. An expanded view of these fingers can be seen in FIG. 3. A more conventional resonant probe coil configuration would use a separate inductor and capacitor. This conventional design would require a second layer of conductor to pass over the first layer without electrical connection. Because the second layer must in this application also be superconductive in order to not exceed the maximum allowable resistance, the structure would be much more difficult to produce. In the present invention a self-resonant mode of operation is achieved by distributing the capacitance throughout the inductance of the sensor coil.
FIG. 4 is an equivalent circuit model of the invention. The spiral inductor (22) is represented by a single inductor (30), which is tapped at numerous points (32) by the elements (34) of the distributed capacitor (36). An expanded view of the first few elements can be found in FIG. 5. The first terminal (38) is at the top and is labeled v 0 . The second terminal (40) of each elemental capacitor (34) is connected to another tap (32) on the inductor (30). In all cases the separation of the taps (32) to which a given elemental capacitor (34) is connected corresponds to one turn of the inductor (22). The last terminal (42) is at the bottom. The first and last terminals (38, 42) may be connected to a preamplifier (44) through a capacitor, or may be connected to nothing except by magnetic coupling.
The performance of the circuit can be analyzed by applying well known standard circuit theory to the equivalent circuit of FIG. 4, assuming a reasonable number of elemental capacitors (perhaps 10 to a few thousand). For the particular case in which there are N turns in the spiral, each turn having K interdigital capacitors (one per tap) of capacitance C, and all turns being approximately the same diameter so that all tap-to-tap-self-inductances L and mutual inductances M are approximately equal, the following difference equations apply: ##EQU1## where the loop currents i p and node voltages v p (0≦p≦KN;i 0 =0; v p =0 for p≦0; v p =v KN for p>KN) are as defined in FIG. 5. M sample and M coup are the mutual inductances between each loop element and the sample under examination and the preamplifier, respectively, and i sample and i coup are the currents in those elements. Note that, in FIG. 4, K=5.
Also note that, for this ideal planar coil, L=M=L s /K 2 , where L s is the inductance of a single loop.
Clearly Equations (1) and (2) can be generalized for cases in which the C, M, and L values vary from tap to tap.
Making the usual sinusoidal steady state assumption of v p =Re[V p e j ωt ] and i p =Re[I p e j ωt ], where V p and I p are complex numbers and j is √(-1), one can rewrite (1) and (2) as ##EQU2##
Alternatively, one may convert the discrete model to a continuous one, obtaining differential equations (5) and (6) below which correspond to (3) and (4) respectively: ##EQU3##
Equation (6) is valid only when there is no abrupt change between neighboring turns of the spiral; it is not accurate at the inner and outer turns of the probe coil. These two equations, however, make it clear (as do the corresponding difference equations) that the current is approximately constant along the length of the line, except at the inner and outer turns.
A further approximation provides more insight. Suppose that all capacitance in a single turn of the spiral is collected in a single lumped capacitance; this would be the case K=1 in the above analysis. The lumped element circuit of FIG. 6 results. For this circuit, with L p =M=L s , the single turn inductance, and C p =C, the following difference equations for the complex amplitudes result:
V.sub.p -V.sub.p-1 =jω[-MΣI.sub.q +M.sub.sample I.sub.sample +M.sub.coup I.sub.coup] for 1≦p≦N (7)
I.sub.p -I.sub.p-1 =jωC(V.sub.p -2V.sub.p-1 +V.sub.p-2) for 2≦p≦N (8)
and, at the end,
I.sub.1 =jωC(V.sub.1 -V.sub.0)
which can be applied to (8) to yield, by extension,
I.sub.p =jωC(V.sub.p -V.sub.p-1) for 1≦p≦N
From this equation, Equation (7) gives
(1-ω.sup.2 NCM)I.sub.p =ω.sup.2 C[M.sub.sample I.sub.sample +M.sub.coup I.sub.coup] (9)
From this it is clear that the current is constant along the length of the spiral and that the coil has a resonant frequency given by
ω.sub.res =ω.sub.s /N.sup.0.5 (10)
where ω s =(MC) -0 .5 is the single-turn resonant frequency.
A device has been designed using these principles and has been fabricated in a thin film of YBa 2 Cu 3 O 7- δ (YBCO) deposited on 5 cm-diameter LaAlO 3 . The design is shown in FIG. 2. A single turn inductance of 0.1 μH and a lumped single turn capacitance (half of the total device capacitance) of 0.6 nF is expected for this two turn coil, from which Equation (10) predicts a resonant frequency of about 15 MHz. A more precise analysis based on fully distributed capacitance (and differential equations similar to Equations 5 and 6) predicts a resonant frequency of 20 MHz and a current distribution which is approximately sinusoidal, being zero at the ends of the spiral inductor and having a single maximum near the midpoint of the length of the coil. The fact that the current distribution is unidirectional (i.e., at a given moment in time, the current flow at all points in the inductor has the same clockwise or counterclockwise sense) is very important in maximizing the sensitivity of the coil to external fields. The realization that the fundamental self-resonant mode has this property is nonobvious; in fact, it is contrary to the advice given by experts in the field that self-resonant modes are not useful for this purpose because of non-unidirectional current flow.
In practice, the sensor would be placed near the source of magnetic signal, as shown schematically in FIG. 8. In an MRI application, this would be the object to be imaged (48). Transfer of the signals in the sensor to the signal processing, display, and recording systems may be achieved by an appropriate matching network (50). For example, ohmic contacts may be placed on the two terminals of the outer turn of the inductor (52, 54). Direct electrical connection may be made to these terminals through a capacitor of relatively low value, ensuring that the resonator is not excessively loaded, and the signals from the circuit applied to an appropriate low noise amplifier. Alternatively, coupling to the circuit may be achieved inductively (as shown in FIGS. 4, 6, and 8), perhaps to a small normal-metal coil which is external to the cryogenic enclosure of the circuit.
The coupling schemes described above except for the one illustrated in FIG. 8 will yield a fractional coupling bandwidth of 1/Q 1 , where Q 1 is the loaded Q of the probe, which may be sufficient for the imaging application. If more bandwidth is required, a broadband matching network similar to the one shown schematically in FIG. 9 may be used. In this figure, the source, represented by the current source I s , conductance G s , and inductance L s , is coupled to the probe coil L p by the mutual inductance M s . A two-section matching network (L 2 and L 3 ) is magnetically coupled to the probe coil and to the preamplifier. This network can be designed (using techniques which have been developed for unrelated impedance-matching and filtering applications) to yield a bandwidth which is 100 or more times larger than the probe bandwidth 1/Q l , at the price of additional loss of signal energy at the preamplifier. Because noise from the source is also suppressed, this results in no loss of performance unless the preamplifier noise or probe and matching network noise becomes dominant. FIG. 10 shows the calculated performance of the circuit shown in FIG. 9. In this case, a 100-fold broadening in bandwidth is obtained at a cost of 13 dB in signal strength. Low-loss matching sections L 2 and L 3 are required, which mandates that these also be superconductive. The matching sections can in fact be similar in structure to the probe coil, possibly coupled to the probe coil through apertures in superconductive planes as shown in FIG. 8.
The matching network (50) shown schematically in FIG. 8 consists of a probe coupling loop (56), two matching coils (58, 60), two conducting shields (62, 64), and an output coupling coil (66). The conducting shields (62, 64) adjust the degree of coupling between the matching coils by changing their mutual inductance. To minimize the loss in the matching network (50), all of the shields and matching coils are superconductive. The matching network (50) is coupled to the output, a preamplifier, through a normal (non-superconductive) output coupling coil (66).
Other applications of such a low loss inductor, and LC circuit, include switching RF power supplies, such as are used in RF heating systems. In addition to the low loss, these applications require that the inductor be capable of handling relatively large currents.
The requirement of a very low loss substrate makes the requirement for only a single superconductive layer even more critical. Sapphire, a single crystal form of alumina (Al 2 O 3 ), has the lowest dielectric loss of any readily available substrate material. Sapphire is inexpensive, very stable mechanically, and available in a wide variety of shapes and sizes. Its thermal expansion coefficient, however, is poorly matched to those of the high temperature superconductors. As a result, superconducting films grown on sapphire substrates experience mechanical stress when thermally cycled. Thin films, up to a few hundred nanometers, can successfully withstand this stress, but the probability of damage to the superconducting properties of the film increases with the film thickness. If more than one layer of superconductor is required, the total thickness of the superconductive structure may exceed the critical thickness above which the superconductive properties degrade due to cracking or other types of mechanical failure.
Yet another advantage of this single layer design is the absence of crossovers. A structure in which one conducting layer passes over another without electrical connection is difficult to achieve epitaxially. In addition to the deposition and patterning of two conducting layers, an insulating layer deposition and patterning step is required. The complexity of this manufacturing process is much greater than for a process requiring only the deposition of a single conducting layer.
A design for the second embodiment of this invention appears in FIG. 11. A coil (70), in most cases of the spiral type, is formed in a layer of superconductive material. Viewed from above, it has a right- or left-handed nature, i.e., as one traces the spiral outward, one moves in either a clockwise or a counterclockwise direction. Its inner and outer ends (76, 74) are terminated in relatively large electrodes, preferably in the form of circular arcs, which form the upper electrodes of two electrodes, the inner capacitive electrode (76) and the outer capacitive electrode (74). Between the two electrodes (74, 76) is the spiral inductor (78).
The top coil (80) is placed on the upper side of the dielectric layer (72), as shown in the cross-sectional view of FIG. 12. A bottom coil (82), also formed in a layer of superconductive material, is placed on the bottom of the dielectric (72). This coil (82) is patterned so that, viewed from above the superconductor-dielectric-superconductor stack (88) the top coil (80) and the bottom coil (82) have opposite handedness. This relative handedness is critical to the operation of the coil (70). The two coils (80, 82) are also patterned so that the electrode (74, 76) of both films face each other. It is critical that the electrodes (74, 76) face each other to ensure that the total inductance of the series combination of the two inductors (78) (connected in series by the two capacitors (90, 92) formed by the terminating electrodes (74, 76)) is nearly four times the inductance of a single layer.
Depending on the application, the superconducting films (80, 82) may be deposited on either side of the same dielectric (72), as shown in FIG. 12, or they may be deposited on separate substrates (84, 86) and then placed with the superconducting films (80, 82) in contact with either side of a dielectric layer (72), as shown in FIG. 13. When the films (80, 82) are deposited on either side of the same dielectric (72), the dielectric (72) is limited to those which are compatible with epitaxial deposition of the superconducting material. The resulting structure is physically robust since all of the interfaces are epitaxial, and is virtually immune to microphonic effects. Alternatively, when the superconducting films (80, 82) are deposited on separate substrates (84, 86) they are then placed against the dielectric layer and held in place by mechanical means. This structure allows separate optimization of the substrates (84, 86) and the dielectric (72). The substrates (84, 86) can be chosen for their compatibility with high-quality crystal growth of the superconducting material without regard to their dielectric loss tangents. The dielectric (72), on the other hand, can be a very thin layer of low-loss material, such as polytetrafluoroethylene, which is not necessarily compatible with superconductor processing.
The equivalent circuit of the device is shown in FIG. 14(a). The self-inductance of each coil (80, 82) has the value L and the mutual inductance between the coils (80, 82) has the value M. In practice, the coils (80, 82) can be designed and located so the M is nearly equal to L, in which case the total circuit inductance L t , as shown in the even simpler equivalent circuit of FIG. 14(b), is nearly 4L. In an optimized design the capacitance of each annular capacitor (90, 92) is made equal to C, so that the effective circuit capacitance shown in FIG. 14(b) as C t is equal to C/2. Thus the resonant frequency of the probe coil has a radian value of ω=(2LC) -0 .5.
FIG. 15 depicts a variation of the embodiment shown in FIG. 13. The substrate material has been removed from the center of the wafers, where it is not needed to support the superconducting films and where the magnetic field is intense. This is done because materials such as LaAlO 3 have a significant magnetic loss tangent, resulting in an avoidable increase in loss, and hence noise, in the circuit. The dielectric layer may also be removed from that circular region in the center to further reduce loss and noise. The spiral inductor patterns can be made to have lines which are much wider than the spaces between them, reducing the fringing magnetic field between the turns of the spirals. This would reduce even further the amount of magnetic energy within the substrates.
FIG. 16 shows the performance of a probe coil as shown in FIG. 13. The substrates (84, 86) are LaAlO 3 5 cm in diameter. The superconducting material is YBa 2 Cu 3 O 7- δ, a high temperature superconductor. When the two superconducting films (80, 82) are placed in contact with either side of a sapphire wafer 0.012 inches thick, a quality factor of 14,000 at a fundamental resonant frequency of 6.52 MHz is observed.
A third embodiment of the invention is shown in FIG. 17. The top view, FIG. 17(a) shows the crossover coil (100) consisting of an interdigitated capacitor (102), a spiral inductor (104), and a crossover lead (106) which electrically connects the inner and outer ends of the spiral inductor (104). The partial cross-section of FIG. 17(b) shows the layered nature of the structure. A first superconducting layer (110) is deposited on the substrate (108) and is subsequently patterned to form the capacitor (102) and the inductor (104). Next, a dielectric layer (112) is deposited. This layer may be patterned or may cover the entire surface of the wafer. Finally, a second superconductive layer (114) is deposited and patterned to form the crossover lead (106).
To maintain the desired quality factor, the crossover lead (106) must be formed of a superconductive material, but it need not be the same material as used for the first superconductive layer (110). The necessity of forming a second superconducting layer (114) atop the dielectric layer (112) places restraints on the material that can be used for the dielectric layer (112). It must combine a low dielectric loss tangent with physical characteristics, such as lattice parameter and chemical composition, that are compatible with the deposition of a high-quality layer of superconducting material. If the second superconducting layer (114) is a high-T c superconductor like YBa 2 Cu 3 O 7- δ, then CeO2 is a good choice. The second superconductive layer (114) must be patterned to form a line between the inner and outer ends of the inductive spiral (104), since full coverage of the wafer with a conducting layer will interfere with the operation of the probe coil.
The primary part of the resonant sensor is the spiral inductor (104), consisting of several turns of a superconducting film (110). Using design techniques which are known to those skilled in the art, the inductor (104) can be designed to present the necessary effective area to the signal source, and its inductance L can be determined. In order to achieve resonance at the desired angular frequency ω=1/sqrt(LC), an interdigital capacitor (102) with appropriate capacitance C is formed in an annular pattern around the perimeter of the inductor (104). The width of this annulus, and the width of and spacing between the interdigital fingers, is determined by design techniques known to those skilled in the art. In this preferred embodiment, the capacitor (102) is formed using the same superconducting film as the inductor (104). The inductor (104) and capacitor (102) are connected in parallel by connecting the outer turn of the inductor (104) to the inner terminal of the capacitor (102) and, by the use of a crossover (106) formed from a second superconducting layer (114), connecting the inner turn of the inductor (104) to the outer electrode of the capacitor (102).
In this preferred embodiment, the capacitor (102) is not a complete annulus, but rather a slit annulus, and the outer terminal of the inductor (104) is connected to one side of the inner annular terminal of the capacitor (102) in such a manner that, as shown in the figure, the direction (clockwise or counterclockwise) of current flow in the inner terminal of the capacitor (102) is the same as the sense of current flow in the inductor (104). Similarly, the inner terminal of the inductor (104) is connected to one side of the outer annular terminal of the capacitor (102) in the manner which results in the current flow in the outer terminal of the capacitor (102) having the same sense as that in the inductor (104). In this way, effective area and sensitivity of the device to external magnetic fields is maximized, and low resonant frequencies are achieved with larger geometries in the capacitor.
The crossover (106) may be formed from a second superconducting film (114) which is deposited after the deposition and patterning of the superconducting film (110) which forms the capacitor (102) and inductor (104) and the deposition and patterning of the insulating film (112) which separates the two superconductors (110, 114). Alternatively, it may actually be a crossunder which is deposited and patterned first, followed by the deposition and patterning of the insulating film, followed finally by the deposition and patterning of the second superconducting film, which forms the inductor and capacitor.
In the preferred embodiment, the superconducting films are high-temperature superconductors which possess low radio-frequency surface resistance at temperatures of 77 K. or above. These materials include YBaCuO, TlBaCaCuO, BiSrCaCuO, and related perovskite compounds. Deposition may be by sputtering, laser ablation, evaporation, or chemical vapor deposition. The intervening dielectric layer may be LaAlO 3 , SrTiO 3 , MgO, CeO 2 , or other materials or combinations of layers of these materials.
In one preferred embodiment, the first superconducting film is deposited by laser ablation and patterned to form the crossunder, which is a single line with a typical length of 1 to 3 cm. Laser ablation is chosen for this layer because it can produce smooth films (upon which subsequent layers can be deposited) over these small areas. The insulating film is also deposited by laser ablation and patterned. The second superconducting film is deposited by sputtering, which is used because this technique has been shown to be capable of producing low-surface-resistance films over the necessary large areas (perhaps 5 to 10 cm).
Transfer of the signals in the sensor to the signal processing, display, and recording systems may be achieved by means known to those skilled in the art. Ohmic contacts may be placed on the two terminals of the parallel LC circuit. Direct electrical connection may be made to the circuit through a capacitor of relatively low value, ensuring that the resonator is not excessively loaded, and the signals from the circuit applied to an appropriate low-noise amplifier. Alternatively, coupling to the circuit may be achieved inductively, perhaps to a small normal-metal coil which is external to the cryogenic enclosure of the circuit, or first to a superconducting broadband matching network (within the cryogenic enclosure) and then to a normal-metal coil.
OPERATIONAL DESCRIPTION
In practice the probe coil is placed between a source and an output device or signal processing electronics. The source may be biological tissue, a weld in an airplane wing, or any other object capable of producing an alternating magnetic field. When the frequency of the source magnetic field is far away from the resonant frequency of the probe coil, very little signal energy is transferred to the output. Near this resonant frequency, however, large currents are induced in the probe coil and are coupled to the output. Because the probe coil need not be physically connected to either the source or the output, only the probe coil (and matching network, if any) need be cooled.
FIG. 7 shows the behavior of the sensor shown in FIG. 2 across its fundamental resonant mode. This sensor was fabricated by epitaxially depositing YBa 2 Cu 3 O 7- δ, a high temperature superconductor material with a critical temperature of about 90 K., onto a substrate of LaAlO 3 . The superconductor film was then subjected to conventional photolithography to form the pattern shown in FIG. 2. One room temperature single loop coil, just external to the cryogenic enclosure holding the sensor in liquid nitrogen at approximately 77 K., was driven by a synthesized frequency source. A second coil on the far side of the enclosure was connected to an oscilloscope to function as the output. The signal from the second coil drives the y axis of the scope, while the frequency generated by the synthesizer drives the x axis. The quality factor (Q) is equal to the peak frequency (f) divided by the full width of the frequency response (Δf) measured at half the maximum power. FIG. 7 shows that a quality factor of approximately 10,000 was achieved at the fundamental frequency of 18.5 MHz (compared to the 15 MHz predicted by Equation 10 and 20 MHz predicted by Equations 5 and 6.). A second device of identical design had a similar Q at a fundamental resonant frequency of 18.7 MHz. It is suspected that this slightly higher frequency was the result of a few broken fingers in the capacitor. These experimental results clearly show that Q factors within the desired range are achievable. It is anticipated that even higher values of Q will be attained using substrates with lower dielectric loss, such as sapphire.
The dual-film magnetic resonance probe coil of FIG. 13 operates is a similar fashion. Again the probe coil (70) is coupled to a signal source and a preamplifier as described above. Here, however, the coupling to the source is necessarily inductive and the coupling to the preamplifier is preferably inductive, although it may be made directly through a series capacitor of small value or a parallel inductance of small value. Moreover, the probe coil may be broadband matched by the use of multiple coupled resonators, as described above. (Broadband, in this context, means greater in bandwidth than the resonant frequency divided by the quality factor of the probe.) In this case the matching resonators as well as the probe are two-coil, dual-film structures.
FIG. 16 shows the behavior of the sensor shown in FIG. 13 across its fundamental resonant mode. This sensor was fabricated by epitaxially depositing YBa 2 Cu 3 O 7- δ, a high temperature superconductor material with a critical temperature of about 90 K., onto two substrates of LaAlO 3 . The superconductor film was then subjected to conventional photolithography to form the pattern shown in FIG. 11. One room temperature single loop coil, just external to the cryogenic enclosure holding the sensor in liquid nitrogen at approximately 77 K., was driven by a synthesized frequency source. A second coil on the far side of the enclosure was connected to an oscilloscope to function as the output. The signal from the second coil drives the y axis of the scope, while the frequency generated by the synthesizer drives the x axis. The quality factor (Q) is equal to the peak frequency (f) divided by the full width of the frequency response (Δf) measured at half the maximum power. FIG. 16 shows that a quality factor of approximately 14,000 was achieved at the fundamental frequency of 6.52 MHz. These experimental results clearly show that Q factors within the desired range are achievable.
The probe coil of FIG. 17 operates in a similar fashion to that of FIG. 2, with the exception of the connection of the inner and outer ends of the inductive spiral. This connection increases the inductance of the device, thus decreasing the operating frequency of the probe coil. In this embodiment using an interdigital capacitor, it is necessary that the dielectric substrate upon which the circuit is built have sufficiently low loss. It is not clear that LaAlO 3 or YSZ, upon which such multilevel structures can be fabricated, has sufficiently low loss. Sapphire is known to possess such low loss, but its small thermal expansion coefficient makes it difficult to produce multilevel structures. Use of a very thin (0.1 micron) crossunder may be necessary, or alternative processes may be needed in order to produce the envisioned circuit.
CONCLUSION, RAMIFICATIONS AND SCOPE
It is thus apparent that the magnetic resonance probe coil of the present invention offers superior performance and greater ease of manufacturing than were heretofore available. The use of a superconductor for the probe coil offers unprecedented sensitivity. Much smaller signals can therefore be detected making the use of extremely high magnetic fields unnecessary. This in turn eases the requirement for cryogenic cooling subsystems in MRI systems. Instead of cooling a large bank of superconducting magnets, only a relatively small probe coil must be chilled. Furthermore, the use of high temperature superconductors relaxes the cooling requirements even more. Rather than expensive and unwieldy cooling equipment necessary for operating temperatures below 30 K., inexpensive and plentiful liquid nitrogen can be used.
Another advantage that this magnetic resonance probe coil offers is ease of manufacturing. In one preferred embodiment, the structure contains only one superconductive layer atop a substrate. Multiple deposition and patterning steps are avoided, as are possible mechanical instabilities associated with complex multilayer structures. This embodiment allows for moderately low operating frequencies.
A second embodiment also avoids the use of a crossover structure while operating at even lower frequencies. The dual-film design involves the deposition and patterning of only two layers of superconducting material. Depending on the engineering capabilities and economic considerations of the manufacturer this structure can be made by the deposition of the superconducting films on either side of a single dielectric, or by the deposition of two superconducting layers on separate substrates and their subsequent mounting in contact with an intervening dielectric layer.
A third embodiment is formed in a multilayer structure comprising two layers of superconducting material separated by a dielectric film. Manufacturers with mature multilayer deposition processes may find this the best way of obtaining very low frequency operation, since a trilayer structure is still rather simple to fabricate.
The extremely high quality factor of the probe even makes is possible to broaden the bandwidth by using a matching network. Because the cost of higher bandwidth is generally a matching loss, the bandwidth can only be broadened with a low-loss matching network and, perhaps more importantly, a low-noise preamplifier. This combination of the magnetic resonance probe coil of the present invention with the low-loss matching network described above, then, allows the flexibility of detecting very weak signals over a broad frequency range, while offering detection of extremely weak signals over a narrower range as long as the preamplifier has sufficiently low noise.
Other applications of such a low-loss inductor, and LC circuit, include switching RF power supplies, such as are used in RF heating systems. In addition to the low loss, these applications require that the inductor be capable of handling relatively large currents.
While the above description contains many specific details, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one of its preferred embodiments. Many other variations are possible and will no doubt occur to others upon reading and understanding the preceding description. Accordingly, the scope of the invention should be determined not by the embodiment illustrated, but by the appended claims and their legal equivalents. | A magnetic resonance probe coil is fabricated using a superconductive material for the coil. Three distinct embodiments are described: a single-layer coil with no crossovers; a dual-film coil wherein the capacitors are formed through an intermediate dielectric layer; a single-layer coil incorporating a superconducting crossover. All of the embodiments are designed to take advantage of the properties of the superconducting material to achieve very high quality factors (Q) of tens of thousands to over a million. The superconductor is patterned into a spiral design to achieve self-resonance at a desired frequency in the range of 1 to 1000 MHz and the device operates at temperatures higher than 30 K. A broadband matching network is also disclosed which, when operated in conjunction with the superconducting magnetic resonance probe coil, allows operation over a wide range of frequencies while maintaining extremely low loss. | 8 |
FIELD OF THE INVENTION
This invention generally relates to the derivatives of novel 3,6 disubstituted azabicyclo[3.1.0]hexanes.
The compounds of this invention are muscarinic receptor antagonists which are useful, inter-alia for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems mediated through muscarinic receptors.
The invention also relates to processes for the preparation of the compounds of the invention, pharmaceutical compositions containing the compounds of the present invention and the methods of treating the diseases mediated through muscarinic receptors.
BACKGROUND OF THE INVENTION
Muscarinic receptors as members of the G Protein Coupled Receptors (GPCRs) are composed of a family of 5 receptor sub-types (M 1 , M 2 , M 3 , M 4 and M 5 ) and are activated by the neurotransmitter acetylcholine. These receptors are widely distributed on multiple organs and tissues and are critical to the maintenance of central and peripheral cholinergic neurotransmission. The regional distribution of these receptor sub-types in the brain and other organs has been documented. For example, the M 1 subtype is located primarily in neuronal tissues such as cereberal cortex and autonomic ganglia, the M 2 subtype is present mainly in the heart where it mediates cholinergically induced bradycardia, and the M 3 subtype is located predominantly on smooth muscle and salivary glands ( Nature, 1986; 323: 411; Science, 1987; 237: 527).
A review in Current opinions in Chemical Biology, 1999; 3: 426, as well as in Trends in Pharmacological Sciences, 2001; 22: 409 by Eglen et. al., describe the biological potentials of modulating muscarinic receptor subtypes by ligands in different disease conditions like Alzheimer's disease, pain, urinary disease condition, chronic obstructive pulmonary disease etc.
A review in J. Med. Chem., 2000; 43: 4333 by Christian C. Felder et. al. describes therapeutic opportunities for muscarinic receptors in the central nervous system and elaborates on muscarinic receptor structure and function, pharmacology and their therapeutic uses.
The pharmacological and medical aspects of the muscarinic class of acetylcholine agonists and antagonists are presented in a review in Molecules, 2001, 6: 142.
N. J. M. Birdsall et. al. in Trends in Pharmacological Sciences, 2001; 22: 215 have also summarized the recent developments on the role of different muscarinic receptor subtypes using different muscaranic receptor of knock out mice.
Muscarinic agonists such as muscarine and pilocarpine and antagonists is such as atropine have been known for over a century, but little progress has been made in the discovery of receptor subtype-selective compounds making it difficult to assign specific functions to the individual receptors. Although classical muscarinic antagonists such as atropine are potent bronchodilators, their clinical utility is limited due to high incidence of both peripheral and central adverse effects such as tachycardia, blurred vision, dryness of mouth, constipation, dementia, etc. Subsequent development of the quarterly derivatives of atropine such as ipratropium bromide are better tolerated than parenterally administered options but most of them are not ideal anti-cholinergic bronchodilators due to lack of selectivity for muscarinic receptor sub-types. The existing compounds offer limited therapeutic benefit due to their lack of selectivity resulting in dose limiting side-effects such as thirst, nausea, mydriasis and those associated with the heart such as tachycardia mediated by the M 2 receptor.
Annual review of Pharmacological Toxicol., 2001; 41: 691, describes the pharmacology of the lower urinary tract infections. Although anti muscarinic agents such as oxybutynin and tolterodine that act non-selectively on muscarinic receptors have been used for many years to treat bladder hyperactivity, the clinical effectiveness of these agents has been limited due to the side effects such as dry mouth, blurred vision and constipation. Tolterodine is considered to be generally better tolerated than oxybutynin. (W. D. Steers et. al. in Curr. Opin. Invest. Drugs, 2: 268, C. R. Chapple et. al. in Urology, 55: 33), Steers WD, Barrot DM, Wein AJ, 1996, Voiding dysfunction: diagnosis classification and management. In Adult and Pediatric Urology, ed. JY Gillenwatter, JT Grayhack, SS Howards, JW Duckett, pp 1220-1325, St. Louis, Mo.; Mosby. 3 rd edition.)
Despite these advances, there remains a need for development of new highly selective muscarinic antagonists which can interact with distinct subtypes, thus avoiding the occurrence of adverse effects.
Compounds having antagonistic activity against muscarinic receptors have been described in Japanese patent application Laid Open Number 92921/1994 and 135958/1994; WO 93/16048; U.S. Pat. No. 3,176,019; GB 940,540; EP 0325 571; WO 98/29402; EP 0801067; EP 0388054; WO 9109013; U.S. Pat. No. 5,281,601. U.S. Pat. Nos. 6,174,900, 6,130,232 and 5,948,792; WO 97/45414 are related to 1,4-disubstituted piperidine derivatives; WO 98/05641 describes fluorinated, 1,4-disubstitued piperidine derivatives; WO 93/16018 and WO96/33973 are other close art references.
A report in J. Med. Chem., 2002; 44:984, describes cyclohexylmethyl piperidinyl triphenylpropioamide derivatives as selective M 3 antagonist discriminating against the other receptor subtypes.
SUMMARY OF THE INVENTION
The present invention provides novel fluoro and sulphonylamino containing 3,6-disubstituted azabicyclo[3.1.0]hexanes as muscarinic receptor antagonists which are useful as safe and effective therapeutic or prophylactic agents for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems and process for the synthesis of the novel compounds. Substitution on the cycloalkyl moeity improves both metabolic stability as well as subtype selectivity.
The invention also provides pharmaceutical compositions containing the novel compounds together with acceptable carriers, excipients or diluents which are useful for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems.
The present invention also includes within its scope prodrugs of the novel compounds. In general, such prodrugs will be functionalized derivatives of these compounds which readily get converted in vivo into the defined compounds. Conventional procedures for the selection and preparation of suitable prodrugs are known to the artisan skilled in the art.
The invention also includes the enantiomers, diastereomers, N-oxides, polymorphs, pharmaceutically acceptable salts and pharmaceutically acceptable solvates of these compounds as well as metabolites having the same type of activity.
The invention further includes pharmaceutical compositions comprising the compounds of the present invention, their prodrugs, metabolites, enantiomers, diastereomers, N-oxides, polymorphs, solvates or pharmaceutically acceptable salts thereof, in combination with a pharmaceutically acceptable carrier and optionally included excipients.
Other advantages of the invention will be set forth in the description which follows, and in part will be apparent from the description or may be learnt by the practice of the invention. The objects and the advantages of the invention may be realized and obtained by means of the mechanisms and combinations pointed out in the appended claims.
In accordance with one aspect of the present invention, there is provided a compound having the structure of Formula I:
and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, esters, enantiomers, diastereomers, N-oxides, polymorphs, prodrugs, metabolites, wherein
Ar represents an aryl or a heteroaryl ring having 1-2 hetero atoms selected from the group consisting of oxygen, sulphur and nitrogen atoms, the aryl or heteroaryl rings may be unsubstituted or substituted by one to three substituents independently selected from lower alkyl (C 1 -C 4 ), lower perhalo alkyl (C 1 -C 4 ), cyano, hydroxy, nitro, lower alkoxy (C 1 -C 4 ), lower perhalo alkoxy (C 1 -C 4 ), unsubstituted amino, N-lower alkyl (C 1 -C 4 ) amino or N-lower alkyl (C 1 -C 4 ) amino carbonyl; R 1 represents a hydrogen, hydroxy, hydroxymethyl, amino, alkoxy, carbamoyl or halogen (e.g. fluorine, chlorine, bromine and iodine); R 2 represents C 3 -C 7 cycloalkyl ring in which from 1 to 4 hydrogen atoms are substituted with fluorine atoms, or sulphonamide derivatives; W represents (CH 2 ) p , where p represents 0 to 1; X represents an oxygen, sulphur, nitrogen or no atom; Y represents CHR 5 CO wherein R 5 represents hydrogen or methyl or (CH 2 ) q wherein q represents 0 to 4; Z represents oxygen, sulphur or NR 10 , wherein R 10 represents hydrogen, C 1-6 alkyl; Q represents (CH 2 ) n wherein n represents 1 to 4, or CHR 8 wherein R 8 represents H. OH, C 1-6 , alkyl, alkenyl, alkoxy or CH 2 CHR 9 , wherein R 9 represents H, OH, lower alkyl (C 1 -C 4 ) or lower alkoxy (C 1 -C 4 ); R 6 and R 7 are independently selected from H, CH 3 , COOH, CONH 2 , NH 2 , CH 2 NH 2 ; and R 4 represents a C 1 -C 15 saturated or unsaturated aliphatic hydrocarbon group in which from 1 to 6 hydrogen atoms may be substituted with the group independently selected from halogen, arylalkyl, arylalkenyl, heteroarylalkyl or heteroarylalkenyl having 1 to 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulphur atoms with an option that any 1 to 3 hydrogen atoms on the ring in said arylalkyl, arylalkenyl, hetero arylalkenyl group may be substituted with lower alkyl (C 1 -C 4 ), lower perhalo alkyl (C 1 -C 4 ), cyano, hydroxyl, nitro, lower alkoxycarbonyl, halogen, lower alkoxy (C 1 -C 4 ), lower perhaloalkoxy (C 1 -C 4 ), unsubstituted amino, N-lower alkylamino (C 1 -C 4 ), N-lower alkylamino carbonyl (C 1 -C 4 ).
In accordance with a second aspect of the present invention, there is provided a compound having the structure of Formula II (Formula I, when R 6 and R 7 =H) and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, esters, enantiomers, diastereomers, N-oxides, polymorphs, prodrugs, metabolites, wherein Ar, R 1 , R 2 , W, X, Y, Z, Q, and R 4 are as defined for Formula I.
In accordance with a third aspect of the present invention there is provided a compound having the structure of Formula III (Formula I wherein W is (CH 2 ) p where p=0, X is no atom and Y is (CH 2 ) q where q=0, R 6 =H, R 7 =H) and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, esters, enantiomers, diastereomers, N-oxides, polymorphs, prodrugs, metabolites, wherein Ar, R 1 , R 2 , Z, Q and R 4 are as defined for Formula I.
In accordance with a fourth aspect of the present invention, there is provided a compound having the structure of Formula IV [Formula I when W is (CH 2 ) p where p=0, X is no atom and Y is (CH 2 ) q where q=0, R 6 =H, R 7 =H, R 2 =
where R 11 is hydrogen or fluoro, R 12 is fluoro or sulphonamide derivatives and s represents 1 to 2, R 1 is hydroxy, Ar is phenyl], and its pharmaceutically acceptable salts, pharmaceutically acceptable solvates, esters, enantiomers, diastereomers, N-oxides, polymorphs, prodrugs, metabolites, wherein R 4 , Z and Q are the same as defined for Formula I.
In accordance with a fifth aspect of the present invention, there is provided a method for treatment or prophylaxis of an animal or human suffering from a disease or disorder of the respiratory, urinary and gastrointestinal systems, wherein the disease or disorder is mediated through muscarinic receptors.
In accordance with a sixth aspect of the present invention, there is provided a method for treatment or prophylaxis of an animal or human suffering from a disease or disorder associated with muscarinic receptors, comprising administering to a patient in need thereof, an effective amount of muscarinic receptor antagonist compound as described above.
In accordance with a seventh aspect of the present invention, there is provided a method for treatment or prophylaxis of an animal or human suffering from a disease or disorder of the urinary system which induce such urinary disorders as urinary incontinence, lower urinary tract symptoms (LUTS), etc.; respiratory system disorders such as bronchial asthma, chronic obstructive pulmonary disorders (COPD), pulmonary fibrosis, etc.; and gastrointestinal system disorders such as irritable bowel syndrome, obesity, diabetes and gastrointestinal hyperkinesis with compounds as described above, wherein the disease or disorder is associated with muscarinic receptors.
In accordance with the eighth aspect of the present invention, there are provided processes for preparing the compounds as described above.
The compounds of the present invention are novel and exhibit significant potency in terms of their activity, which was determined by in vitro receptor binding and functional assays and in vivo experiments using anaesthetized rabbit. The compounds that were found active in in vitro assay were tested in vivo. Some of the compounds of the present invention were found to be potent muscarinic receptor antagonists with high affinity towards M 3 receptors. Therefore, the present invention provides the pharmaceutical compositions for the possible treatment for the disease or disorders associated with muscarinic receptors. In addition, the compounds of the present invention can be administered orally or parenterally.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the present invention may be prepared by techniques well known in the art and familiar to the average synthetic organic chemist. In addition, the compounds of the present invention may be prepared by the following novel and inventive reaction sequences:
The compounds of Formula I of the present invention may be prepared by the reaction sequence as shown in Scheme I. The preparation comprises condensing a compound of Formula V with the compound of Formula VI wherein
Ar represents an aryl or a heteroaryl ring having 1-2 hetero atoms selected from the group consisting of oxygen, sulphur and nitrogen atoms, the aryl or heteroaryl rings may be unsubstituted or substituted by one to three substituents independently selected from lower alkyl (C 1 -C 4 ), lower perhalo alkyl (C 1 -C 4 ), cyano, hydroxy, nitro, lower alkoxy (C 1 -C 4 ), lower perhalo alkoxy (C 1 -C 4 ), unsubstituted amino, N-lower alkyl (C 1 -C 4 ) amino or N-lower alkyl (C 1 -C 4 ) amino carbonyl; R 1 represents a hydrogen, hydroxy, hydroxymethyl, amino, alkoxy, carbamoyl or halogen (e.g. fluorine, chlorine, bromine and iodine); R 2 represents a C 3 -C 7 cycloalkyl ring in which from 1 to 4 hydrogen atoms are substituted with fluorine atoms, or sulphonamide derivatives; W represents (CH 2 ) p , where p represents 0 to 1; x represents an oxygen, sulphur, nitrogen or no atom; Y represents CHR 5 CO wherein R 5 represents hydrogen or methyl or (CH 2 ) q wherein q represents 0 to 4; z represents oxygen, sulphur or NR 10 , wherein R 10 represents hydrogen, C 1-6 alkyl; Q represents (CH 2 ) n wherein n represents 1 to 4, or CHR 8 wherein R 8 represents H, OH, C 1-6 , alkyl, alkenyl, alkoxy or CH 2 CHR 9 , wherein R 9 represents H, OH, lower alkyl (C 1 -C 4 ) or lower alkoxy (C 1 -C 4 ); R 6 and R 7 are independently selected from H, CH 3 , COOH, CONH 2 , NH 2 , CH 2 NH 2 ; and
P is any protecting group for an amino group, in the presence of a condensing agent to give a protected compound of Formula VII which on deprotection in the presence of a deprotecting agent in an organic solvent gives an unprotected intermediate of Formula VIII which is finally N-alkylated or benzylated with a suitable alkylating or benzylating agent, L-R 4 to give a compound of Formula I wherein L is any leaving group and R 4 represents C 1 -C 15 saturated or unsaturated aliphatic hydrocarbon groups in which any 1 to 6 hydrogen atoms may be substituted with the group independently selected from halogen, arylalkyl, arylalkenyl, heteroarylalkyl or heteroarylalkenyl having 1 to 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulphur atoms with an option that any 1 to 3 hydrogen atoms on the ring in said arylalkyl, arylalkenyl, hetero arylalkenyl group may be substituted with lower alkyl (C 1 -C 4 ), lower perhalo alkyl (C 1 -C 4 ), cyano, hydroxyl, nitro, lower alkoxycarbonyl, halogen, lower alkoxy (C 1 -C 4 ), lower perhaloalkoxy (C 1 -C 4 ), unsubstituted amino, N-lower alkylamino (C 1 -C 4 ), N-lower alkylamino carbonyl (C 1 -C 4 ).
P is any protecting group for an amino group for a compound of Formula V and is selected from benzyl and t-butyloxy carbonyl groups.
The reaction of the compound of Formula V with a compound of Formula VI to give a compound of Formula VII is carried out in the presence of a condensing agent which is selected from the group consisting of 1-(3-dimethylamino propyl)-3-ethyl carbodiimide hydrochloride (EDC) and 1,8-diazabicyclo [5.4.0]undec-7-ene (DBU).
The reaction of the compound of Formula V with a compound of Formula VI to give a compound of Formula VII is carried out in a suitable solvent selected from the group consisting of N,N-dimethylformamide, dimethylsulfoxide, toluene, and xylene at a temperature ranging from about 0-140° C.
The deprotection of the compound of Formula VII to give a compound of Formula VIII is carried out with a deprotecting agent which is selected from the group consisting of palladium on carbon, trifluoroacetic acid (TFA) and hydrochloric acid.
The deprotection of the compound of Formula VII to give a compound of Formula VIII is carried out in a suitable organic solvent selected from the group consisting of methanol, ethanol, tetrahydrofuran and acetonitrile at temperatures ranging from about 10-50° C.
The N-alkylation or benzylation of the compound of Formula VIII to give a compound of Formula I is carried out with a suitable alkylating or benzylating agent, L-R 4 wherein L is any leaving group known in the art, preferably selected from halogen, O-mestyl and O-tosyl group.
The N-alkylation or benzylation of the compound of Formula VIII to give a compound of Formula I is carried out in a suitable organic solvent such as N,N-dimethylformamide dimethylsulfoxide, tetrahydrofuran and acetonitriie, at temperatures ranging from about 25-100° C.
Suitable salts of the compounds represented by the Formula I were prepared so as to solubilize the compound in aqueous medium for biological evaluations. Examples of such salts include pharmacologically acceptable salts such as inorganic acid salts (e.g. hydrochloride, hydrobromide, sulphate, nitrate and phosphorate), organic acid salts (e.g. acetate, tartrate, citrate, fumarate, maleate, toluenesulphonate and methanesulphonate). When carboxyl group is included in the Formula I as a substituent, it may be an alkali metal salt (e.g. sodium, potassium, calcium, magnesium, and the like). These salts may be prepared by the usual prior art techniques, such as treating the compound with an equivalent amount of inorganic or organic, acid or base in a suitable solvent.
The compound of Formula IV [Formula I, when W is (CH 2 ) p where p=0, X is no atom, Y is (CH 2 ) p where q=O, R 6 =H, R 7 =H, R 2 =
where R 11 =H or F, R 12 =F and s represents 1 to 2,
R 1 =OH, Ar=phenyl] may be prepared by the following reaction sequence as depicted in Scheme-II
The preparation comprises condensing a compound of Formula IX with the compound of Formula X wherein Z, Q and s have the same meanings as defined earlier for Formula I, R 11 is hydrogen or fluoro and R 12 is fluoro. P is any protecting group for an amino group, in the presence of a condensing agent to give a protected compound of Formula XI which on deprotection in the presence of a deprotecting agent in an organic solvent gives an unprotected intermediate of Formula XIII which is finally N-alkylated or benzylated with a suitable alkylating or benzylating agent L-R 4 to give a compound of Formula IV wherein L is any leaving group and R 4 is defined above.
P is any protecting group for an amino group for a compound of Formula X and is selected from benzyl and t-butyloxy carbonyl groups.
The reaction of the compound of Formula IX with a compound of Formula X to give a compound of Formula XI is carried out in the presence of a condensing agent which is selected from the group consisting of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (EDC) and 1,8-diazabicyclo [5.4.0]undec-7-ene (DBU).
The reaction of the compound of Formula IX with a compound of Formula X to give a compound of Formula XI is carried out in a suitable solvent selected from the group consisting of N,N-dimethylformamide, dimethylsulphoxide, toluene, and xylene at a temperature ranging from about 0-140° C.
The deprotection of the compound of Formula XI to give a compound of Formula XII is carried out in a suitable organic solvent selected from the group consisting of methanol, ethanol, tetrahydrofuran and acetonitrile at temperatures ranging from about 10-50° C.
The deprotection of the compound of Formula XI to give a compound of Formula XII is carried out with a deprotecting agent which is selected from the group consisting of palladium on carbon, trifluoroacetic acid (TFA) and hydrochloric acid.
The N-alkylation or benzylation of the compound of Formula XII to give a compound of Formula IV is carried out with a suitable alkylating or benzylating agent, L-R 4 wherein L is any leaving group known in the art, preferably selected from halogen, O-mestyl and O-tosyl group.
The N-alkylation or benzylation of the compound of Formula XII to give a compound of Formula IV is carried out in a suitable organic solvent such as N,N-dimethylformamide, dimethylsulphoxide, tetrahydrofuran and acetonitrile, at temperatures ranging from about 10-100° C.
Suitable salts of the compounds represented by the Formula IV were prepared so as to solubilize the compound in aqueous medium for biological evaluations. Examples of such salts include pharmacologically acceptable salts such as inorganic acid salts (e.g. hydrochloride, hydrobromide, sulphate, nitrate and phosphorate), organic acid salts (e.g. acetate, tartrate, citrate, fumarate, maleate, toluenesulphonate and methanesulphonate). When carboxyl group is included in the Formula I as a substituent, it may be an alkali metal salt (e.g. sodium, potassium, calcium, magnesium, and the like). These salts may be prepared by the usual prior art techniques, such as treating the compound with an equivalent amount of inorganic or organic, acid or base in a suitable solvent.
Acid of Formula IX can be synthesized following the procedures described in J. Org. Chem., 2001; 66:6775; Bioorg. and Med. Chem. 2000; 8:825 and references cited therein.
The compound of Formula IV [Formula I, when W is (CH 2 ) p where p=0, X is no atom, Y is (CH 2 ) p where q=O, R 6 =R 7 =H, R 2 =
where R 11 =H or F, R 12 =F or sulphonamide and s represents 1 to 2, R 1 =OH, Ar=phenyl) can also be prepared by reaction sequence as shown in Scheme-III.
The preparation comprises condensing a compound of Formula IX with a compound of Formula XIII wherein Z, Q and R 4 have the same meanings as described earlier for Formula I.
The reaction of the compound of Formula IX with a compound of Formula XIII is carried out in the presence of a condensing agent which is selected from the group consisting of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (EDC) and 1,8-diazabicyclo [5.4.0]undec-7-ene (DBU).
The reaction of the compound of Formula IX with a compound of Formula XIII is carried out in a suitable solvent selected from the group consisting of N,N-dimethylformamide, dimethyl sulfoxide, toluene, and xylene at a temperature ranging from about 0-140° C.
The compound of Formula IV (Formula I, when W is (CH 2 ) p where p=0, X is no atom, Y is (CH 2 ) p where q=0, R 6 =R 7 =H, R 2 =
where R 11 =H, R 12 =substituted sulphonamide and s represents 1 to 2, R 1 =OH, Ar=phenyl) of the present invention may be prepared by the reaction sequence as shown in Scheme-IV. The preparation comprises condensing a compound of Formula XIV with a compound of Formula X, where Z and Q have the same meanings as described earlier for Formula I to give a compound of Formula XV. The starting compound of Formula XIV was prepared by the known procedure described in Bioorganic and Medicinal Chemistry, 2000; 8:825.
The compound of Formula XVI is obtained by the deprotection of Formula XV in an organic solvent in the presence of a deprotecting agent. The intermediate of Formula XVI is finally N-alkylated or benzylated with suitable alkylating or benzylating agent L-R 4 to give a compound of Formula XVII wherein L is any leaving group and R 4 is the same as defined above.
P is any protecting group for an amino group for a compound of Formula X and is selected from benzyl and t-butyloxy carbonyl groups.
The reaction of the compound of Formula XIV with a compound of Formula X to give a compound of Formula XV is carried out in the presence of a condensing agent which is selected from the group consisting of 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (EDC) and 1,8-diazabicyclo[5.4.0]undec-7-ene (DBU).
The reaction of the compound of Formula XIV with a compound of Formula X to give a compound of Formula XV is carried out in a suitable solvent selected from the group consisting of N,N-dimethylformamide, dimethylsulphoxide, toluene, and xylene at a temperature ranging from about 0°-140° C.
The deprotection of the compound of Formula XV to give a compound of Formula XVI is carried out in a suitable solvent selected from the group consisting of methanol, ethanol, tetrahydrofuran and acetonitrile at temperature ranging from about 10°-50° C.
The N-alkylation or benzylation of the compound of Formula XVI to give a compound of Formula XVII is carried out with a suitable alkylating or benzylating agent, L-R 4 where L is any leaving group, known in the art, preferably selected from halogen, O-mestyl and O-tosyl group.
The N-alkylation or benzylation of the compound of Formula XVI to give a compound of Formula XVII is carried out in a suitable organic solvent such as N,N-dimethylformamide, dimethylsulfoxide, tetrahydrofuran and acetonitrile, at a temperature ranging from about 10°-100° C.
The reduction of the compound of Formula XVII to give a compound of Formula XVIII is carried out with triphenylphosphine in the presence of a suitable organic solvent such as tetrahydrofuran and water.
The compound XVIII on treatment with acid chlorides in a suitable solvent selected from the group consisting of dichloromethane, dichloroethane and chloroform gives the compound of Formula IV.
The acid chlorides may be selected from the group consisting of phenylacetylchloride, 4-nitrophenyl sulfonyl chloride, benzene sulfonyl chloride, benzyloxyacetyl chloride, 4-methoxy phenylsulfonyl chloride and 4-bromophenylsulfonyl chloride.
Suitable salts of the compounds represented by the Formula IV were prepared so as to solubilize the compound in aqueous medium for biological evaluations. Examples of such salts include pharmacologically acceptable salts such as inorganic acid salts (e.g. hydrochloride, hydrobromide, sulphate, nitrate and phosphorate), organic acid salts(e.g. acetate, tartrate, citrate, fumarate, maleate, toluenesulphonate and methanesulphonate). When carboxyl group is included in the Formula I as a substituent, it may be an alkali metal salt (e.g. sodium, potassium, calcium, magnesium, and the like). These salts may be prepared by the usual prior art techniques, such as treating the compound with an equivalent amount of inorganic or organic, acid or base in a suitable solvent.
In the above schemes, where specific bases, condensing agents, protecting groups, deprotecting agents, N-alkylating benzylating agents, solvents etc. mentioned, it is to be understood that other bases, condensing agents, protecting groups, deprotecting agents, N-alkylating, benzylating agents, solvents etc. known to those skilled in the art may be used. Similarly, the reaction temperature and duration may be adjusted according to the desired needs.
Preferred compounds according to the invention and capable of being produced by Scheme I-IV and are shown in Table 1 include:
Compound
No.
Chemical Name
1A.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-
2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetamide
1B.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-
2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetamide
2.
(2R(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-
2-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenylacetamide
3.
(2Ror 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-
(aminomethyl)-yl]-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-
phenyl acetamide
4.
(2R or 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-
(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-
2-phenyl acetamide
5.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-phenyl acetylamino cyclopentyl]-2-hydroxy-
2-phenylacetamide
6.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-(4-nitrophenyl)sulphonylamino cyclopentyl]-2-
hydroxy-2-phenylacetamide
7.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-phenylsulphonylamino cyclopentyl]-2-
hydroxy-2-phenylacetamide
8.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-benzyloxyacetylamino cyclopentyl]-2-
hydroxy-2-phenylacetamide
9.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-(4-methoxyphenyl) sulphonylamino
cyclopentyl]-2-hydroxy-2-phenylacetamide
10.
(2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-
yl]-2-[(1R or 1S, 3R or 3S)-3-(4-bromophenyl)sulphonylamino cyclopentyl]-
2-hydroxy-2-phenylacetamide
Table I
Formula-IV
S.No.
R 11
R 12
Z
Q
R 4
1A
F
F
NH
CH 2
CH 2 Ph
1B
F
F
NH
CH 2
CH 2 Ph
2
H
F
NH
CH 2
CH 2 Ph
3
F
F
NH
CH 2
CH 2 Ph
4
H
F
NH
CH 2
CH 2 Ph
5
H
NH
CH 2
CH 2 Ph
6
H
NH
CH 2
CH 2 Ph
7
H
NH
CH 2
CH 2 Ph
8
H
NH
CH 2
CH 2 Ph
9
H
NH
CH 2
CH 2 Ph
10
H
NH
CH 2
CH 2 Ph
(Formula I, W is (CH 2 )p where p = 0, X is no atom, Y is (CH 2 )q
where q = 0, R 6 = R 7 = H, R 2 =
,
s = 1, R 1 = OH, Ar = phenyl)
Because of their valuable pharmacological properties, the compounds of the present invention may be adminisered to an animal for treatment orally, or by parenteral route. The pharmaceutical compositions of the present invention are preferably produced and administered in dosage units, each unit containing a certain amount of at least one compound of the invention and/or at least one physiologically acceptable addition salt thereof. The dosage may be varied over extremely wide limits as the compounds are effective at low dosage levels and relatively free of toxicity. The compounds may be administered in the low micromolar concentration, which is therapeutically effective, and the dosage may be increased as desired up to the maximum dosage tolerated by the patient.
The present invention also includes within its scope prodrugs of the compounds of Formula I, II, III and IV. In general, such prodrugs will be functional derivatives of these compounds, which readily are converted in vivo into the defined compounds. Conventional procedures for the selection and preparation of suitable prodrugs are known.
The present invention also includes the enantiomers, diastereomers, N-oxides, polymorphs, solvates and pharmaceutically acceptable salts of these compounds as well as metabolites having the same type of activity. The present invention further includes the pharmaceutical composition comprising the molecules of Formulae I, II, III and IV or prodrugs, metabolites, enantiomers, diastereomers, N-oxides, polymorphs, solvates or pharmaceutically acceptable salts thereof, in combination with pharmaceutically acceptable carrier and optionally included excipient.
The examples mentioned below demonstrate the general synthetic procedure as well as the specific preparation of the preferred compound. The examples are provided to illustrate the details of the invention and should not be constrained to limit the scope of the present invention.
EXPERIMENTAL DETAILS
Various solvents, such as acetone, methanol, pyridine, ether, tetrahydrofuran, hexane, and dichloromethane, were dried using various drying agents according to the procedure described in the literature. IR spectrum were recorded as nujol mulls or a thin neat film on a Perkin Elmer Paragon Instrument and Nuclear Magnetic Resonance (NMR) were recorded on a Varian XL-300 MHz instrument using tetramethylsilane as an internal standard.
EXAMPLE 1
Preparation of (2R)-(1α,5α,6α)-N-3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetamide (Compound Nos. 1A and 1B)
Step a: Preparation of (2R,5R)-2-tert-butyl-5-phenyl-1,3-dioxalan-4-one
The compound was synthesized following the procedure described in J. Org. Chem. 2000; 65:6283.
Step b: Preparation of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
To a suspension of the compound obtained at step a (1.36 mmol) in tetrahydrofuran (12 ml) was added lithium diisopropyl amide (LDA) in tetrahydrofuran (1.5 mmol) drop wise at −78° C. under nitrogen atmosphere. The reaction mixture was stirred at the same temperature for 2 hours. A solution of 2-cyclopenten-1-one (1.52 mmol) in tetrahydrofuran (2 ml) was added to the reaction mixture dropwise and stirred for additional 3 hours. The reaction mixture was quenched with saturated aqueous ammonium chloride solution and extracted with ethyl acetate. The organic layer was dried and the residue obtained after removing the solvents in vacuo was purified by column chromatography (100-200 mesh silica gel). The product was eluted with 10% ethylacetate-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.70-7.26 (m,5 Ar—H), 5.43-5.37 (d, 1H), 2.91-2.88 (m,1H), 2.37-1.77 (m, 6H), 0.92 (s, 9H) IR(DCM): 1791 and 1746 cm −1
Step c: Preparation of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
To a solution of the compound of step-b (1 mmol) in chloroform (15 ml) was added diethyl amino sulphur trifluoride (DAST), (3.3 mmol) at 0° C. under nitrogen atmosphere. The reaction mixture was stirred at the same temperature for 30 minutes and then at room temperature for 3 days. After being cooled to 0° C., the reaction mixture (RM) was quenched carefully by adding water. The organic layer was separated and the aqueous layer extracted with chloroform. The combined organic layers were dried and the residue obtained after removing the solvent was purified by column chromatography (100-200 mesh size silica gel) eluting the compound with 5% ethylacetate-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.73-7.35 (m, 5 Ar—H), 5.49 (s, 1H), 2.86-2.82 (m, 1H), 2.27-1.80 (m, 6H), 0.98 (s,H) IR(DCM): 1793 cm −1
Step d: Preparation of (2R) [(1S or 1 R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylaceticacid
The solution of the compound of step-c (1 mmol) in methanol (10 ml) was stirred with 3N aqueous sodium hydroxide solution for overnight at room temperature. The reaction mixture was concentrated under reduced pressure. The residue was diluted with water and extracted with dichloromethane. The aqueous layer was acidified with conc. hydrochloric acid and extracted with ethylacetate. The organic layer was dried and concentrated under reduced pressure to give the product.
m.pt.:123° C. 1 HNMR(CDCl 3 ) δ-values: 7.69-7.37(m, 5 Ar—H), 3.29-3.20(m, 1H), 2.39-1.68 (m, 6H)
Step e: Preparation of (1α,5α,6α)-6-aminomethyl-3-benzyl-3-azabicyclo[3.1.0]hexane
The compound was synthesized as per the procedure of EP0413455A2.
Step f: Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetamide
A solution of (2R)-[(1S or 1R)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid (1 mmol) and (1α,5α,6α)-6-aminomethyl-3-benzyl-3-azabicyclo[3.1.0]hexane(1.1 mmol) in DMF (10 ml) was cooled to 0° C. 1-Hydroxybenzotriazole (HOBT, 1.1 mmol) and N-methylmorpholine (NMM, 2 mmol) were added to the reaction mixture and reaction mixture stirred for 1 hour at 0° C. 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide (EDC.HCl) (1 mmol) was added to the reaction mixture at 0° C. The reaction mixture was stirred at 0° C. for 1 hour 30 minutes and then at room temperature for overnight. The reaction mixture was poured into saturated sodium bicarbonate solution and extracted with ethylacetate. The organic layer was washed with water and dried. The residue obtained after the removal of solvent was purified by column chromatography (100-200 mesh silica gel) eluting the compounds with 25-30% ethylacetate-hexane mixture.
Compound-1A:
1 HNMR (CDCl 3 ) δ-values: 7.58-7.22 (m, 10 ArH), 6.33 (bs, 1H), 3.56 (s, 2H), 3.30 (m, 1H), 3.05-2.89 (m, 4H), 2.32-2.29 (m, 2H), 2.16-1.21 (m, 9H) IR (KBr): 1654 cm −1
Compound-1B:
1 HNMR (CDCl 3 ) δ-values: 7.58-7.22 (m, 10 ArH), 6.39 (bs, 1H), 3.56 (s, 2H), 3.48 (m, 1H), 3.48 (m, 1H), 3.07-2.89 (m, 4H), 2.32-2.29 (m, 2H), 2.16-1.21 (m, 9H) IR (KBr): 1652 cm −1
Compound 1A and Compound 1 B are a Pair of Diastereomers.
EXAMPLE 2
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetamide (Compound No. 2)
Step-a: Preparation of (2R)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-hydroxy cyclopentyl]-5-phenyl-1,3-dioxalan-4-one
To a solution of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxalan-4-one (1 mmol) in methanol (10 ml) cooled to 0° C., sodium borohydride (2 mmol) was added in small lots with stirring. The reaction mixture was stirred at 0° C. for 1 hr. It was concentrated under reduced pressure and the residue diluted with water and extracted with ethylacetate. The organic layer was dried and the residue obtained after the removal of solvents was purified by column chromatography (100-200 mesh silica gel) eluting the compound with 20% ethylacetate-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.68-7.29 (m, 5H, ArH), 5.45 (d, 1H), 4.30 (m, 1H), 3.25 (m, 1H), 2.65-2.63 (m, 1H), 1.80-1.63 (m, 6H), 0.92 (s, 9H) IR(DCM): 1789 cm −1 , 3386 cm −1
Step-b: Preparation of (2R)-2-tert-butyl-5-[1R or 1S, 3R or 35]-3-fluorocyclopentyl]-5-phenyl-1,3-dioxolan-4-one
The solution of the compound of step-a (1 mmol) in chloroform (10 ml) was cooled to 0° C. and DAST (1.5 mmol) was added dropwise under nitrogen atmosphere. The reaction mixture (RM) was stirred at 0° C. for 30 minutes and then at room temperature for 3 days. The RM was cooled and carefully quenched with aqueous ammonium chloride solution. The organic layer was separated and aqueous layer extracted with ethylacetate. The combined organic layer was dried and residue obtained after removing the solvents was purified by column chromatography (100-200 mesh, silica gel) eluting the compound with 5% ethylacetate-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.68-7.28 (m, 5H, Ar—H), 5.46 (d, 1H), 5.39 (m, 1H), 2.90 (m, 1H), 1.98-1.25 (m, 6H), 0.93 (s, 9H)
Step-c: Preparation of (2R)-[(1R or 1S, 3R or 3S]-3-fluorocyclopentyl]-2-hydroxy-2-phenylacetic acid
The compound was synthesized following the procedure of Example 1, step-d using (2R,5R)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-5-phenyl-1,3-dioxolan-4-one instead of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyl]-5-phenyl-1,3-dioxolan-4-one.
1 HNMR(CDCl 3 ) δ-values: 7.66-7.27 (m, 5 Ar—H), 5.30-5.00 (m, H), 3.32-3.16 (m, 1H), 2.05-1.26 (m, 6H). IR(DCM): 1710 cm −1
Step-d: Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[1R or 1S, 3R or 3S]-3-fluorocyclopentyl]-2-hydroxy-2-phenylacetamide
The compound was synthesized following the procedure of Example 1, step-f, using (2R)-[(1R or 1S, 3R or 3S-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetic acid instead of (2R)-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid.
1 HNMR(CDCl 3 ) δ-values: 7.71-7.24 (m, 10H, Ar—H), 6.04 (b, 1H), 5.21-5.10 (m, 1H), 3.55 (s, 2H), 3.26-2.86 (m, 5H), 2.31-2.28 (m, 2H), 2.00-1.20 (m, 9).
EXAMPLE 3
Preparation of (2R or 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenyl acetamide (Compound No. 3)
Step a: Preparation of (2R or 2S,5R or 5S)-2-tert-butyl-5-phenyl-1,3-dioxalan-4-one
The compound was synthesized as per the procedure described in J. Org. Chem. 2000; 65:6283, using DL-Mandelic acid instead of R-(−)-Mandelic acid.
Step b: Preparation of (2R or 2S,5R or 5S)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
The compound was synthesized following the procedure of Example 1, step-b, using (2R or 2S, 5R or 5S)-2-tert-butyl-5-phenyl-1,3-dioxalan-4-one instead of (2R,5R)-2-tert-butyl-5-phenyl-1,3-dioxalan-4-one.
Step c: Preparation of (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
The compound was prepared following the procedure of Example 1, step-c, using (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxalan-4-one instead of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxalan-4-one.
1 HNMR(CDCl 3 ) δ-values: 7.67-7.29(m, 5 Ar—H), 5.34(s, 1H), 2.80-2.76(m, 1H), 2.23-1.70(m, 6H), 0.92(s, 9H)
Step d: Preparation of (2R or 2S,5R or 5S)-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid
The compound was synthesized following the procedure of Example 1, step-d-d, using (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyi]-5-phenyl-1,3-dioxalan-4-one instead of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one.
1 HNMR(CDCl 3 ) δ-values: 7.65-7.31 (m, 5 Ar—H), 3.23-3.14(m, 1H), 2.25-1.62(m 6H) IR (KBr): 1724 cm −1
Step e: Preparation of (2R or 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyly)-yl]-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenyl acetamide
The compound was synthesized following the procedure of Example 1, step-f, using (2R or 2S, 5R or 5S)-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid instead of (2R,5R)-2-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid.
1 HNMR(CDCl 3 ) δ-values: 7.58-7.23 (m, 10 Ar—H), 6.33 (bs, 1H), 3.56 (s, 2H), 3.47 (s, 1H), 3.33-3.25(m, 1H), 3.05-2.88(m, 4H), 2.31-2.28(m, 2H), 2.21-1.66(m, 9H) IR (KBr): 1652 cm −1
HPLC: Single compound (Diastereomers could not be separated).
EXAMPLE 4
Preparation of (2R or 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetamide (Compound No. 4)
Step a: Preparation of (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S, 3R or 3)-3-hydroxycyclopentyl]-5-phenyl-1,3-dioxalan-4-one
To a solution of (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S)-3-oxocyclopentyl]-5-phenyl-1,3-dioxolan-4-one (1 mmol) in methanol (10 ml)cooled to 0° C. Sodium borohydride (2 mmol) was added in small lots with stirring. The RM was stirred at 0° C. for 1 hour. It was concentrated under reduced pressure and the residue diluted with water and extracted with EtOAc. The organic layer was dried and the residue obtained after removal of solvents was purified by column chromatography (100-200 mesh silicagel) eluting the compound with 20% EtOAc-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.68-7.29(m, 5 Ar—H), 5.45(d, 1H), 4.3(m, 1H), −3.25(m, 1H), 2.65-2.63(m, 1H), 1.80-1.63(m, 6H), 0.92(s, 9H) IR (DCM): 1789 cm −1 , 3386 cm −1
Step b: Preparation of (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
A solution of the compound of step-a (1 mmol) in chloroform (10 ml) was cooled to 0° C. and DAST (1.5 mmol) was added dropwise under nitrogen atmosphere. The RM was stirred at 0° C. for 30 minutes and then at room temperature for 3 days. The RM was cooled and quenched with aqueous ammonium chloride solution. The organic layer was separated and aqueous layer extracted with EtOAc. The combined organic layers were dried and the residue obtained after removing the solvents was purified by column chromatography (100-200 mesh size, silica gel) eluting the compound with 5% EtOAc-hexane mixture.
1 HNMR(CDCl 3 ) δ-values: 7.69-7.23(m, 5 Ar—H), 5.42(d, 1H), 5.28-5.16(m, 1H), 2.92-2.86(m, 1H), 1.97-1.24(m, 6H), 0.90(s, 9H) IR (DCM): 1791 cm −1
Step c: Preparation of (2R or 2S)-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetic acid
The compound was synthesized following the procedure of Example 1, step-d, using (2R or 2S, 5R or 5S)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one instead of (2R,5R)-2-tert-butyl-5-[(1R or 1S)-3,3-difluorocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
1 HNMR(CDCl 3 ) δ-values: 7.66-7.25(m, 5 Ar—H), 5.304.99(m, 1H), 3.81-3.76(m, 1H), 2.01-1.64(m, 6H) IR (KBr): 1722 cm −1
Step d: Preparation of (2R or 2S)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetamide
The compound was synthesized following the procedure of Example 1, step-f, using (2R or 2S)-[(1R or 1S, 3R or 3S)-3-fluorocyclopentyl]-2-hydroxy-2-phenyl acetic acid instead of (2R)-[(1R or 1S)-3,3-difluorocyclopentyl]-2-hydroxy-2-phenylacetic acid.
1 HNMR(CDCl 3 ) δ-values: 7.66-7.25(m, 10 Ar—H),6.05(bs, 1H), 5.30-5.03 (m, 1H),3.98 (s, 2H), 3.56-2.87 (m, 5H), 2.31-2.28(m, 2H),1.97-1.11(m, 9H) IR (DCM): 1652 cm −1
EXAMPLE 5
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-phenylacetylamino cyclopentyl]-2-hydroxy-2-phenylacetamide (Compound No. 5)
Step a: Preparation of (2R,5R)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-azidocyclopentyl]-5-phenyl-1,3-dioxalan-4-one
To a solution of (2R,5R)-2-tert-butyl-5-[(1R or 1S, 3R or 3S)-3-hydroxycyclopentyl]-5-phenyl-1,3-dioxalan-4-one (1 mmol) and triethylamine (2.5 mmol) in ethyl acetate (10 ml) was added methane sulphonyl chloride (2 mmol) and the RM stirred for 1 hour at 0° C. and then at room temperature for 1 hour. Saturated aq. sodium bicarbonate solution was added, the organic layer separated and washed with water The organic layer was dried and the residue obtained after the removal of solvent was used as such for the next step.
The residue (1 mmol) was dissolved in DMF (10 ml) and to it sodium azide (4 mmol) was added. The RM was heated at 90-95° C. for 4 hours, cooled to room temperature, diluted with water and extracted with EtOAc. The organic layer was dried and the residue obtained after removing the solvent was used as such.
1 HNMR(CDCl 3 ) δ-values: 7.66-7.26 (m, 5 Ar—H), 5.40 (s, 1H), 4.00-3.97 (m, 1H), 2.83-2.78 (m, 1H), 1.80-1.04 (m, 6H), 0.93 (s, 9H) IR (DCM): 1791 and 2099 cm −1
Step b: Preparation of (2R)-[(1R or 1S, 3R or 3S)-3-azidocyclopentyl]-2-hydroxy-2-phenyl acetic acid
To a solution of the compound of step-a (1 mmol) in 10 ml of methanol, 3N aq. sodium hydroxide solution was added and the RM stirred for overnight at room temperature. The RM was concentrated under reduced pressure, diluted with water and extracted with dichloromethane. The aqueous layer was acidified with 1N hydrochloric acid and extracted with chloroform. The organic layer was washed with water, dried and concentrated under reduced pressure to give the required product.
1 HNMR(CDCl 3 ) δ-values: 7.65-7.26(m, 5 Ar—H), 4.07-3.97 (m, 1H), 3.22-3.14 (m, 1H), 1.89-1.25 (m, 6H) IR (DCM): 1712 and 2102 cm −1
Step c: Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-azidocyclopentyl]-2-hydroxy-2-phenylacetamide
To a solution of the compound of step-b (1 mmol) and (1α,5α,6α)-6-aminomethyl-3-benzyl-3-azabicyclo[3.1.0]hexane (0.9 mmol) in DMF (10 ml) was added NMM (2 mmol) and HOBT (1.1 mmol) at 0° C. and stirred at the same temperature for 1 hour. EDC.HCl (1 mmol) was then added and the RM stirred for 1 hour at 0° C. and then at room temperature for 4 days. The RM was poured into water and extracted with EtOAc. The organic layer was dried and the residue obtained after the removal of solvent was purified by column chromatography.
1 HNMR(CDCl 3 ) δ-values: 7.74-7.22 (m, 10 Ar—H), 6.07 (bs, 1H), 3.98-3.96 (m, 1), 3.55 (s, 2H), 3.04-2.99 (m, 5H), 2.31-2.28 (m, 2H), 1.76-1.19 (m, 9H) IR (DCM): 1654 and 2097 cm −1
Step-d: Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-aminocyclopentyl]-2-hydroxy-2-phenyl acetamide
To a solution of the compound of, step-c, (9 mmol) in a mixture of THF and water (75+15 ml), triphenyl phosphine (27 mmol) was added and the RM refluxed for 18 hours. The RM was cooled to room temperature, solvent removed in vacuo and the residue diluted with water. The pH was made acidic with 1N HCl and the RM extracted with chloroform. The aqueous layer was then made basic with 1N sodium hydroxide solution and extracted with chloroform. The organic layer was washed with water, dried and concentrated under reduced pressure. The residue was used as such for the next step.
Step e: Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S) 3 -phenylacetylamino cydopentyl]-2-hydroxy-2-phenylacetamide
To a solution of the compound of step-d, triethylamine (2.2 mmol), dimethyl aminopyridine (1 mg) in chloroform was added phenylacetyl chloride (2.2 mmol) at 0° C. The RM was stirred for overnight at room temperature. Aqueous sodium hydroxide was added and the organic layer separated. The organic layer was washed with water, dried and the solvent removed in vacuo. The residue was purified by column chromatography.
m.pt.:56-61° C. IR (DCM): 1650 cm −1
EXAMPLE 6
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-34(4-nitrophenyl)sulphonylamino-cyclopentyl]-2-hydroxy-2-phenylacetamide (Compound No. 6)
The compound was synthesized following the procedure of Example 5, step-e, using 4-nitrophenyl sulphonyl chloride instead of phenylacetyl chloride.
m.pt.:67-71° C. 1 HNMR(CDCl 3 ) δ-values: 8.35-8.26 (m, 2 ArH), 8.06-7.97 (m, 2 ArH), 7.51-7.26 (m, 10 ArH), 6.34 (bs, 1H), 3.67-2.90 (m, 9H), 2.35-1.15 (m, 10H) IR (KBr): 1652 and 1529 cm −1
EXAMPLE 7
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-phenylsulphonylaminocyclopentyl]-2-hydroxy-2-phenylacetamide (Compound No. 7)
The compound was synthesized following the procedure of Example 5, step-e, using benzene sulphonyl chloride instead of phenylacetyl chloride.
m.pt.:52-56° C. 1 HNMR(CDCl 3 ) δ-values: 7.88-7.26 (m, 15 ArH), 6.26 (bs, 1H), 3.67-2.86(m, 9H), 2.35-1.10(m, 12H) IR (KBr): 1654 cm −1
EXAMPLE 8
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2[(1R or 1S, 3R or 3S)-3-benzyloxyacetylaminocyclopentyl]-2-hydroxy-2-phenylacetamide (Compound No. 8)
The compound was synthesized following the procedure of Example 5, step-e, using benzyloxyacetyl chloride instead of phenylacetyl chloride.
1 HNMR(CDCl 3 ) δ-values: 7.59-7.26 (m, 15 ArH), 6.26 (bs, 1H), 4.55 (d, 2H), 3.95-3.56 (m, 4H), 3.28 (s, 2H), 3.04-2.90 (m, 4H), 2.32-2.29 (m, 2H), 2.05-1.13 (m, 10H) IR (DCM): 1655 cm −1
EXAMPLE 9
Preparation of (2R)-(1α,α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-(4-methoxyphenyl)sulphonylamino cyclo pentyl]-2-hydroxy-2-phenylacetamide (Compound No. 9)
The compound was synthesized following the procedure of Example 5, step-e, using 4-methoxyphenyl sulphonyl chloride instead of phenylacetyl chloride.
1 HNMR(CDCl 3 ) δ-values: 7.85-6.96(m, 14 ArH), 6.30(bs, 1H),3.89(s, 3H), 3.6 (s, 2H), 3.05-2.91 (m, 5H), 2.36-2.34 (m, 2H), 1.83-0.93 (m, 10H) IR (DCM): 1661 cm −1
EXAMPLE 10
Preparation of (2R)-(1α,5α,6α)-N-[3-benzyl-3-azabicyclo[3.1.0]hexyl-6-(aminomethyl)-yl]-2-[(1R or 1S, 3R or 3S)-3-(4-bromophenyl)sulphonylaminocyclopentyl]-2-hydroxy-2-phenylacetamide (Compound No. 10)
The compound was synthesized following the procedure of Example 5, step-e, using 4-bromophenyl sulphonyl chloride instead of phenylacetyl chloride.
1 HNMR(CDCl 3 ) δ-values: 7.73-7.26 (m, 14 ArH), 6.26 (bs, 1H), 3.57-2.86 (m, 7H), 2.33-2.29(m, 2H), 1.85-1.19(m, 10H) IR (DCM): 1651 cm −1
BIOLOGICAL ACTIVITY
Radioligand Binding Assays:
The affinity of test compounds for M 2 and M 3 muscarinic receptor subtypes was determined by [ 3 H]-N-methylscopolamine binding studies using rat heart and submandibular gland respectively as described by Moriya et al., (Life Sci, 1999, 64(25):2351-2358) with minor modifications.
Membrane preparation: Submandibular glands and heart were isolated and placed in ice cold homogenising buffer (HEPES 20 mM, 10 mM EDTA, pH 7.4) immediately after sacrifice. The tissues were homogenised in 10 volumes of homogenising buffer and the homogenate was filtered through two layers of wet gauze and filtrate was centrifuged at 500 g for 10 min. The supernatant was subsequently centrifuged at 40,000 g for 20 min. The pellet thus obtained was resuspended in same volume of assay buffer (HEPES 20 mM, EDTA 5 mM, pH 7.4) and were stored at −70° C. until the time of assay.
Ligand binding assay: The compounds were dissolved and diluted in DMSO. The membrane homogenates (150-250 μg protein) were incubated in 250 μl of assay buffer (HEPES 20 mM, pH 7.4) at 24-25° C. for 3 h. Non-specific binding was determined in the presence of 1 μM atropine. The incubation was terminated by vacuum filtration over GF/B fiber filters(Wallac). The filters were then washed with ice cold 50 mM Tris HCl buffer (pH 7.4). The filter mats were dried and bound radioactivity retained on filters was counted. The IC 50 & Kd were estimated by using the non-linear curve fitting program using G Pad Prism software. The value of inhibition constant Ki was calculated from competitive binding studies by using Cheng & Prusoff equation ( Biochem Pharmacol, 1973, 22: 3099-3108), Ki=IC 50 /(1+L/Kd), where L is the concentration of
[ 3 H]NMS used in the particular experiment.
Functional Experiments Using Isolated Rat Bladder:
Methodology:
Animals were euthanized by overdose of urethane and whole bladder was isolated and removed rapidly and placed in ice cold Tyrode buffer with the following composition (mMol/L) NaCl 137; KCl 2.7; CaCl 2 1.8; MgCl 2 0.1; NaHCO 3 11.9; NaH 2 PO 4 0.4; Glucose 5.55 and continuously gassed with 95% O 2 and 5% CO 2 .
The bladder was cut into longitudinal strips (3 mm wide and 5-6 mm long) and mounted in 10 ml organ baths at 30° C., with one end connected to the base of the tissue holder and the other end connected to a polygraph through a force displacement transducer. Each tissue was maintained at a constant basal tension of 2 g and allowed to equilibrate for 1 hour during which the PSS was changed every 15 min. At the end of equilibration period the stabilization of the tissue contractile response was assessed with 1 μmol/L of Carbachol consecutively for 2-3 times. Subsequently a cumulative concentration response curve to carbachol (10 −9 mol/L to 3×10 −5 mol/L) was obtained. After several washes, once the baseline was achieved, cumulative concentration response curve was obtained in presence of NCE (NCE added 20 min. prior to the second CRC).
The contractile results were expressed as % of control E max. ED50 values were calculated by fitting a non-linear regression curve (Graph Pad Prism). pKB values were calculated by the formula pKB=−log [(molar concentration of antagonist/(dose ratio-1))]
where,
dose ratio=ED50 in the presence of antagonist/ED50 in the absence of antagonist.
The result of the in-vitro test are listed in Table II.
In-Vitro Tests
TABLE II
Receptor Binding
Assay
M 2
M 3
Functional
pKi
pKi
Assay pK B
Compound No. 1A
6.87
8.25
9.1 ± 0.2
Compound No. 1B
6.64
8.21
8.98 ± 0.06
Compound No. 2
6.9
8.4
8.84 ± 0.07
Compound No. 3
6.6
8.2
8.55 ± 0.25
Compound No. 4
6.86
8.23
8.33 ± 0.15
Compound No. 5
6.08
7.4
7.07 ± 0.11
Compound No. 6
<5.8
7.66
7.21 ± 0.20
Compound No. 7
<5.8
7.3
6.89 ± 0.29
Compound No. 8
6.68
7.46
7.08 ± 0.18
Compound No. 9
<6
6.69
—
Compound No. 10
<6
6.89
—
While the present invention has been described in terms of its specific embodiments, certain modifications and equivalents will be apparent to those skilled in the art and are intended to be included within the scope of the present invention. | This invention generally relates to the derivatives of novel 3,6 disubstituted azabicyclo[3.1.0] hexane's. The compounds of this invention are MUSCARINIC receptor antagonists which are useful, inter-ail for the treatment of various diseases of the respiratory, urinary and gastrointestinal systems mediated through MUSCARINIC receptors. The invention also relates to processes for the preparation of the compounds of the invention, pharmaceutical compositions containing the compounds of the present invention and the methods of treating the diseases mediated through MUSCARINIC receptors. | 2 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to valve fastening means and in particular to a valve fastening means for attaching a hydraulic valve to a tractor with a front end loader.
BACKGROUND OF THE INVENTION
Tractors with front end loaders and any associated tools that are operated hydraulically usually include a valve arranged at the attachment point of the front end loader on the tractor or on a foundation on the tractor. This valve connects the hydraulics of the tractor with the hydraulics of the front end loader.
Conventional valves include a number of screw holes, which enables attachment to an attachment plate that is mounted on a custom made fastening means on the tractor. One problem is that the valve is relatively heavy and that it is coupled to relatively stiff hydraulic hoses, which contribute to make it difficult to handle and difficult to mount.
SUMMARY OF THE INVENTION
In view of the foregoing one object with the present invention is to provide a valve fastening means that simplifies engaging and disengaging of a valve on a tractor with a front end loader. Another object is to provide a valve fastening means that is cheaper than conventional ones.
A common idea of the invention is that it should be possible in a first step to attach the valve fastening means, in a second step to adjust the position of it, and in a third step to lock it in place, and that one person readily can perform all the steps without any help from another person.
This may be accomplished with the valve fastening means according to the invention as defined in the dependent claims.
According to a first aspect of the invention the invention relates to a valve fastening means for attaching a hydraulic valve to a tractor. The valve fastening means comprises a tractor part adapted to be attached to a tractor and a valve part adapted for direct assembly of the valve, wherein the valve comprises at least two screw holes, each adapted to receive a screw. The valve part of the valve fastening means comprises at least two slits, of which at least a first slit comprises an opening adapted to let the head of the screw pass, and all the slits each comprises a groove that is sufficiently narrow to prevent the head of the screw pass from passing but sufficiently wide to allow the thread of the screw to pass.
In a preferred embodiment the valve fastening means comprises three slits, of which at least two slits each comprises an opening adapted to let the head of the screw pass, and of which all slits each comprises a groove that is sufficiently narrow to prevent the head of the screw pass from passing but sufficiently wide to allow the thread of the screw to pass.
In another preferred embodiment the grooves are parallel to each other so that the valve, when mounted in the valve fastening means without having the screws fully tightened, can be moved along the grooves in such way that the screws are moved in their respective groove.
Preferably one of the slits does not have any opening for letting the head of the screw pass and optionally this slit is displaced from the slits with an opening and from the position of the screw holes on the valve, whereby the screw that is extending through the slit that does not have any opening has to be screw out in order to enable movement of the valve to a position where the screws, which are extending through the slits that have an opening, are positioned just in front of these openings.
In yet another preferred embodiment the valve part comprises three slits. A first slit and a second slit are arranged one after the other in a common horizontal line, and a third slit is arranged in parallel, but vertically displaced in relation to the other two slits. Each of the first slit and the third slit comprises an opening adapted to let the head of the screw pass and a first groove that is sufficiently narrow to prevent the head of the screw from passing but sufficiently wide to allow the thread of the screw to pass and that extends in parallel and in the same direction in relation to their respective opening, and wherein the second slit comprises a groove but not an opening.
Preferably the third slit comprises a second groove that extends in parallel but in opposite direction from the opening of the slit in relation to the first slit.
In yet another preferred embodiment the slits are arranged relative each other in such way that the valve fastening means can be attached to the tractor in two different orientations, of which one is upside-down in relation to the other, whereby the valve can be arranged properly oriented on the valve fastening means irrespective of the orientation of the valve fastening means on the tractor.
Preferably the tractor part and the valve part are arranged at an angle to each other.
One advantage of the present invention over conventional valve fastening means is that no attachment plate is required. Previously, as described above, the valve has been attached to an attachment plate and thereafter the attachment plate has been attached to an holder intended for this purpose. Thanks to the invention the valve fastening means can be attached to the tractor, and the valve can in a simple and reliable way be attached directly to the valve fastening means.
Embodiments of the invention are defined in the dependent claims. Other objects, advantages and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will now be described with reference to the accompanying drawings, wherein
FIG. 1 schematically illustrates a valve fastening means according to the invention, to which a valve is attached,
FIGS. 1-6 schematically illustrate the process from the situation when a valve is threaded on to the valve fastening means until the situation when the valve is attached to the valve fastening means,
FIGS. 7-10 schematically illustrate a valve that is attached to a valve fastening means according to a second embodiment of the invention,
FIGS. 11-14 schematically illustrate a valve that is attached to a valve fastening means according to the second embodiment, wherein the valve fastening means is turned upside-down with regards to FIGS. 7-10 , and
FIG. 15 schematically illustrates a perspective view of a tractor with a front end loader and an attached valve.
DETAILED DESCRIPTION OF EMBODIMENTS
FIG. 15 schematically illustrates a perspective view of a tractor 13 with a front end loader 14 and an attached valve 2 . The front end loader 14 and the tool 15 belonging to it is operated using hydraulics of the tractor via a valve 2 that is arranged at the attachment point of the front end loader 14 on the tractor 13 or on a foundation on the tractor 13 . The valve connects the hydraulics of the tractor with the hydraulics of the front end loader. The invention relates to improvements associated with the valve fastening means which is used to attach the valve to the tractor.
As shown in FIG. 1 the valve fastening means comprises two main parts that are put at an angle to each other. A first part, which hereinafter will be referred to as tractor part 1 a , is intended to be attached in a suitable manner and on a suitable place on the tractor. A second part, which hereinafter will be referred to as valve part 1 b , is adapted for attachment of a valve 2 . As shown in FIG. 1 , three slits 6 , 7 and 8 are arranged in the valve part lb and three screws 3 , 4 and 5 extend into the valve.
FIGS. 2-6 schematically illustrate one embodiment of a method for attaching a valve to a valve fastening means according to the present invention.
As shown in FIG. 2 , the valve is provided with three screw holes 10 , 11 and 12 , which are adapted to receive the screws 3 , 4 and 5 . The screw holes 10 and 11 are arranged on the same height or horizontal line and the screw holes 11 and 12 are arranged on the same vertical line, whereby the three screw holes form a right-angled triangle. In FIG. 2 , the valve is shown in the situation when it is going to be attached to the valve fastening means. In this situation, two screws 3 and 5 has been screw in a few turns in two of the screw holes 10 and 12 , respectively. However, the screw hole 11 is empty at this stage. The slits 6 and 8 are each provided with an opening 6 a and 8 a , respectively. The screw heads 3 and 5 can be inserted in the openings 6 a and 8 a , respectively, in order to attach the valve before it is adjusted laterally and finally is fixed.
FIG. 3 schematically illustrates the valve on the valve fastening means after the screw heads 3 and 5 have been moved in the direction D 1 through the openings 6 a and 8 a in the slits 6 and 8 , respectively. Thereafter, as shown in FIG. 4 , the valve can be moved in direction D 2 , whereby the screws are displaced from the openings 6 a and 8 a in the longitudinal grooves 6 b and 8 b , respectively.
When the valve has been moved to a desired position the valve can be fixed. This is accomplished by, as shown in FIG. 5 , inserting the remaining screw 4 into the hitherto empty slit 7 . This slit is in the present embodiment not provided with any opening and consists of only a groove, which groove is corresponding to the grooves 6 b and 8 b in the slits 6 and 8 , respectively. The reason to why there is no opening is that the screw 4 is intended to be screw in into the slit 7 after the valve has been attached the valve fastening means 1 . Hence there is no need for any opening. Moreover, the lack of any opening in the slit 7 efficiently locks the valve in place, since the screw has to be removed in order to remove the valve 2 . The slit is with advantage be displaced relatively the slits 6 and 8 , in such way that the screws 3 and 5 has to be moved into their respective groove 6 b and 8 b in order to make the hole 11 available through the slit 7 and to make it possible to screw in the screw 4 into the hole 11 (see FIG. 2 ).
With advantage the screws 3 and 5 , which only have been screw in a few turns, are screw home at the same time as the last screw 4 is tightened Thereby the valve position is fixed. Before the screws 3 , 4 and 5 are screw home it is, as indicated in FIG. 6 , possible to laterally adjust the valve 1 in the direction D 3 .
FIG. 7-10 schematically illustrate a second embodiment of the valve fastening means 1 that is mirrored with regards to the valve fastening means shown in FIGS. 1-6 . Also the hole pattern for the screw holes 10 - 12 on the valve is mirrored with regards to the valve shown in FIGS. 1-6 . However, the same reference numbers are used in all figures independently of whether the structures are mirrored or not.
In FIGS. 7 and 8 , the valve fastening means 1 and the valve are in the relative positions that correspond to the relative positions in FIG. 3 , i.e. with the screws 3 and 5 in front of the openings 6 a and 8 a . From FIG. 7 it is appreciated that no screw hole 11 is available through the slit 7 in this position. Instead the right part of the screw hole is visible through the groove 6 b . Thus the valve has to be moved to the left with regards to the valve fastening means, i.e. towards the position that is shown in FIGS. 9 and 10 before the screw can be inserted into the last screw hole 11 .
One advantage with the valve fastening means according to the invention is that it is turnable, i.e. the valve part lb can be attached in any orientation on the tractor with maintained functionality.
FIGS. 11-14 show the second embodiment of the valve fastening means 1 arranged upside-down with regards to the arrangement in FIGS. 7-10 . Thus the slit 8 is arranged in an upper part and the slits 6 and 7 are arranged below the slit 8 . The screw 3 , which is arranged in the screw hole 10 on the valve, is in this embodiment inserted through the opening 8 a , while the screw 5 , which is arranged in the screw hole 12 , is inserted through the opening 6 a . In accordance with the function of the valve fastening means when it is arranged in the opposite orientation (upside-down), as in FIGS. 7-10 , the third screw hole 11 is covered sufficiently much not to be available as long as the screws remains in the openings 6 a and 8 a . However, in FIG. 11 a portion of the screw hole 11 can be observed through the left part of the groove 8 c.
In the situation that is shown in FIGS. 13 and 14 the valve 2 has been displaced to the right with regards to the valve fastening means 1 and the third screw 4 has been screw in through a second groove 8 c in the slit 8 . Thus the slit 7 is not used at all when the valve fastening means 1 has this orientation. The function of the slit 7 is than provided by the left groove 8 c in the slit 8 .
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, on the contrary, it is intended to cover various modifications and equivalent arrangements within the appended claims. | A valve fastening element ( 1 ) for attaching a hydraulic valve ( 2 ) to a tractor ( 13 ). The valve fastening element ( 1 ) includes a tractor part ( 1 a ) adapted to be attached on the tractor and a valve part ( 1 b adapted for direct assembly of the valve ( 2 ), wherein the valve ( 2 ) includes at least two screw holes ( 10,11,12 ), each adapted to receive a screw ( 3,4,5 ). The valve part ( 1 b ) of the valve fastening element ( 1 ) includes at least two slits ( 6,7,8 ), of which at least a first slit ( 6,8 ) includes an opening ( 6 a ,8 a ) adapted to let the head of the screw pass, and all slits include a groove ( 6 b ,7,8 b ,8 c ) that is sufficiently narrow to prevent the head of the screw ( 3,4,5 ) from passing but sufficiently wide to allow the thread of the screw ( 3,4,5 ) to pass. | 4 |
[0001] Under 35 U.S.C. §120, this application is a continuation of U.S. application Ser. No. 12/759,550, filed Apr. 13, 2010, now U.S. Pat. No. 8,011,964, which is a continuation of U.S. application Ser. No. 12/189,725, filed Aug. 11, 2008, now U.S. Pat. No. 7,719,847, which is a continuation of U.S. patent application Ser. No. 11/858,086, filed Sep. 19, 2007, now U.S. Pat. No. 7,522,424, which is a continuation of U.S. application Ser. No. 11/492,556, filed Jul. 24, 2006, now U.S. Pat. No. 7,295,443, which is a continuation of U.S. application Ser. No. 10/887,635 filed Jul. 8, 2004, now U.S. Pat. No. 7,095,618, which is a continuation-in-part application of U.S. application Ser. No. 10/064,966, which was filed on Sep. 4, 2002, now U.S. Pat. No. 6,859,369, which is a continued-in-part continuation-in-part application of U.S. application Ser. No. 10/167,925, which was filed on Jun. 11, 2002, now U.S. Pat. No. 7,222,205, which is a continuation application of U.S. application Ser. No. 09/610,904 which was filed Jul. 6, 2000, now U.S. Pat. No. 6,438,638, and is titled “Flashtoaster for reading several types of flash memory cards with or without a PC.” U.S. application Ser. No. 10/064,966 is also a continuation-in-part of U.S. application Ser. No. 10/039,685 which was filed Oct. 29, 2001, now U.S. Pat. No. 6,832,281 and is titled, “Flashtoaster for reading several types of flash memory cards with or without a PC” and a continuation-in-part of U.S. application Ser. No. 10/002,567 which was filed Nov. 1, 2001 and is titled, “Active Adapter Chip for Use in a Flash Card Reader.” The priority of the above-referenced applications is hereby claimed, and the entireties of the above-referenced applications are incorporated herein by this reference, and all of the above-referenced applications are assigned to the assignee of the present invention.
1. FIELD
[0002] The present invention relates generally to flash media adapters, and more specifically to an improved configuration of the same.
2. BACKGROUND
[0003] In U.S. patent application Ser. No. 10/002,567, entitled “Active Adapter Chip for Use in a Flash Card Reader”, filed Nov. 1, 2001, and assigned to the assignee of the present application, a universal active adapter chip is disclosed that can be used to construct a flash media system or various active flash media adapters using the CompactFlash card or PCMCIA (PC Card) form factor. A standard reader that reads CompactFlash cards or PC cards can then read any of the other flash-memory cards that plug into the CompactFlash or PC Card adapter. The adapters come with a conversion chip that makes each of the flash media work just like a CompactFlash or PC Card media, as applicable.
[0004] FIG. 1 shows a multi-standard card reader system 142 . In the field of multi-standard adapters, multi-memory media adapter 140 may be an active adapter or, alternatively, may be a passive adapter. Reader 142 can adapt on the host side to either CompactFlash card 149 , PCMCIA card 153 , or IDE card 151 . On the media side, the reader can adapt to a MultiMediaCard 141 , or a Secure Digital card 143 , which have the same form factor but slightly different pin-out; a SmartMedia card 145 , which has a different pin-out; or a Memory Stick 147 . In general, the reader 142 can adapt to any generic flash media 146 that has a similar or smaller form factor.
[0005] It is possible to place the connector such that all the media sit in one opening. FIG. 2 is a cutaway side view of a PCMCIA adapter card 200 of the type that is available as a standard commercial product today. FIG. 2 illustrates several drawbacks in the typical configuration of a PCMCIA adapter. Adapter 200 includes two PCBs, namely PCB 210 and PCB 220 . The two PCBs are separated by a mounting frame (typically plastic), not shown. The mounting frame acts as a spacer between PCB 210 and PCB 220 , which holds the two PCBs together at a specified distance and functions in other capacities as described below. The space between the two PCBs creates the opening (port) 211 into which the flash media cards are inserted. PCB 230 is straddle-mounted between PCB 210 and PCB 220 . PCB 230 contains the active components including controller chip 231 that perform handshaking and data transfer. PCB 230 is connected to a PCMCIA connector 240 . PCB 230 is mounted between PCB 210 and PCB 220 with interconnects 212 . PCB 210 has two sets of floating contact pins, contact pin set 214 includes nine contact pins and contact pin set 215 includes ten contact pins, which provide interfaces for MMC/SD and MemoryStick flash media respectively. PCB 220 has two sets of floating contact pins 224 and 225 , each including 11 pins, which together provide the interface for SmartMedia flash media.
[0006] The mounting frame that holds PCB 210 and 220 together is configured such that each type of flash media is inserted in a particular location within the connector. In FIG. 2 , opening 211 is a simplified view. Typically, the opening is stepped with different widths and heights in different locations that index the flash media cards into specific locations upon insertion. This allows each flash medium to be properly aligned with the corresponding contact pin set(s). Additionally, stops are typically provided to stop the insertion at the correct depth, again, to guarantee connection to the right contact pin set.
[0007] This typical approach has several serious drawbacks.
Manufacturing
[0008] The straddle-mount configured flash media adapter is very expensive to manufacture for several reasons. Often such devices require manual labor for manufacturing and testing, or the use of very expensive soldering robots, instead of standard production techniques. A further problem is the additive effect of manufacturing tolerances, such as primary connector (i.e., PCMCIA) to PCB, to straddle mount connector to secondary PCB to contacts on PCB, resulting in as many as two, three, or in some cases even four tolerances adding up, which makes requirements for tolerances either absurdly expensive, or causes a big yield problem in manufacturing. Additionally, PCB 230 must be thin enough so that it can be mounted between PCB 210 and PCB 220 in the space allocated for the insertion of the various flash media. That is, PCB 230 , together with the interconnects 212 that mount it between PCB 210 and PCB 220 must be no larger than opening 211 . The manufacture of thin PCBs to accommodate this design point adds to the expense and complexity of manufacturing the flash media adapter.
Contact Pins
[0009] The floating contact pins are subject to damage and deterioration. The various flash media cards have different thickness, and even the same flash media may have different thickness if produced by different manufacturers. The flash media cards exert pressure upon the floating contact pins, which eventually causes their resiliency to be reduced. When subsequently, a thinner flash media card is inserted into the flash media adapter, the corresponding contact pins may not make connection with the flash media card. Additionally if a flash media card is inserted incorrectly (e.g., upside down), removal of the flash media card may damage the contact pins.
Interface
[0010] Some devices don't have the 68-pin PCMCIA interface. For example, some recent notebook computer models only have the electrically equivalent 50-pin CF interface. Typical adapter cards such as PCMCIA adapter card 200 are incompatible with a 50-pin CF interface.
SUMMARY
[0011] An embodiment of the present invention provides a multi-memory media adaptor comprised of a first planar element having an upper surface and a lower surface and a second planar element having an upper surface and a lower surface. The two planar elements are formed from a single piece of molded plastic and disposed so as to form a port capable of receiving a memory media card. The adapter has at least one set of contact pins protruding from the lower surface of the first planar element or the upper surface of the second planar element such that the at least one set of contact pins are disposed within the port. The at least one set of contact pins are capable of contacting the contacts of a memory media card inserted into the port.
[0012] Other features and advantages of embodiments of the present invention will be apparent from the accompanying drawings, and from the detailed description, that follows below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The invention may be best understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention. In the drawings:
[0014] FIG. 1 illustrates a multi-standard card reader system;
[0015] FIG. 2 is a cutaway side view of a PCMCIA adapter card of the type that is available as a standard commercial product today;
[0016] FIG. 3 is a cutaway side view of an integrated standard connector adapter card according to one embodiment of the present invention;
[0017] FIG. 4 is a table of pin mappings for the SmartMedia, MMC/SD, and Memory Stick to a 21-pin connector in accordance with one embodiment of the present invention;
[0018] FIG. 5 is a table of pin mappings for the xD, standard MMC/SD, standard Memory Stick, SmartMedia, miniSD, RSMMC, and MS Duo to an 18-pin connector in accordance with one embodiment of the present invention;
[0019] FIG. 6 illustrates an integrated standard connector adapter card, according to one embodiment of the present invention, in front view, top view, and bottom view;
[0020] FIG. 7 illustrates an integrated standard connector adapter card, according to one embodiment of the present invention, in front view and top view; and
[0021] FIG. 7A illustrates an alternative embodiment of an adapter 700 A in accordance with one embodiment of the invention.
DETAILED DESCRIPTION
[0022] An embodiment of the present invention provides a multi-memory media adapter card configured to reduce or eliminate some of the drawbacks of typical adapter card configuration. In accordance with various embodiments of the present invention, the top and bottom PCBs of prior art configurations are replaced by molded plastic elements that provide greater structural integrity. The straddle-mounted controller board is replaced with a PCB adjacent to the bottom element and having a surface mounted standard connector that may be a PCMCIA or a CompactFlash connector. The contact pins are formed so as to better maintain their resiliency and avoid damage upon removal of the memory media card. In one embodiment, a light pipe is locked in place between the top and bottom elements of the adapter card so as to conduct light from a signal lamp on the PCB through the port.
[0023] It is an intended advantage of one embodiment of the present invention to reduce the manufacturing cost and complexity of an adapter card. It is another intended advantage of one embodiment of the present invention to provide an adapter card with greater structural integrity. It is another intended advantage of one embodiment of the present invention to provide an adapter card with contact pins that retain their resiliency to a greater degree than floating contact pins. It is another intended advantage of one embodiment of the present invention to provide an adapter card with contact pins that are less likely to be damaged upon removal of a memory media card. It is another intended advantage of one embodiment of the present invention to provide an adapter card with a surface mounted standard connector including PCMCIA and CompactFlash connectors.
[0024] In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the understanding of this description.
[0025] Reference throughout the specification to “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 present invention. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.
[0026] Similarly, it should be appreciated that in the foregoing description of exemplary embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description are hereby expressly incorporated into this Detailed Description, with each claim standing on its own as a separate embodiment of this invention.
[0027] FIG. 3 is a cutaway side view of an integrated standard connector adapter card according to one embodiment of the present invention. Adapter card 300 , shown in FIG. 3 , includes a top planar element 310 and a bottom planar element 320 , both of which may be PCBs. Alternatively, the top planar element 310 and the bottom planar element 320 may be formed from molded plastic. A spacer, not shown, holds the two planar elements apart, forming port 311 into which memory media cards are inserted. In order to meet the low height requirements (thickness of PCMCIA or CF cards), the ports are registered on one opening, and contacts are distributed on both sides. Additionally, the port 311 may be formed with card stops to prevent improper insertion of memory media cards.
[0028] For one embodiment, both planar elements and the spacer between them are created from molded plastic. For such an embodiment, the molded plastic provides greater resistance to pressure applied to the outer surfaces of adapter card 300 . This helps to prevent planar element 310 and planar element 320 from contacting each other and possibly damaging internal components.
[0029] Adapter 300 also includes a number of sets of contact pins, shown collectively as contact pin set 315 , protruding from the lower surface of planar element 310 and from the upper surface of planar element 320 . The contact pins electrically couple to corresponding contacts on a memory media card inserted into port 311 . For an embodiment in which the planar elements 310 and 320 are formed from molded plastic, contact pin sets 315 may be formed from injected contacts with protruding pins. This provides a more robust contact pin than the floating contact pins of the prior art, thereby lessening the likelihood that the resiliency of the contact pin will be reduced to the point that the pin no longer contacts the inserted memory media card. Alternatively, or additionally, the contact pins may be angled or shaped such that damage due to the abrupt removal of an improperly (or properly) inserted card is reduced or eliminated. For example the terminal end of the contact pin may be angled or curved toward the planar surface from which the contact pin protrudes, or may be spherically shaped.
[0030] Adapter 300 includes planar element 330 that has standard connector 340 mounted thereon. Planar element 330 is adjacent to bottom planar element 320 . Standard connector 340 , which may be for example, a compact flash, PCMCIA, USB, or serial ATA connector is surface-mounted to planar element 330 . Interconnects 312 that electrically connect the standard connector 340 to contact pins 315 are also located on planar element 330 . The adapter connects the proper pin from the contact pins to planar element 330 . Simple wiring such as individual wires, flat cables, printed-circuit board (PCB), or wiring traces can be used. In accordance with an embodiment of the present invention, the need for a straddle-mounted PCB, and its associated manufacturing costs and complexity, is eliminated. Moreover, by eliminating the layers of a straddle-mount configuration, registration accuracy is improved. For one embodiment, a single PCB may comprise bottom planar element 320 and planar element 330 .
[0031] For one embodiment, a multi-memory media adapter having only 21 pins is used to accommodate various commercially available flash memory media. FIG. 4 is a table of pin mappings for the SmartMedia, MMC/SD, and Memory Stick to a 21-pin connector in accordance with one embodiment of the present invention.
[0032] Pin 18 is a ground pin for each connector. Pin 19 is a power pin for SmartMedia, while pin 20 is a power pin for MMC/SD, and Memory Stick.
[0033] The SmartMedia interface has a parallel data bus of 8 bits. These are mapped to pins 1 8 . While no separate address bus is provided, address and data are multiplexed. Control signals for latch enables, write enable and protect, output enable, and ready handshake are among the control signals.
[0034] For the Memory Stick and MMC/SD flash-memory-card interfaces, parallel data or address busses are not present. Instead, serial data transfers occur through serial data pin DIO, which is mapped to pin 7 for the Memory Stick, and pin 10 (D 0 ) for the MMC/SD flash-memory-card interfaces. Data is clocked in synchronization to clock MCLK and CLK, for Memory Stick and MMC/SD, respectively, on pin 21 . A BS, for Memory Stick, occupies pin 6 , and a command signal CMD, for MMC/SD, occupies pin 4 . The Memory Stick interfaces require only 4 pins plus power and ground, while MMC/SD requires 8 pins plus power and ground.
[0035] Thus, it is possible to accommodate SmartMedia, MMC/SD, and Memory Stick with a 21-pin connector (i.e., instead of 41 pins) by multiplexing the available pins. For one embodiment, the controller chip (e.g., controller chip 231 ) differentiates the pin configuration for each flash memory media type. The controller may include a shifter connected to the data and clock signals from the MMC/SD and Memory Stick flash-memory cards. The shifter may clock one bit (serial) or word (parallel) of data each clock pulse. A cyclical redundancy check (CRC) can be performed on the data to detect errors.
[0036] For an alternative embodiment, a multi-memory media adapter, having only 18 pins, is used to accommodate various commercially available flash memory media including media that have recently become commercially available. Such recent additions include a miniSD card (i.e., an MMC/SD card with a smaller form factor), an MS Duo (i.e., a Memory Stick card with a smaller form factor), a Reduced Size MultiMedia Card (RSMMC), and an xD card (a controller-less Flash media, similar in function to SmartMedia).
[0037] FIG. 5 is a table of pin mappings for the xD, standard MMC/SD, standard Memory Stick, SmartMedia, miniSD, RSMMC, MMC/SD, and MS Duo to an 18-pin connector in accordance with one embodiment of the present invention.
[0038] For such an embodiment, pin 1 is a ground pin and pin 18 is a power pin for each connector. The data lines for the SmartMedia and xD interface cards have a parallel data bus of 8 bits denoted as DO-D 7 that occupy pins 10 - 17 . These data bus lines are multiplexed to serve as card-detect lines for the remaining media types.
[0039] As described in application Ser. No. 09/610,904 (now U.S. Pat. No. 6,438,638), the signal lines to the controller are normally pulled high. When a card is inserted, the card pulls its connected pins low. Detection of card type is determined by detection of which of the mapped card detect lines is pulled low as illustrated in FIG. 5 , or by the (binary) state of data or other card pins mapped to a common set of controller pins as described in the aforesaid parent application. See, e.g., FIGS. 4A-E of 09/610,904, now U.S. Pat. No. 6,438,638. While no separate address bus is provided, address and data are multiplexed.
[0040] The data lines of the miniSD and RSMMC and the Memory Stick (and MS Duo) flash-memory-card interfaces are denoted as SDD 0 -SDD 3 and MSD 0 -MSD 3 , respectively, and occupy pins 4 - 7 .
[0041] Thus, it is possible to accommodate xD, standard MMC/SD, standard Memory Stick, SmartMedia, miniSD, RSMMC, MMC/SD, and MS Duo with an 18-pin connector by multiplexing the available pins. Again, the controller chip may differentiate the pin configuration for each flash memory media type.
[0042] FIG. 6 illustrates an integrated standard connector adapter card according to one embodiment of the present invention in front view, top view, and bottom view. Adapter card 600 , shown in FIG. 6 , includes two housings, namely housing 610 and housing 620 . For one embodiment of the invention, the pins are in a single row. As shown from the top view of adapter card 600 , a top-front set of pins 611 in housing 610 can be used to interface to an xD card, a top-rear set of pins 612 in housing 610 can be used to interface to a SmartMedia card. A top-front set of pins 621 in housing 620 can be used to interface an RSMMC card. As shown in the bottom view of adapter card 600 , a bottom-front set of pins 613 in housing 610 can be used to interface to an SD/MMC MMC/SD card, a bottom-rear set of pins 614 in housing 610 can be used to interface to a standard size Memory Stick card. A bottom-front set of pins 622 in housing 620 can be used to interface a miniSD card. A bottom-rear set of pins 623 in housing 620 can be used to interface a Memory Stick MS Duo.
[0043] FIG. 7 illustrates an integrated standard connector adapter card, according to one embodiment of the present invention, in front view and top view. Adapter card 700 , shown in FIG. 7 , includes three housings, namely section 710 (Memory Stick), section 720 (SM/xD), and section 730 (MMC/SD). This arrangement allows pins to be laid out in a planar fashion, thus effecting saving in layout and allowing for assignment of one drive for each section. The spacing is designed so that only one media can be inserted at a time. For one embodiment, the Memory Stick could be on the top portion of section 710 (with MS Duo on the bottom portion), while SmartMedia is on the top portion of section 720 with xD on the bottom portion of section 720 . According to one such embodiment, the MMC (including the recently designed 8-bit MMC) could be on the top-rear portion of the MMC/SD section 730 , while the SD could be on the bottom-rear portion of the MMC/SD section 730 . RSMMC could be on the top-front portion of the MMC/SD section 730 and miniSD could be on the bottom-front portion of the MMC/SD section 730 .
[0044] FIG. 7A illustrates an alternative embodiment of an adapter 700 A in accordance with one embodiment of the invention. As shown in FIG. 7A , adapter 700 includes sections 710 , 720 , and 730 with sections 710 and 730 positioned vertically, but section 720 stacked horizontally upon section 730 . In such an embodiment, external pins 711 , 721 , and 731 may be positioned as shown to avoid intersection or congestion of the external connections.
[0045] As described above in reference to FIG. 3 , an adapter in accordance with one embodiment of the invention includes a planar element that may have a controller chip attached to a standard connector (e.g., PCMCIA, USB, WiFi, Firewire, IDE, CF, or serial ATA connector) mounted thereon. In accordance with an alternative embodiment of the invention, the controller chip is integrated into the housing of the adapter. For example, the adapter may be formed of a single piece of molded plastic, with the controller chip and an associated memory device (e.g., ROM) embedded into the molded plastic. For such an embodiment, the continuous molded plastic that forms the adapter also forms the device package for the controller die.
General Matters
[0046] Embodiments of the present invention provide an improved configuration for a multi-memory media adapter card. For one embodiment, the adapter may comprise an injected plastic part, forming the mechanical port, as well as holding any and all contacts in its structure, thus eliminating the multiple tolerances of conventional configurations (i.e., two PCBs sandwiching a mechanical frame). For one embodiment, two half shells with integrated contacts are snapped together, allowing for a simple, but accurate mounting by means of guides for snapping them together. In particular, the total assembly of the port may be composed of two parts, a top and bottom, each with contacts and plastic, each containing part or the entire port opening, hence reducing the number of added tolerances to a maximum of one or two. By reducing the number of sub-assemblies from three or more to two or less, an easier, more precise manufacturing can be done, with only slightly higher tooling cost. However, due to the fact that it is a high-volume, commodity-type device, the higher tooling costs would be more than offset by the lower part cost, the better yield, etc. Further, by embedding the contacts in a plastic injection, such problems as metal fatigue, travel, etc., can be controlled much better, improving dramatically the life-cycle time for the port side connectors. For one embodiment of the invention, the controller and associated memory device are integrated into the adapter, rendering the adapter a complete card reader.
[0047] For one embodiment, a light pipe may be locked in place between the two half shells to conduct light from a signal lamp (e.g., LED) on the PCB to the user side of the opening, similar to networking lights sometimes integrated into networking connectors.
[0048] For one embodiment, the straddle-mount configuration is replaced with a surface mounted standard connector. This reduces the manufacturing costs and complexities associated with the straddle-mount configuration.
[0049] For one embodiment of the invention, the controller and associated memory device are integrated into the adapter rendering the adapter a complete card reader.
[0050] Embodiments of the present invention have been described in reference to flash media such as xD, standard MMC/SD, standard Memory Stick, SmartMedia, miniSD, RSMMC, and MMC/SD, and MS Duo. In general, embodiments of the invention are applicable to any generic flash media.
[0051] While the invention has been described in terms of several embodiments, those skilled in the art will recognize that the invention is not limited to the embodiments described, but can be practiced with modification and alteration within the spirit and scope of the appended claims. The description is thus to be regarded as illustrative instead of limiting. | A multi-memory media adapter to read a plurality of different types of memory media cards. Signals are mapped to the contact pins depending upon the type of memory media card. In one embodiment, a controller connected to an interconnection means maps at least one signal to the contact pins depending upon the type of memory card inserted. | 8 |
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